U.S. patent application number 10/352809 was filed with the patent office on 2004-07-29 for post installation cured braided continuous composite tubular.
This patent application is currently assigned to Halliburton Energy Services, Inc.. Invention is credited to Dusterhoft, Ronald G., Kalman, Mark, Zamora, Frank.
Application Number | 20040144535 10/352809 |
Document ID | / |
Family ID | 32736071 |
Filed Date | 2004-07-29 |
United States Patent
Application |
20040144535 |
Kind Code |
A1 |
Kalman, Mark ; et
al. |
July 29, 2004 |
Post installation cured braided continuous composite tubular
Abstract
A method for providing a barrier at a predetermined location in
downhole operations comprises: providing a first tubular sleeve of
a woven material comprising a plurality of fibers in a braided
arrangement and including a conductor, impregnating the sleeve with
a curable resin, radially enlarging the sleeve at the predetermined
downhole location, and curing the resin. The present method can
also be used to provide a barrier at a desired location within a
wellbore while drilling, to restrict sand flow into a wellbore
while allowing fluid flow into the wellbore, or to protect a
metallic sand screen by employing the composite braided tubular
sleeve as a protective shroud.
Inventors: |
Kalman, Mark; (Katy, TX)
; Dusterhoft, Ronald G.; (Houston, TX) ; Zamora,
Frank; (Duncan, OK) |
Correspondence
Address: |
CONLEY ROSE, P.C.
P. O. BOX 3267
HOUSTON
TX
77253-3267
US
|
Assignee: |
Halliburton Energy Services,
Inc.
Houston
TX
|
Family ID: |
32736071 |
Appl. No.: |
10/352809 |
Filed: |
January 28, 2003 |
Current U.S.
Class: |
166/278 ;
166/230 |
Current CPC
Class: |
E03B 3/16 20130101; E21B
43/103 20130101; D04C 1/06 20130101; E03B 3/15 20130101 |
Class at
Publication: |
166/278 ;
166/230 |
International
Class: |
E03B 003/18 |
Claims
What is claimed is:
1. A method of providing a barrier at a predetermined location in
downhole operations, the method comprising: a) providing a first
tubular sleeve of a woven material comprising a plurality of fibers
in a braided arrangement, said tubular sleeve including a conductor
selected from the group consisting of electrical conductors and
optical fibers; b) impregnating the sleeve with a curable resin; c)
radially enlarging the sleeve at the predetermined downhole
location; and d) curing the resin.
2. The method according to claim 1 wherein step d) is accomplished
by providing an exothermic reaction near the sleeve.
3. The method according to claim 1 wherein step d) is accomplished
by curing cement near the sleeve such that heat from the cement
curing cures the resin.
4. The method according to claim 1, further including providing at
least a second tubular sleeve that is coaxial with the first
tubular sleeve.
5. The method according to claim 1 wherein the conductor is an
optical fiber.
6. The method according to claim 1 wherein the conductor includes
at least two of: electrically conducting wires for data
transmission, optical fibers for data transmission, and
electrically conducting wires for power transmission.
7. The method according to claim 1 wherein the conductor includes
at least one sensor.
8. The method according to claim 1, further including the step of
installing the sleeve on the outer diameter of an expandable
metallic casing or screen.
9. The method according to claim 8, further including expanding the
expandable casing or screen, wherein the sleeve expands during the
expansion of the metallic casing.
10. A method of installing a tubular member in a wellbore, the
method comprising: a) providing an expandable tubular member; b)
providing a flexible tubular sleeve around the tubular member, the
sleeve comprising a plurality of fibers woven in a braided
arrangement and a curable component; c) installing the expandable
tubular member in the wellbore; d) expanding the expandable tubular
member and flexible tubular sleeve in the wellbore; and e) curing
the curable component of the tubular sleeve so as to form a rigid
sleeve.
11. The method according to claim 10 wherein the tubular braided
sleeve is installed in the wellbore simultaneously with the
expandable metallic casing or screen.
12. The method according to claim 10 wherein the tubular braided
sleeve is installed in the wellbore after the expandable metallic
casing is placed in the well.
13. The method according to claim 10 wherein step e) is
accomplished by providing an exothermic reaction near the
sleeve.
14. The method according to claim 10 wherein step e) is
accomplished by curing cement near the sleeve such that heat from
the cement curing cures the resin.
15. The method according to claim 10 wherein the tubular braided
sleeve includes at least one of: electrically conducting wires for
data transmission, optical fibers for data transmission, sensors,
and electrically conducting wires for power transmission.
16. A method of providing a barrier at a desired location within a
wellbore while drilling, comprising: providing a tubular sleeve of
a biaxially woven material; positioning the sleeve at the desired
location; impregnating the sleeve with a curable resin; radially
expanding the sleeve at the desired location; and curing the
resin.
17. The method of claim 16 wherein the desired location is in a
water-producing zone and the cured sleeve forms a water
barrier.
18. The method of claim 16 wherein the desired location is in a low
fracture gradient zone.
19. The method of claim 16 wherein the wellbore is air or foam
drilled.
20. The apparatus of claim 16 where sleeve is expanded using a
fluid.
21. A method for restricting sand flow into a wellbore while
allowing fluid flow into the wellbore, comprising providing a
braided tubular sleeve; positioning the sleeve at a desired
location where it is desired to restrict sand flow; impregnating
the sleeve with a curable composition; expanding the sleeve such
that it contacts the borehole wall; and curing the curable
composition so as to set the sleeve such that liquids can pass
through the set sleeve but particulates cannot.
22. The method according to claim 21, further including the step of
cleaning the sleeve by providing a fluid flow from the inside of
the sleeve outward through the sleeve.
23. A method for protecting a metallic sand screen by employing a
composite braided tubular sleeve as a protective shroud.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
TECHNICAL FIELD OF THE INVENTION
[0003] The present invention relates to sealing and conveying
fluids, maintaining borehole integrity and transmitting power and
data signals within a well bore.
BACKGROUND OF THE INVENTION
[0004] In the present description, the terms "casing" and "tubing"
refer to generally cylindrical pipes conventionally used to convey
fluids in a wellbore. A wellbore is a hole drilled in the earth
such as for the production of hydrocarbons, geothermal energy,
water and other fluids as well as for injection of fluids into the
earth.
[0005] Wells are typically drilled using a drill bit at the end of
a length of tubing. During drilling, a drilling fluid, such as mud,
is pumped down through the tubing and flows up the annulus between
the tubing and the borehole wall. After a desired length of
borehole has been drilled, a casing is placed in the hole and
sealed against the borehole wall. The casing may be installed in
order to isolate the natural formation fluids from the pressure of
the drilling fluid, including but not limited to drilling mud,
water, air, and foams, to prevent fluid intrusion into the wellbore
(from a water producing zone, for example), or to prevent fracture
of the formation by the pressure exerted by the drilling mud or
loss of that mud into the formation. Likewise, because the wellbore
may pass through several distinct geological formations, each of
which may contain its own formation fluids, casing may be installed
and sealed against the borehole wall in order to isolate the
formations from each other. During drilling of highly deviated
wellbores, casing may also be installed in order to prevent
collapse of the wellbore.
[0006] In some situations, there may be localized regions where the
casing does not seal the formation but where sealing is desired.
These situations include but are not limited to: areas where pipe
has been intentionally perforated, areas where corrosion or
mechanical damage has resulted in loss of pressure and fluid
integrity, and areas where additional mechanical support is
required in order to ensure pressure integrity. In many instances,
it is desirable to be able to quickly set a temporary or permanent
conduit for these and other purposes.
[0007] Another function that is often desirable downhole relates to
controlling the flow of particulate matter into or out of the well.
One example is the need to install screens to prevent formation
sand from flowing into the wellbore. Such screens allow fluid flow
but restrict the movement of the particulates. The present
invention allows the mesh size of the sand screen to be adjusted to
a desired level. For example, expanding the braided sleeve such
that the helically wound fibers lie at substantially 45.degree. to
each other provides a maximum mesh size. Other configurations of
the same sleeve provide smaller mesh sizes, down to virtually
zero.
[0008] In addition, data obtained from measuring devices located in
a wellbore can be valuable during drilling and production.
Measurement of parameters such as temperature, pressure, fluid
composition, status of downhole equipment, geophysical surveys
during production, stresses and forces on pipes and equipment can
be taken at various depths in the wellbore, including at or near
the drill bit or over the production interval, and are useful and
important over the lifespan of a wellbore.
[0009] It is also desirable to transmit power into a wellbore in
order to energize downhole equipment and sensors. It is also
desirable to locate sensors in various locations within the
wellbore, and to have sensors integrated into the conductor or the
pipe wall--such as fiber optic distributed temperature or strain
sensing systems. Data transmission and power transmission into and
out of a wellbore is challenging because of the difficulty in
installing continuous electrical or optical fiber conductors
(hereafter referred to as conductors) in the downhole drilling and
production environment. Typically, casing and tubing are
manufactured in short lengths that are assembled at the well.
[0010] There are shortcomings with various methods employed within
the current art to assure a continuous electrical or optical
conductor. Conductors and sensors that are installed externally to
the casing or production string, are subject to damage during
installation. In addition, the installed conductors or sensors must
assure isolation of wellbore fluids between zones, or between the
wellbore and the surface. Conductors that are installed internal to
the production tubing can interfere with the flow of wellbore
fluids and intervention operations. If the pipe is jointed, it may
not be practical to integrate the conductor into the pipe wall
because of the complexity of connections.
[0011] A relatively new method of installing wellbore casing is
through the use of expandable tubulars to reduce borehole sizes and
the number of diameter transitions in deeper wells. The tubing is
expanded downhole by pulling a mandrel through the bore. Thus, with
an expandable tubular cased well, it is not feasible to install a
conductor internal to the wellbore, and the likelihood of damage
during installation and communication between zones is increased if
installed externally.
[0012] For all of these reasons, there remains a need for a device
that will allow installation of a pipe for sealing and fluid
conveyance, where the installation is relatively easy. It is
further desirable to provide a such a pipe that incorporates wires
or fibers for data and power conveyance, even if the pipe will be
expanded by a mandrel after installation.
[0013] One technique that has been proposed for sealing casing
sections downhole, which is described in J. L. Saltel et al.,
"In-Situ Polymerization of an Inflatable Sleeve to Reline Damaged
Tubing and Shut-Off Perforations," Offshore Technology Conference,
pp. 1-11 (May 1996). A cable carrying seven electrical power
conductors is used to lower an inflatable sleeve which carries a
permanent sleeve (comprised of resins, fibers, and elastomers)
downhole. The inflatable sleeve is pressurized to push the
permanent seal against the inside surface of the casing. Electric
power provided down the wireline from the surface is used to
generate heat to increase the temperature of the resin for a
sufficient period of time to cross link (or "cure") the resin in
the permanent sleeve. The permanent sleeve is left downhole to
maintain a seal over perforated sections of the casing.
[0014] Nonetheless, there is still a need for an expandable casing
that can be set quickly. In addition, there is a need for a system
that provides integrated conductors that can withstand drilling and
the downhole environment and are easily positioned, and for a
system that improves the effectiveness and efficiency of expandable
tubulars downhole.
[0015] Methods of integrating the conductors into continuous coiled
tubing and other spoolable products have been developed. Two
examples are disclosed in U.S. Pat. No. 6,148,866, entitled
"Composite Spoolable Tube," and U.S. Pat. No. 5,542,472, entitled
"Metal Coiled Tubing with Signal Transmitting Passageway."
Nonetheless, the devices disclosed in those patents are limited by
their use of coiled tubing. These products have diameter
limitations of about 4.5-inch OD as a result of maximum allowable
spooling strain and thus are not suitable when larger diameters are
desired.
SUMMARY
[0016] The present invention provides a method for installation of
a light weight, high strength, and high temperature continuous
conduit for fluid conveyance that is extremely compact prior to
installation.
[0017] In one embodiment, the present invention includes the
application of a tubular braided sleeve that may be installed in a
folded state and inflated or expanded in situ, along with a curable
resin that may be applied to the sleeve at any time including prior
to installation or after inflation. Uses of the present invention
include but are not limited to: primary casing or tubing, repairs
to casing or tubing, sealing of damaged casing or tubing, sealing
of perforated or otherwise non-pressure tight pipe, support for
pipe, and other uses related to the sealing and conduction of
fluids inside a wellbore.
[0018] The sleeve of the present invention comprises a braided
sleeve made from a plurality of elastic and non-elastic filaments
in a tubular configuration. Like woven materials, braided fibers
are mechanically interlocked with one another. Because all the
fibers within a braided structure are continuous and mechanically
locked, the braided structure is highly efficient in distributing
loads. Because all the fibers in the structure are involved in a
loading event, braid absorbs a great deal of energy as it fails.
Braided structures also have superior fatigue resistance. While
micro-cracking may occur in a braided structure, failure
propagation tends to be arrested at the intersections of the
reinforcing fibers.
[0019] The preferred tubular braided sleeve is flexible and may be
transported, handled and installed in a flat configuration.
Multiple sleeves can be utilized if desired, in order to provide
for a thicker finished conduit. During installation, the sleeve is
preferably inflated by either a temporary bladder, a permanent
fluid tight layer in the sleeve, or by other mechanical means such
as a mandrel drawn through the inner diameter of the sleeve. A
bladder layer is typically polymeric in nature.
[0020] The sleeve of the present invention is often used in
conjunction with a resin or other curable agent that can solidify
and set the sleeve into a desired tubular cross section. The
curable agent, typically a thermoset polymer resin, is preferably
impregnated into the tubular braided sleeve prior to installation,
such as during manufacture, but can alternatively be introduced to
the sleeve at any point in the process, including during or after
installation and inflation. The curable agent with which the sleeve
is impregnated preferably includes a mixture of resin and a curing
agent. The mixture is cured to form a hardened epoxy layer after
exposure to heat.
[0021] Implementations of the invention may include a local heat
source for generating heat energy to cure the curable agent
impregnated in the sleeve.
[0022] In one preferred embodiment, a longitudinal cable may be
utilized to support the tubular braided sleeve during installation.
Such a cable may be external or internal to the sleeve and may be
removed after installation and curing of the resin. In other
embodiments, metallic conductors or optical fiber may be
incorporated into the sleeve to provide for signal and data
communication to downhole equipment and sensors as well as sensors
in the wall of the cured tubular sleeve.
[0023] Implementations of the invention may include applications
external to metallic casing. In one application, the casing is a
metallic expandable tubular, used in well construction for reducing
or eliminating diameter transitions, such as in a monobore well.
The tubular braided sleeve expands during the casing expansion.
This is particularly useful in combination with embedded metallic
conductors or optical fiber for use in conductors because of the
difficulty in providing for signal and data communication in
monobore wells. The tubular braided sleeve may be used to reinforce
the metallic expandable casing, reducing the weight and thickness
requirement for the metallic expandable casing for a given
structural capacity. A thinner wall will result in a reduction of
the force and pressure required to expand the metallic expandable
casing as well as the time required to accomplish that expansion.
These factors may also allow for a larger diameter change during
expansion of the metallic expandable casing.
[0024] One configuration for installation of the present invention
is to install a metallic casing inside the sleeve prior to the
curing process. Alternatively, the sleeve may be run into the
wellbore on the outside of a string of metallic or fiberglass pipe
that will also be permanently installed.
[0025] Another use for the present invention is as a means of
installing and fixing in place a composite screen for the purposes
of particulate control, more specifically for confining sand to the
formation while allowing the production fluid to flow out of the
formation into the wellbore. The tubular braided sleeve may also be
used as a protective device for conventional metallic screens to
reduce the risk of damage during handling and installation.
DETAILED DESCRIPTION
[0026] For a more detailed understanding of the present invention,
reference is made to the accompanying drawings, in which:
[0027] FIG. 1 is a perspective view of a braided sleeve in
accordance with a preferred embodiment of the present
invention;
[0028] FIGS. 2 and 3 are schematic end views showing the sleeve of
FIG. 1 in flat and expanded configurations, respectively;
[0029] FIG. 4 is a perspective view illustrating the present sleeve
stored on a spool;
[0030] FIG. 5 is a schematic cross-section of a sleeve in
accordance with an embodiment of the invention being used to seal a
section of previously perforated or damaged casing;
[0031] FIG. 6 is an elevation of a braided sleeve including a
longitudinal conductor in accordance with an alternative embodiment
of the invention; and
[0032] FIG. 7 is a schematic cross-section of a sleeve in
accordance with an embodiment of the invention being expanded in
conjunction with an expandable casing using a mandrel.
DETAILED DESCRIPTION
[0033] The present invention refers to applications of a tubular
braided sleeve such as the one shown in FIG. 1. The braided sleeve
100 preferably comprises a plurality of monofilament (?) fibers 102
and 104 braided or woven to form a continuous tube. As is known in
the art, fibers 102 are wound in a clockwise direction while fibers
104 are wound in a counterclockwise direction. The fibers can be
braided biaxially or triaxially and can be formed of any suitable
material, including glass fiber, carbon fiber, aramid, and the
like. Because of the flexibility of the individual filaments, the
tubular sleeve can be stored and manipulated between a first,
unexpanded position, wherein the tube is substantially flat, and a
second, expanded position in which the tube forms a substantially
round cylinder. In addition, because the fibers forming the tube
can move relative to each other, the tube can be shifted through a
range of configurations. At one extreme, the length of the sleeve
is at a maximum and the circumference of the tube, whether
flattened or rounded, is at a minimum. At the other extreme, the
length of the sleeve is at a maximum and the circumference of the
sleeve, whether flattened or rounded, is at a minimum. Referring
briefly to FIG. 2, the braided sleeve 100 is shown in the flat or
unexpanded position. Similarly, FIG. 3 depicts sleeve 100 in an
expanded configuration and illustrates how, when so expanded, the
sleeve forms a cylindrical, tubular shape. The ability to transport
and store the tubular braided sleeve in the flat position allows
for handling of the sleeve with significantly reduced space
requirements. For example, the flattened sleeve can be conveniently
stored on a spool, as illustrated in FIG. 4.
[0034] A curable resin (not shown), which may be applied to the
fibers of tubular sleeve 100 at any time including prior to
installation or after inflation is used to harden the sleeve in the
desired expanded shape. The curable resin may incorporate multiple
components such as curing agents to facilitate curing. The curable
resin, typically a thermoset polymer resin, is impregnated into the
tubular braided sleeve and hardened, typically by application of
additional heat, radiation or steam The curable resin may be
introduced to the sleeve at any point in the process: prior to
installation, during installation, or after installation and
inflation. In some applications, the braided sleeve may be used
without resin. The curable resin may simply harden so as to render
the braided sleeve stiff or rigid, or it may seal the woven fibers
of the braided sleeve so that it forms a fluid-impermeable
tube.
[0035] Some embodiments of the invention may include a local energy
source for generating heat to cure the curable agent impregnated in
the sleeve. The local source of heat may be a localized exothermic
chemical reaction, steam, heat generated by electrical resistance,
or any other process typical for curing thermoset resins. The
localized exothermic chemical reaction may be the curing of casing
cement in the vicinity of the sleeve, or may be any other suitable,
strategically positioned chemical reaction. Because wellbore
temperatures may vary along the length of the tubular braided
sleeve, the amount of heat applied to cure the resin may be varied
by variation in the composition or location of the energy source.
Also, the chemistry of the curable resin and curing agent(s) may be
varied along the length of the sleeve to provide a desired heat
profile and to account for variation in temperature or other
environmental conditions.
[0036] The article of the present invention may be shifted from its
flattened state to a rounded stated using a bladder or inflation of
the tubular braided sleeve. If used, the bladder preferably
comprises a temperature-resistant polymeric material.
[0037] In one embodiment of the application of the present
invention, shown in FIG. 5, tubular sleeve 100 is used to seal a
section of previously perforated or damaged casing 112. This
embodiment is also representative of sealing a lost circulation
zone in an open hole. In this embodiment, the objective is to
control or eliminate fluid flow and fluid pressure communication
between the formation 110 and the wellbore 111 in a well where the
casing 112 has been perforated so as to form a plurality of
perforations 114, or where a wellbore has become or is predicted to
become unstable. To seal the perforated casing, tubular braided
sleeve 100 is installed in the perforated area, expanded and cured
in such a manner that the outer surface 118 of sleeve 100 is in
contact with the inside surface 120 of casing 112. In one
embodiment, tubular sleeve 100 (including the curable resin and any
curing agents) may be provided with an inner inflatable bladder 122
or other interior impermeable layer. Sleeve 100 and bladder 122 are
lowered into the wellbore to the depth at which it is desired to
seal the casing. Sleeve 100 is then inflated by application of a
fluid (not shown), pressurized by a device 126 at the surface of
the well, acting on interior bladder or impermeable layer 122.
Alternatively, sleeve 100 can be expanded outwardly against the
casing by drawing a mandrel (not shown) through the sleeve.
[0038] The tubular sleeve is then preferably hardened using a
localized application of heat. After the resin is cured and the
tubular sleeve has hardened, the inflatable bladder (if used) may
be withdrawn.
[0039] Other applications of the present invention include patching
a water-producing zone during the drilling phase of a wellbore,
placing the sleeve over a low fracture gradient zone to enable
drilling to continue without setting a liner or additional casing
string. The present invention may also be utilized to stabilize a
wellbore from collapse and to place across a loss circulation zone.
Further, the present invention may be placed in air or foam drilled
holes and used as part of a sand control device. Any of the
applications of the present invention may be temporary or
permanent. Removal after temporary installation can be achieved by
drilling out the hardened sleeve.
[0040] If desired, multiple sleeves 100 can be utilized so as to
provide a thicker finished conduit. Multiple sleeves may be applied
by sequential operations of installation of a sleeve, inflation of
the sleeve, curing of the resin, and withdrawal of the bladder (if
used) or simultaneously by installation of multiple concentric
sleeves. As above, each sleeve can be inflated by either a
temporary bladder, a permanent fluid tight layer in the sleeve, or
other mechanical means such as a mandrel drawn through the inner
diameter of the sleeve.
[0041] In a further embodiment, metallic conductors or optical
fiber may be incorporated into the sleeve so as to provide a signal
and data communication link to downhole equipment and sensors
and/or sensors embedded in or affixed to the wall of the cured
tubular sleeve. The sleeve provides a robust, protected conduit for
conductors and fibers in an otherwise hostile environment. As shown
in FIG. 6, a longitudinal conductor 130 comprising a metallic wire
or bundle of wires, which can alternatively comprise a optical
fiber or bundle of fibers, can be incorporated into the uncured
tubular braided sleeve and become set in place when the sleeve is
cured. In the embodiment shown in FIG. 6, the conductor 130 runs
parallel to the axis of the sleeve. Although not wound helically,
conductor 130 is preferably woven into the helically would fibers
102, 104. Alternatively, the conductor(s) may be woven into the
fibers of the sleeve in a helical manner. Connectors (not shown)
for extending the conductor or optical fiber can also be
incorporated into the ends of the sleeve.
[0042] In still another embodiment, implementations of the
invention may include applications external to metallic casing or
sand screens. In one such application, shown in FIG. 7, the casing
comprises a metallic expandable tubular 146, used in well
construction for reducing or eliminating diameter transitions, such
as in a monobore well. In this application, the sleeve may be run
into the well prior to placement of the metallic casing or can be
inserted into the well on the outer diameter of the metallic
casing. In order to maintain a continuous sleeve, a longitudinal or
helical seam may be required that is either stitched or adhered
together during installation. The tubular braided sleeve 148
expands as the casing or screen is expanded by the drawing of a
mandrel 142 which is pulled toward the surface using a cable or
wireline 144. This configuration is particularly useful in
combination with embedded metallic conductors or optical fiber for
use in conductors because of the difficulty in providing for signal
and data communication in monobore or reduced diameter transition
wells. Because the structural support provided by the tubular
braided sleeve may reduce the forces and stresses on the metallic
expandable casing, one advantage of the present invention is to
reduce the weight and thickness requirement for the metallic
expandable casing or screen thereby decreasing the forces and
pressure required to expand the metallic expandable casing or
screen as well as the time required to accomplish that expansion.
These factors may also allow for a larger diameter change during
expansion of the metallic expandable casing or screen. The heat
required for curing can be provided by circulating high temperature
fluids within the bore of the tubular, by electrical resistance
heating of conductors embedded in the composite braid, by an
exothermic reaction of casing cement in the vicinity of the sleeve,
or by any other practical means.
[0043] In another embodiment of the invention, for use as
production tubing or casing in deep wells, an internal cable (not
shown) is placed within the tubular braid in order to support the
tension loading during installation. The internal cable may be
metallic, high performance polymer, or other material capable of
bearing high longitudinal tensile stress. The internal cable is
preferably incorporated into the braid to distribute the load due
to the weight of the sleeve to the cable and may optionally also
support the weight of a device at the bottom of the sleeve, such as
a bottom hole assembly. Similarly, a longitudinal cable may be
utilized to support the tubular braided sleeve during installation.
Such a cable may be external or internal to the sleeve and may be
removed after installation and curing of the resin.
[0044] Another use for the present invention is as a means for
installing and fixing in place a composite screen for the purposes
of particulate control, more specifically for confining sand to the
formation while allowing the production fluid to flow out of the
formation into the wellbore. Current sand screens are manufactured
as multiple layers of corrosion resistant steel expanded metal and
wire screens. A composite braided sleeve, or multiple braided
sleeves, can be employed as a sand screen. A tubular braided sleeve
can also be used as a protective shroud or layer over conventional
metallic screens. The composite braided tubular sleeve could also
incorporate metallic and/or fiber optic conductors and/or sensors
into the fabric to make a smart sand screen.
[0045] The braiding configuration can easily be optimized for the
necessary mesh size as required to minimize particulate flow into
the wellbore. It may also be possible to provide an adjustable mesh
size by axially compressing or expanding the mesh to change the
mesh size to allow for screen cleaning by backflushing the screen.
The braided sleeve impregnated with a resin can be used as a means
for providing a composite screen that can be inflated either
mechanically or hydraulically (using a bladder inside to expand).
Once the sleeve is in contact with the formation face and allowed
to set, it would act as a sand control device that conforms to the
wellbore.
[0046] During drilling operations, a patch of braided sleeve can be
used to cover a water-producing zone or a low fracture gradient
zone, or can be placed within a horizontal wellbore to stabilize
the wellbore against collapse. The braided sleeve can be placed
around the drill string and expanded at the pre-specified
location.
[0047] While preferred embodiments of the present invention have
been disclosed and described herein, it will be understood that
variations and modifications can be made without departing from the
scope of the invention. For example, one or more of the various
embodiments described above can be combined. The preceding
discussion is not intended to limit the claims that follow. In
addition, unless specifically so stated, the sequential recitation
of claims is not intended be a requirement that the steps be
performed in any particular order, or that one step be completed
before another step begins.
* * * * *