U.S. patent application number 10/113392 was filed with the patent office on 2003-10-02 for system and method for preventing sand production into a well casing having a perforated interval.
Invention is credited to Jones, Gary W..
Application Number | 20030183395 10/113392 |
Document ID | / |
Family ID | 28453589 |
Filed Date | 2003-10-02 |
United States Patent
Application |
20030183395 |
Kind Code |
A1 |
Jones, Gary W. |
October 2, 2003 |
System and method for preventing sand production into a well casing
having a perforated interval
Abstract
A well completion system and method for preventing sand
production into a well casing (38) having a perforated interval
(42) is disclosed. The system comprises a sand control screen (40)
having expandable end sections (60, 62) each of which having an
attachment member (72, 74) positioned exteriorly therearound. An
expander tool (44) is operably disposed within the sand control
screen (40) such that when the sand control screen (40) is
positioned within the well casing (38) across the perforated
interval (42), the expander tool (44) radially expands the end
sections (60, 62) such that the attachment members (72, 74) are
placed in contact with the interior of the well casing (38),
thereby creating a fluid seal and a friction grip between the end
sections (60, 62) and the well casing (38).
Inventors: |
Jones, Gary W.; (Tomball,
TX) |
Correspondence
Address: |
LAWRENCE R. YOUST
Smith, Danamraj & Youst, P.C.
Suite 1200, LB 15
12900 Preston Road
Dallas
TX
75230-1328
US
|
Family ID: |
28453589 |
Appl. No.: |
10/113392 |
Filed: |
April 1, 2002 |
Current U.S.
Class: |
166/380 ;
166/205; 166/207; 166/236 |
Current CPC
Class: |
E21B 43/103 20130101;
E21B 43/108 20130101; E21B 43/08 20130101; E21B 43/105
20130101 |
Class at
Publication: |
166/380 ;
166/205; 166/207; 166/236 |
International
Class: |
E21B 043/10 |
Claims
What is claimed is:
1. A method for preventing sand production into a well casing
having a perforated interval positioned within a wellbore, the
method comprising the steps of: installing the well casing within
the wellbore; disposing a sand control screen having expandable end
sections within the well casing across the perforated interval; and
setting the sand control screen by radially expanding the end
sections, thereby creating a friction grip between the end sections
and the well casing.
2. The method as recited in claim 1 wherein the step of setting the
sand control screen by radially expanding the end sections further
comprises expanding the end sections with an expander tool having
two expander members, each of the expander members expanding one of
the end sections by traveling longitudinally therethrough.
3. The method as recited in claim 2 wherein the step of setting the
sand control screen by radially expanding the end sections further
comprises simultaneously expanding the end sections.
4. The method as recited in claim 2 wherein the step of setting the
sand control screen by radially expanding the end sections further
comprises sequentially expanding the end sections.
5. The method as recited in claim 2 wherein the step of setting the
sand control screen by radially expanding the end sections further
comprises hydraulically operating the expander tool.
6. The method as recited in claim 5 wherein the step of
hydraulically operating the expander tool further comprises
providing fluid pressure to the expander tool from the surface via
a tubing string.
7. The method as recited in claim 5 wherein the step of
hydraulically operating the expander tool further comprises
providing fluid pressure to the expander tool from a downhole fluid
source.
8. The method as recited in claim 2 wherein the step of setting the
sand control screen by radially expanding the end sections further
comprises electrically operating the expander tool.
9. The method as recited in claim 2 wherein the step of setting the
sand control screen by radially expanding the end sections further
comprises moving the expander members toward one another to expand
the end sections.
10. The method as recited in claim 2 wherein the step of setting
the sand control screen by radially expanding the end sections
further comprises moving the expander members away from one another
to expand the end sections.
11. The method as recited in claim 2 wherein the step of setting
the sand control screen by radially expanding the end sections
further comprises contacting a frustaconical surface of the
expander members with an inner radial surface of the end
sections.
12. The method as recited in claim 1 wherein the step of setting
the sand control screen by radially expanding the end sections
further comprises creating a fluid seal between the well casing and
the end sections.
13. A method for preventing sand production into a well casing
having a perforated interval positioned within a wellbore, the
method comprising the steps of: installing the well casing within
the wellbore; disposing a sand control screen having expandable end
sections within the well casing across the perforated interval; and
setting the sand control screen by radially expanding the end
sections with an expander tool having two expander members, each of
the expander members expanding one of the end sections by
contacting a frustaconical surface of the expander members with an
inner radial surface of the end sections and traveling
longitudinally therethrough, thereby creating a fluid seal and a
friction grip between the end sections and the well casing.
14. The method as recited in claim 13 wherein the step of setting
the sand control screen by radially expanding the end sections
further comprises simultaneously expanding the end sections.
15. The method as recited in claim 13 wherein the step of setting
the sand control screen by radially expanding the end sections
further comprises sequentially expanding the end sections.
16. The method as recited in claim 13 wherein the step of setting
the sand control screen by radially expanding the end sections
further comprises hydraulically operating the expander tool.
17. The method as recited in claim 16 wherein the step of
hydraulically operating the expander tool further comprises
providing fluid pressure to the expander tool from the surface via
a tubing string.
18. The method as recited in claim 16 wherein the step of
hydraulically operating the expander tool further comprises
providing fluid pressure to the expander tool from a downhole fluid
source.
19. The method as recited in claim 13 wherein the step of setting
the sand control screen by radially expanding the end sections
further comprises electrically operating the expander tool.
20. The method as recited in claim 13 wherein the step of setting
the sand control screen by radially expanding the end sections
further comprises moving the expander members toward one another to
expand the end sections.
21. The method as recited in claim 13 wherein the step of setting
the sand control screen by radially expanding the end sections
further comprises moving the expander members away from one another
to expand the end sections.
22. A well completion system for preventing sand production into a
well casing having a perforated interval, the well casing
positioned within a wellbore, the system comprising: a sand control
screen having expandable end sections, the sand control screen
positioned within the well casing across the perforated interval; a
pair of attachment members one positioned exteriorly about each of
the end sections; and an expander tool operably disposed within the
sand control screen and adapted to radially expand the end sections
such that the attachment members are places in contact with the
well casing, thereby creating a friction grip between the end
sections and the well casing.
23. The system as recited in claim 22 wherein the expander tool
simultaneously expands the end sections.
24. The system as recited in claim 22 wherein the expander tool
sequentially expands the end sections.
25. The system as recited in claim 22 wherein the expander tool is
hydraulically operated.
26. The system as recited in claim 25 wherein the expander tool is
hydraulically operated by fluid pressure provided from the surface
via a tubing string.
27. The system as recited in claim 25 wherein the expander tool is
hydraulically operated by providing fluid pressure from a downhole
fluid source.
28. The system as recited in claim 22 wherein the expander tool is
electrically operated.
29. The system as recited in claim 22 wherein the expander tool
further comprises two expander members, each of the expander
members expanding one of the end sections by traveling
longitudinally therethrough.
30. The system as recited in claim 29 wherein the expander members
move toward one another to expand the end sections.
31. The system as recited in claim 29 wherein the expander members
move away from one another to expand the end sections.
32. The system as recited in claim 29 wherein the expander members
each have a frustaconical surface that contacts an inner radial
surface of the end sections to expand the end sections.
33. The system as recited in claim 22 wherein the attachment
members create a fluid seal with the well casing when the
attachment members are placed in contact with the well casing.
34. A well completion system for preventing sand production into a
well casing having a perforated interval, the well casing
positioned within a wellbore, the system comprising: a sand control
screen having expandable end sections, the sand control screen
positioned within the well casing across the perforated interval; a
pair of attachment members one positioned exteriorly about each of
the end sections; and an expander tool operably disposed within the
sand control screen having two expander members, each of the
expander members adapted to radially expand one of the end sections
by traveling longitudinally therethrough such that the attachment
members are placed in contact with the well casing, thereby
creating a friction grip between the end sections and the well
casing.
35. The system as recited in claim 34 wherein the expander tool
simultaneously expands the end sections.
36. The system as recited in claim 34 wherein the expander tool
sequentially expands the end sections.
37. The system as recited in claim 34 wherein the expander tool is
hydraulically operated.
38. The system as recited in claim 37 wherein the expander tool is
hydraulically operated by fluid pressure provided from the surface
via a tubing string.
39. The system as recited in claim 37 wherein the expander tool is
hydraulically operated by providing fluid pressure from a downhole
fluid source.
40. The system as recited in claim 34 wherein the expander tool is
electrically operated.
41. The system as recited in claim 34 wherein the expander members
move toward one another to expand the end sections.
42. The system as recited in claim 34 wherein the expander members
move away from one another to expand the end sections.
43. The system as recited in claim 34 wherein the expander members
each have a frustaconical surface that contacts an inner radial
surface of the end sections to expand the end sections.
44. The system as recited in claim 34 wherein the attachment
members create a fluid seal with the well casing when the
attachment members are placed in contact with the well casing.
Description
TECHNICAL FIELD OF THE INVENTION
[0001] This invention relates, in general, to completing a well
that traverses a hydrocarbon bearing subterranean formation and, in
particular, to a system and method for preventing sand production
into a well casing having a perforated interval by radially
expanding the end sections of a sand control screen to provide a
fluid seal and a friction grip between the sand control screen and
the well casing.
BACKGROUND OF THE INVENTION
[0002] Without limiting the scope of the present invention, its
background will be described with reference to producing fluid from
a subterranean formation, as an example.
[0003] After drilling each of the sections of a subterranean
wellbore, individual lengths of relatively large diameter metal
tubulars are typically secured together to form a casing string
that is positioned within each section of the wellbore. This casing
string is used to increase the integrity of the wellbore by
preventing the wall of the hole from caving in. In addition, the
casing string prevents movement of fluids from one formation to
another formation. Conventionally, each section of the casing
string is cemented within the wellbore before the next section of
the wellbore is drilled. Accordingly, each subsequent section of
the wellbore must have a diameter that is less than the previous
section.
[0004] For example, a first section of the wellbore may receive a
conductor casing string having a 20-inch diameter. The next several
sections of the wellbore may receive intermediate casing strings
having 16-inch, 133/8-inch and 95/8-inch diameters, respectively.
The final sections of the wellbore may receive production casing
strings having 7-inch and 41/2-inch diameters, respectively. Each
of the casing strings may be hung from a casing head near the
surface. Alternatively, some of the casing strings may be in the
form of liner strings that extend from near the setting depth of
previous section of casing. In this case, the liner string will be
suspended from the previous section of casing on a liner
hanger.
[0005] Once this well construction process is finished, the
completion process may begin. The completion process comprises
numerous steps including creating hydraulic openings or
perforations through the production casing string, the cement and a
short distance into the desired formation or formations so that
production fluids may enter the interior of the wellbore. In
addition, the completion process may involve formation stimulation
to enhance production, installation of sand control devices to
prevent sand production and the like. The completion process also
includes installing a production tubing string within the well
casing. Unlike the casing string that forms a part of the wellbore
itself, the production tubing string is used to produce the well by
providing the conduit for formation fluids to travel from the
formation depth to the surface.
[0006] Typically, the production tubing string extends from the
surface to the formation traversed by the well and includes a
production packer. The purpose of the packer is to support the
production tubing and other completion equipment, such as a sand
control screen that may be placed adjacent to the producing
formation, and to seal the annulus between the outside of the
production tubing and the inside of the well casing to block
movement of fluids through the annulus past the packer location.
Accordingly, once the production tubing string, including the
production packer and sand control screen are in place, all
production from the formation that enters the production tubing
must pass through the sand control screen.
[0007] It has been found, however, that in certain deep or
high-angled wellbores in which relatively small diameter production
casing is used, it may be desirable to complete the well without
extending the production tubing string all the way to the producing
formation. While the diameter of the production tubing that is
installed within a well is determined based upon a number of
factors, the maximum diameter of the production tubing is limited
by the various restrictions within the well including the
production casing and any tools within the production casing. Use
of relatively small diameter production tubing over long distances
may cause a pressure drop in the formation fluids traveling
therethrough that is unnecessarily large which in turn causes the
rate of production from the formation to be unnecessarily
constrained. Accordingly, if the production tubing string does not
extend into the last section of the production casing and formation
fluids are produced directly into and travel within the last
section of the production casing, the pressure drop in the
formation fluids may be reduced.
[0008] It has been found, however, that in such deep or high-angled
wellbores wherein the production tubing string is not extended all
the way to the producing formation, sand control may remain a
problem. Specifically, the unfiltered formation fluids that are
being produced directly into and traveling within the production
casing may contain abrasive particulate matter.
[0009] A need has therefore arisen for a system and method for
preventing sand production into a wellbore even when the production
tubing string is not extended all the way to the producing
formation. Accordingly, a need has arisen for such a system and
method that provide for placement of a sand control screen within a
wellbore that do not require the sand control screen to be coupled
within the production tubing string.
SUMMARY OF THE INVENTION
[0010] The present invention disclosed herein comprises a system
and method for preventing the production of sand into a wellbore
even when the production tubing string is not extended all the way
to the producing formation. The system and method provide for the
placement of a sand control screen within a wellbore that do not
require the sand control screen to be coupled within the production
tubing string. Instead, the sand control screen of the present
invention is placed directly within the production casing across
the perforated interval such that when the end sections of the sand
control screen of the present invention are expanded, a fluid seal
and a friction grip are created between the sand control screen and
the well casing.
[0011] The well completion system of the present invention
comprises a sand control screen that has expandable end sections.
Each of the expandable end sections has an attachment member
positioned on its exterior surface. The sand control screen may be
run downhole into the well casing on a jointed tubing string, a
coiled tubing string, an electric line or other similar device. The
sand control screen is positioned within the well casing across the
perforated interval. Thereafter, an expander tool that is operably
disposed within the sand control screen may be used to expand the
end sections of the sand control screen. For example, the expander
tool may have two expander members such that each of the expander
members is adapted to radially expand one of the end sections of
the sand control screen by traveling longitudinally therethrough.
Upon expansion of the end sections, the attachment members are
placed in intimate contact with the interior surface of the well
casing, thereby creating a fluid seal and a friction grip between
the end sections of the sand control screen and the well
casing.
[0012] In one embodiment of the system for preventing sand
production into a well casing having a perforated interval, the
expansion of the two end sections of the sand control screen may
take place simultaneously. In another embodiment, the expansion of
the two end sections of the sand control screen may take place
sequentially.
[0013] In one embodiment of the system of the present invention,
the expander tool may be hydraulically operated. For example, fluid
pressure may be provided from the surface via a tubing string or a
downhole pump may be used to provide fluid pressure from a downhole
fluid source. In another embodiment, the expander tool may be
electrically operated using, for example, an electric motor to
drive a rotating shaft.
[0014] In one embodiment of the system of the present invention,
the pair of expander members of the expander tool may move toward
one another to expand the end sections. In another embodiment, the
pair of expander members of the expander tool may move away from
one another to expand the end sections. In yet another embodiment,
an expander tool having a single expander member may be used to
expand both end sections. In any of these embodiments, each
expander member may have a frustaconical surface that contacts an
inner radial surface of the end sections to facilitate the
expansion of the end sections.
[0015] Broadly stated, the method of the present invention involves
installing the well casing within the wellbore, disposing a sand
control screen having expandable end sections within the well
casing across the perforated interval and setting the sand control
screen by radially expanding the end sections, thereby creating a
friction grip between the end sections and the well casing.
[0016] More specifically, the method of the present invention
involves installing the well casing within the wellbore, disposing
a sand control screen having expandable end sections within the
well casing across the perforated interval and setting the sand
control screen by radially expanding the end sections with an
expander tool having two expander members, each of the expander
members expanding one of the end sections by contacting a
frustaconical surface of the expander members with an inner radial
surface of the end sections and traveling longitudinally
therethrough, thereby creating a fluid seal and a friction grip
between the end sections and the well casing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] For a more complete understanding of the features and
advantages of the present invention, reference is now made to the
detailed description of the invention along with the accompanying
figures in which corresponding numerals in the different figures
refer to corresponding parts and in which:
[0018] FIG. 1 is a schematic illustration of an offshore oil and
gas platform installing a sand control screen having expandable end
sections according to the present invention;
[0019] FIG. 2 is a half sectional view of a sand control screen
having expandable end sections according to the present invention
positioned within a casing string prior to installation within the
casing string;
[0020] FIG. 3 is a half sectional view of a sand control screen
having expandable end sections according to the present invention
positioned within a casing string after installation within the
casing string;
[0021] FIG. 4 is a half sectional view of a sand control screen
having expandable end sections according to the present invention
positioned within a casing string after installation within the
casing string and after the installation of a tubing string;
[0022] FIG. 5 is a half sectional view of a sand control screen
having expandable end sections according to the present invention
positioned within a casing string prior to installation within the
casing string;
[0023] FIG. 6 is a half sectional view of a sand control screen
having expandable end sections according to the present invention
positioned within a casing string after installation within the
casing string; and
[0024] FIG. 7 is a half sectional view of a sand control screen
having expandable end sections according to the present invention
positioned within a casing string after installation within the
casing string and after the installation of a tubing string.
DETAILED DESCRIPTION OF THE INVENTION
[0025] While the making and using of various embodiments of the
present invention are discussed in detail below, it should be
appreciated that the present invention provides many applicable
inventive concepts which can be embodied in a wide variety of
specific contexts. The specific embodiments discussed herein are
merely illustrative of specific ways to make and use the invention,
and do not delimit the scope of the present invention.
[0026] Referring initially to FIG. 1, a sand control screen having
expandable end sections according to the present invention is being
installed from an offshore oil and gas platform that is
schematically illustrated and generally designated 10. A
semi-submersible platform 12 is centered over a submerged oil and
gas formation 14 located below sea floor 16. A subsea conduit 18
extends from deck 20 of platform 12 to wellhead installation 22
including subsea blowout preventers 24. Platform 12 has a hoisting
apparatus 26 and a derrick 28 for raising and lowering pipe
strings.
[0027] Wellbore 32 extends through the various earth strata
including formation 14. A casing string 34 is cemented within
wellbore 32 by cement 36. Casing string 34 includes a production
casing liner 38 at its lower end. Placed within production casing
38 is a sand control screen 40 having expandable ends that is
positioned across perforations 42. As explained in greater detail
below, to install sand control screen 40 within production casing
string 38 the end sections of sand control screen 40 are
plastically deformed using expander tool 44 by, for example,
pumping fluid down through a coiled tubing string 52 that is in
fluid communication with expander tool 44. Once sand control screen
40 has been set and coiled tubing string 52 along with expander
tool 44 has been retrieved to the surface, a relatively large
diameter production tubing string (not pictured) may be installed
within casing string 34 to a point above production casing 38.
[0028] Referring now to FIG. 2, therein is depicted more detailed
view of a sand control screen of the present invention that is
designated 40. Production casing 38 has been installed within
wellbore 32. Specifically, production casing 38 has been hung off
casing string 34 at liner hanger 50 and has been cemented within
wellbore 32. In addition, perforations 42 have been made in a
section of production casing 38 using a known technique such as
firing a shaped charge perforating gun.
[0029] As illustrated, in deep well applications, the size of
production casing 38 may be relative small, such as 41/2 inches in
diameter. In such cases, it may be desirable to complete the well
without extending the production tubing string all the way to
formation 14 as long sections of relatively small diameter
production tubing cause an unnecessarily large pressure drop during
the production of formation fluids which in turn causes the rate of
production from formation 14 to be unnecessarily constrained.
[0030] To achieve the required sand control in such cases, sand
control screen 40 is positioned within production casing 38. Sand
control screen 40 is initially supported by a coiled tubing string
52 that extends from the surface. In the illustrated embodiment,
sand control screen 40 includes a base pipe 54 that has a plurality
of openings 56 which allow the flow of production fluids
therethrough. Wrapped around base pipe 54 is a screen wire 58 that
forms a plurality of turns having gaps therebetween through which
formation fluids flow. The number of turns and the gap between the
turns are determined based upon the characteristics of formation
14. Ribs may be provided between base pipe 54 and screen wire
58.
[0031] It should be understood by those skilled in the art that
while FIG. 2 has depicted a wire wrapped sand control screen, other
types of filter media could alternatively be used in conjunction
with the sand control screen of the present invention, including,
but not limited to, a fluid-porous, particulate restricting,
sintered metal material such as a plurality of layers of a wire
mesh that are sintered together to form a porous sintered wire mesh
screen designed to allow fluid flow therethrough but prevent the
flow of particulate materials of a predetermined size from passing
therethrough.
[0032] One unique feature of sand control screen 40 of the present
invention is the radially expandable end sections 60, 62. Radially
expandable end section 60 includes a cylindrical ramp section 64
and a radially reduced section 66. Likewise, radially expandable
end section 62 includes a cylindrical ramp section 68 and a
radially reduced section 70. Disposed exteriorly of radially
reduced section 66 is an attachment member 72. Similarly, disposed
exteriorly of radially reduced section 70 is an attachment member
74.
[0033] Attachment members 72, 74 are capable of providing both
anchoring capabilities and sealing capabilities. Attachment members
72, 74 may be constructed from a polymeric material such as rubber
or other nonmetallic materials or may be constructed from a metal
such as lead or other suitable material that can expand radially
when radially reduced sections 66, 70 are expanded and that can
provide a suitable fluid seal and gripping force against the
interior of production casing 38. Attached members 72, 74 may
additionally have slips, metal rings or other anchoring devices to
improve the gripping force between sand control screen 40 and
production casing 38. Also, even though FIG. 2 has depicted single
attached members 72, 74 on each end section 60, 62, it should be
understood by those skilled in the art that other numbers of
attachment members could alternatively be used without departing
from the principles of the present invention.
[0034] Disposed within sand control screen 40 is expander tool 44.
In the illustrated embodiment, expander tool 44 has a support
member 76 that is coupled to the lower end of coiled tubing string
52. Initially, support member 76 is also coupled to the upper end
of sand control screen 40 by shear pins (not pictured) or other
suitable devices that hold support member 76 within sand control
screen 40 but allows the release of support member 76 as required.
Accordingly, sand control screen 40 may be lowered into wellbore 32
and into alignment with perforations 42 on coiled tubing string
52.
[0035] In the illustrated embodiment, expander tool 44 has a pair
of oppositely disposed expander members 78, 80. Each of the
expander members 78, 80 has a tapered cone section 82, 84 having a
frustaconical outer surface. Expander tool 44 also includes a
piston section 86. Piston section 86 is in fluid communication with
coiled tubing string 52 via support member 76.
[0036] In operation, once sand control screen 40 is positioned
within production casing 38 across perforations 42, as depicted in
FIG. 2, expander tool 44 may be operated to expand the diameter of
end sections 60, 62 of sand control screen 40. Specifically,
expander member 78 is longitudinally moved through end section 60
and expander member 80 is longitudinally moved through end section
62, as best seen in FIG. 3. In the illustrated embodiment, this is
achieved by pumping a fluid down coiled tubing string 52 and into
piston section 86 to urge expander member 78 and expander member 80
away from one another. As shown, the fluid pressure urges expander
member 78 upwardly such that the frustaconical surface of tapered
cone section 82 of expander member 78 contacts the interior wall of
cylindrical ramp section 64. Likewise, the fluid pressure urges
expander member 80 downwardly such that the frustaconical surface
of tapered cone section 84 of expander member 80 contacts the
interior wall of cylindrical ramp section 68.
[0037] As the fluid pressure increases, tapered cone sections 82,
84, respectively apply a radially outward force to cylindrical ramp
sections 64, 68. When this force is sufficient to plastically
deform cylindrical ramp sections 64, 68, expander members 78, 80
begin to travel longitudinally within cylindrical ramp sections 64,
68 in opposite directions from one another. As the movement of
expander members 78, 80 progresses, cylindrical ramp sections 64,
68 and radially reduced sections 66, 70 are substantially uniformly
expanded from their original diameters to a diameter similar to the
diameter of expander members 78, 80. As this expansion occurs,
attachment members 72, 74 expand into intimate contact with the
interior surface of production casing 38. Once attachment members
72, 74 are expanded, a fluid seal and a friction grip are created
between sand control screen 40 and production casing 38.
[0038] It should be noted by those skilled in the art that the
force necessary to plastically deform end sections 60, 62 of sand
control screen 40 is dependent upon a variety of factors including
the ramp angle of tapered cone sections 82, 84, the amount of the
desired expansion of end sections 60, 62, the material of end
sections 60, 62 and the like. Since only a short segment of end
sections 60, 62 are being expanded at any one time, however, the
fluid pumped through coiled tubing string 52 provides sufficient
force to expander tool 44 to expand end sections 60, 62. This force
may be controlled by adjusting the flow rate and pressure at which
the fluid is delivered through coiled tubing string 52.
[0039] Also, it should be noted by those skilled in the art that
even though FIG. 2 has described expanding end sections 60, 62 of
sand control screen 40 simultaneously, the end sections of a sand
control screen of the present invention could alternatively be
expanded sequentially. For example, upward movement of expander
member 78 could be disallowed until the downward stroke of expander
member 80 has been accomplished, or vice versa. Likewise, the ramp
angle of tapered cone section 82 could be altered relative to the
ramp angle of tapered cone section 84 such that the force generated
by the fluid pressure preferentially urges upward movement of
expander member 78 relative to downward movement of expander member
80, or vice versa.
[0040] Further, it should be apparent to those skilled in the art
that the use of direction terms such as above, below, upper, lower,
upward, downward and the like are used in relation to the
illustrated embodiments as they are depicted in the figures, the
upward direction being toward the top of the corresponding figure
and the downward being toward the bottom of the corresponding
figure. Accordingly, it should be noted that the sand control
screen of the present invention and the systems and methods for
setting the sand control screen of the present invention are not
limited to the vertical orientation as they are equally well suited
for use in inclined, deviated and horizontal wellbores.
[0041] Once the expansion of end sections 60, 62 of sand control
screen 40 is complete, expansion tool 44 may be retrieved to the
surface with coiled tubing string 52. Specifically, if support
member 76 is coupled to sand control screen 40 using shear pins,
upward jarring on coiled tubing string 52 may be used to break the
shear pins and release expansion tool 44 from sand control screen
40 to allow retrieval. Once expansion tool 44 and coiled tubing
string 52 have been retrieved, a production tubing string 88
including production packer 90 may be installed within casing 34
down to a point above the top of production casing 38, as best seen
in FIG. 4.
[0042] Referring now to FIG. 5, therein is depicted a sand control
screen of the present invention that is designated 140. Production
casing 138 has been installed within wellbore 132. Specifically,
production casing 138 is a slotted liner which has been hung off
casing string 134 at liner hanger 150. Casing string 134 has been
cemented within wellbore 132 with cement 136 but no cement has been
placed around slotted liner 138. In addition slotted liner 138
includes a packer 148 that is used to seal the annulus between
slotted liner 138 and wellbore 132.
[0043] As illustrated, in deep well applications, the size of
slotted liner 138 may be relative small such that it may be
desirable to complete the well without extending the production
tubing string all the way to formation 114. Accordingly, to achieve
the required sand control, sand control screen 140 is positioned
within slotted liner 138. Sand control screen 140 is initially
supported by an electric line 152 that extends from the surface. In
the illustrated embodiment, sand control screen 140 includes a base
pipe 154 that has a plurality of openings 156 which allow the flow
of production fluids therethrough with a screen wire 158 wrapped
therearound.
[0044] One unique feature of sand control screen 140 of the present
invention is the radially expandable end sections 160, 162.
Radially expandable end section 160 includes a cylindrical ramp
section 164 and a radially reduced section 166. Likewise, radially
expandable end section 162 includes a cylindrical ramp section 168
and a radially reduced section 170. Disposed exteriorly of radially
reduced section 166 is an attachment member 172. Similarly,
disposed exteriorly of radially reduced section 170 is an
attachment member 174.
[0045] Disposed within sand control screen 140 is expander tool
144. In the illustrated embodiment, expander tool 144 has a support
member 176 that is coupled to the lower end of electric line 152.
Initially, support member 176 is also coupled to the upper end of
sand control screen 140 by shear pins (not pictured) or other
suitable devices that hold support member 176 within sand control
screen 140 but allows the release of support member 176 as
required. Accordingly, sand control screen 140 may be lowered into
wellbore 132 and into alignment with opening 142 of slotted liner
138 on electric line 152.
[0046] In the illustrated embodiment, expander tool 144 has a pair
of oppositely disposed expander members 178, 180. Each of the
expander members 178, 180 has a tapered cone section 182, 184
having a frustaconical outer surface. Expander tool 144 also
includes a piston section 186.
[0047] In operation, once sand control screen 140 is positioned
across openings 142 of slotted liner 138, as depicted in FIG. 5,
expander tool 144 may be operated to expand the diameter of end
sections 160, 162 of sand control screen 140. Specifically,
expander member 178 is longitudinally moved through end section 160
and expander member 180 is longitudinally moved through end section
162, as best seen in FIG. 6. In the illustrated embodiment, this
may be achieved by operating a downhole power unit disposed within
support member 176. Electricity for the downhole power unit is
provided via electric line 152. The downhole power unit may be used
to rotate a threaded member within piston section 186 which urges
expander member 178 and expander member 180 toward one another.
Alternatively, the downhole power unit may be used to pump fluid
from a downhole hydraulic fluid source disposed with support member
176 into piston section 186 to urges expander member 178 and
expander member 180 toward one another. In either case, expander
member 176 is downwardly urged such that the frustaconical surface
of tapered cone section 182 of expander member 176 contacts the
interior wall of cylindrical ramp section 164. Likewise, expander
member 180 is upwardly urged such that the frustaconical surface of
tapered cone section 184 of expander member 180 contacts the
interior wall of cylindrical ramp section 168.
[0048] Tapered cone sections 182, 184, respectively apply a
radially outward force to cylindrical ramp sections 164, 168. When
this force is sufficient to plastically deform cylindrical ramp
sections 164, 168, expander members 178, 180 begin to travel
longitudinally within cylindrical ramp sections 164, 168 in
opposite directions toward one another. As the movement of expander
members 178, 180 progresses, cylindrical ramp sections 164, 168 and
radially reduced sections 166, 170 are substantially uniformly
expanded from their original diameters to a diameter similar to the
diameter of expander members 178, 180. As this expansion occurs,
attachment elements 172, 174 expand into intimate contact with
slotted liner 138. Once attachment elements 172, 174 are expanded,
a fluid seal and a friction grip are created between sand control
screen 140 and slotted liner 138.
[0049] Once the expansion of end sections 160, 162 of sand control
screen 140 is complete, expansion tool 144 may be retrieved to the
surface with electric line 152. Specifically, if support member 176
is coupled to sand control screen 140 using shear pins, upward
jarring on electric line 152 may be used to break the shear pins
and release expansion tool 144 from sand control screen 140 to
allow retrieval. Once expansion tool 144 and electric line 152 have
been retrieved, a production tubing string 188 including production
packer 190 may be installed within casing 134 down to a point above
the top of slotted liner 138, as best seen in FIG. 7.
[0050] While this invention has been described with reference to
illustrative embodiments, this description is not intended to be
construed in a limiting sense. Various modifications and
combinations of the illustrative embodiments as well as other
embodiments of the invention, will be apparent to persons skilled
in the art upon reference to the description. It is, therefore,
intended that the appended claims encompass any such modifications
or embodiments.
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