U.S. patent application number 11/012502 was filed with the patent office on 2005-06-30 for multiple expansion sand screen system and method.
This patent application is currently assigned to NOBLE DRILLING SERVICES INC.. Invention is credited to King, Charles H., Maurer, William C..
Application Number | 20050139359 11/012502 |
Document ID | / |
Family ID | 34703617 |
Filed Date | 2005-06-30 |
United States Patent
Application |
20050139359 |
Kind Code |
A1 |
Maurer, William C. ; et
al. |
June 30, 2005 |
Multiple expansion sand screen system and method
Abstract
In one embodiment, a wellbore completion method includes
disposing an expandable screen assembly into a wellbore, in which
the expandable screen assembly includes a base pipe, an
intermediate expansion system, and a screen element. The method
further includes radially expanding the base pipe and radially
expanding the intermediate expansion system after radially
expanding the base pipe.
Inventors: |
Maurer, William C.;
(Houston, TX) ; King, Charles H.; (Austin,
TX) |
Correspondence
Address: |
BAKER BOTTS L.L.P.
2001 ROSS AVENUE
SUITE 600
DALLAS
TX
75201-2980
US
|
Assignee: |
NOBLE DRILLING SERVICES
INC.
|
Family ID: |
34703617 |
Appl. No.: |
11/012502 |
Filed: |
December 15, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60532934 |
Dec 29, 2003 |
|
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|
Current U.S.
Class: |
166/380 ;
166/207; 166/384 |
Current CPC
Class: |
E21B 43/103 20130101;
E21B 43/108 20130101; E21B 43/105 20130101; E21B 43/08
20130101 |
Class at
Publication: |
166/380 ;
166/384; 166/207 |
International
Class: |
E21B 043/04 |
Claims
1. A wellbore completion method, comprising: disposing an
expandable screen assembly into a wellbore, the expandable screen
assembly comprising a base pipe, an intermediate expansion system
disposed outside the base pipe, and a screen element disposed
outside the intermediate expansion system; radially expanding the
base pipe; and radially expanding the intermediate expansion system
after radially expanding the base pipe.
2. The method of claim 1, further comprising disposing a completion
fluid into an annular space between a wall of the wellbore and the
expandable screen assembly.
3. The method of claim 1, wherein radially expanding the
intermediate expansion system comprises chemically expanding.
4. The method of claim 1, wherein radially expanding the
intermediate expansion system comprises thermally expanding.
5. The method of claim 1, wherein radially expanding the
intermediate expansion system comprises electrically expanding.
6. The method of claim 1, wherein radially expanding the
intermediate expansion system comprises mechanically expanding.
7. A wellbore completion system, comprising: an expandable screen
assembly configured to be disposed into a wellbore, the expandable
screen assembly comprising a base pipe, an intermediate expansion
system outside of the base pipe, and a screen element outside of
the intermediate expansion system; an expander operable to radially
expand the base pipe; and an actuation system operable to radially
expand the intermediate expansion system.
8. The system of claim 7, further comprising a pump operable to
dispose a completion fluid into an annular space between a wall of
the wellbore and the expandable screen assembly.
9. The system of claim 7, wherein the expander comprises a cone
expander.
10. The system of claim 7, wherein the actuation system comprises a
chemical expansion system.
11. The system of claim 7, wherein the actuation system comprises a
thermal expansion system.
12. The system of claim 7, wherein the actuation system comprises a
electrical expansion system.
13. The system of claim 7, wherein the actuation system comprises a
mechanical expansion system.
14. The system of claim 7, wherein the actuation system comprises a
plurality of expandable spheres.
15. A wellbore completion method, comprising: disposing an
expandable screen assembly into a wellbore, the expandable screen
assembly comprising a base pipe, an intermediate expansion system,
and a screen element; radially expanding the intermediate expansion
system; and radially expanding the base pipe after radially
expanding the intermediate expansion system.
16. The method of claim 1.5, further comprising disposing a
completion fluid into an annular space between a wall of the
wellbore and the expandable screen assembly.
17. The method of claim 15, wherein radially expanding the
intermediate expansion system comprises chemically expanding.
18. The method of claim 15,, wherein radially expanding the
intermediate expansion system comprises thermally expanding.
19. The method of claim 15, wherein radially expanding the
intermediate expansion system comprises electrically expanding.
20. The method of claim 15, wherein radially expanding the
intermediate expansion system comprises mechanically expanding.
21. An expandable screen assembly, comprising: a base pipe; an
intermediate expansion system outside of the base pipe; an
actuation system operable to radially expand the intermediate
expansion system; and a screen element outside of the intermediate
expansion system.
22. The system of claim 21, wherein the actuation system comprises
a chemical expansion system.
23. The system of claim 21, wherein the actuation system comprises
a thermal expansion system.
24. The system of claim 21, wherein the actuation system comprises
a electrical expansion system.
25. The system of claim 21, wherein the actuation system comprises
a mechanical expansion system.
26. The system of claim 21, wherein the actuation system comprises
a plurality of expandable spheres.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of Ser. No. 60/532,934,
entitled "Expandable Sand Screen Utilizing Multiple Expansion
System," filed provisionally on Dec. 29, 2003.
TECHNICAL FIELD OF THE INVENTION
[0002] This invention relates generally to the field of wellbore
completion and, more particularly, to a multiple expansion sand
screen system and method.
BACKGROUND OF THE INVENTION
[0003] Sand control is important during completion and subsequent
production of a wellbore that is in hydraulic communication with
Earth formations susceptible to production of solid materials from
the formation. Such formations are known in the art as
"unconsolidated" and, if not protected with suitable wellbore
equipment, may produce solid materials of a character and quantity
so as to damage the wellbore, or at least reduce its capacity to
produce oil and gas from the formation. Devices known in the art as
"sand screens" are typically used to protect such unconsolidated
formations. Sand screens include a structural member, called a
"base pipe", having apertures therein to maintain the mechanical
integrity of the sand screen (meaning to provide mechanical support
for the screen. A "filter layer" is typically disposed outside the
base pipe. Many different types of filter layer are used,
including, for example, wound wire and mesh screen.
[0004] More recently, radially plastically deformable sand screens,
called "expandable sand screens" have been used in some wellbores
to increase productivity of wellbores completed in unconsolidated
Earth formations. A principal reason for the use of expandable sand
screens is to mechanically support the unconsolidated formation
prior to initiating fluid production. By supporting the formation
prior to initiating production, it is possible to reduce loss of
formation permeability due to movement of solid materials against
the screen during fluid production. A conventional (non-expandable)
sand screen must necessarily have an external diameter smaller than
the drilled out diameter of the wellbore ("open hole") prior to
insertion of the sand screen, in order for the screen to fit in the
wellbore. The smaller screen diameter results in an annular space
between the outer surface of the screen and the wall of the
wellbore, which may become filled with formation solids moved from
the formation during fluid production. Expandable sand screens are
intended to provide a way to close the annular space prior to
beginning fluid production, and thus prevent movement of formation
solids. Expandable sand screens are run into the wellbore in an
unexpanded state, wherein the external diameter of the screen is
less than the drilled out diameter of the wellbore. After
insertion, the screen is expanded using one or more types of
expansion tools, preferably to cause the screen to be placed into
firm contact with the wellbore wall.
[0005] During the expansion of expandable sand screens, it is
advantageous to push the sand screen outward to an extent so that
it "conforms" to, and applies pressure to, the wellbore wall in
order to hold the sand in place and increase oil and/or gas flow
into the wellbore. Many wellbores may include sections where the
actual diameter of the wellbore exceeds the drilled out diameter
(drill bit diameter) due to washout or other cause. In such
sections, it maybe necessary to expand a screen to 35 or 40 percent
greater than its unexpended diameter in order to place the screen
in form contact with the wall of the wellbore.
[0006] One problem with expandable screens known in the art is that
they are difficult to expand more than about 30 to 35 percent
because the base pipes made out of carbon steel or stainless steel
begin to fail. As a result, these screens may often not be expanded
enough to apply the high contact pressures needed to hold the sand
in place in enlarged wellbores, thus resulting in failure of the
sand screen or inadequate production. Conversely, if expanded to
the degree necessary to provide a suitable amount of contact
pressure, the base pipe may be weakened to an extent so as to have
very little resistance to crushing under external pressure, thus
leaving the wellbore susceptible to failure.
SUMMARY OF THE INVENTION
[0007] It is desirable to have an expandable sand screen that can
be made to conform to the wall of a wellbore, even if it is
necessary to expand the screen to 35 percent or more beyond the
unexpanded diameter of the screen, while maintaining sufficient
mechanical integrity to resist failure of the screen and consequent
loss of the wellbore.
[0008] In one embodiment, a wellbore completion method includes
disposing an expandable screen assembly into a wellbore, in which
the expandable screen assembly includes a base pipe, an
intermediate expansion system, and a screen element. The method
further includes radially expanding the base pipe and radially
expanding the intermediate expansion system after radially
expanding the base pipe.
[0009] Embodiments of the invention may provide a number of
technical advantages. In one embodiment, an expandable screen
possesses high collapse strength (e.g., 1000 to 3000 psi) due to
the strong base pipe. Such a screen may also be quickly and
reliably expanded with fixed or compliant cone expanders without
limited expansion like prior fixed-cone expansion screens.
[0010] Other technical advantages are readily apparent to one
skilled in the art from the following figures, descriptions, and
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIGS. 1 and 2 are cross-sectional elevation views
illustrating a wellbore completion method in accordance with one
embodiment of the present invention.
DETAILED DESCRIPTION
[0012] FIGS. 1 and 2 are cross-sectional elevation views
illustrating a wellbore completion method in accordance with one
embodiment of the present invention. Referring first to FIG. 1, a
wellbore completion system 100 is utilized in completing a wellbore
101 drilled within a formation 102. Wellbore 101 may be drilled
using any suitable drilling techniques and may have any suitable
diameter, length, and direction. Formation 102 may be any suitable
geological formation; however, the present invention is
particularly suitable for unconsolidated formations, such as
sandstone.
[0013] Holding the sand or other particles from formation 102 in
place during the completion process is important for effective oil
and/or gas flow into wellbore 101. Thus, expandable sand screens
are sometimes utilized to hold the sand in place. A major problem
with prior expandable sand screens is that they are difficult to
expand more than about 30-35% before the base pipes from which they
are made begin to fail. Thus, these prior screens may often not be
expanded enough to apply high contact pressures to hold the sand in
place.
[0014] Therefore, according to the teachings of one embodiment of
the invention, an expandable screen assembly 104 is utilized that
includes, in the illustrated embodiment, a base pipe 106, an
intermediate expansion system 108, and a screen element 110. Among
other things, expandable screen assembly 104 possesses high
collapse strength due to the strength of base pipe 106 in addition
to facilitating quick and reliable expansion without limited
expansion.
[0015] Base pipe 106 may be any suitable pipe of any suitable size
and configuration and may be formed from any suitable material,
including without limitation, carbon steel and stainless steel.
Base pipe 106 includes any suitable size and number of apertures
formed therein to enable flow of fluid from formation 102 into the
wellbore 101. Base pipe 106 may also have any suitable length and
may be formed from one or more sections. Base pipe 106 may be
disposed in wellbore 101 by any suitable method, such as the
utilization of a suitable work string 112. As described in further
detail below, any suitable method may be utilized to expand base
pipe 106, such as a cone expander 114 or other suitable expander
element. The expansion of base pipe 106 also expands intermediate
expansion system 108 and screen element 110.
[0016] Intermediate expansion system 108 is disposed around the
outside of base pipe 106 and may or may not couple directly to base
pipe 106. Intermediate expansion system 108 is formed from one or
more components that are operable to radially expand via an
actuation system 116. Radial expansion of intermediate expansion
system 108 causes radial expansion of screen element 110.
Intermediate expansion system 108 may be any suitable material
formed from one or more components that expand in response to
actuation of actuation system 116.
[0017] Actuation system 116 may be any suitable actuation system
that functions to radially expand intermediate expansion system
108. For example, actuation system 116 may be a chemical expansion
system, a thermal expansion system, an electrical expansion system,
a mechanical expansion system, or any other suitable actuation
system.
[0018] In a chemical expansion system embodiment, spheres of any
suitable material that swell when immersed in a suitable chemical
may be utilized. The chemical may be pumped down base pipe 106 and
through the apertures formed in base pipe 106 in any suitable
manner in order to contact the swellable spheres. For example, a
suitable rubber or elastomer that swells in the presence of a
liquid such as crude oil may be utilized. As another example,
compressible elastic spheres that are coated with a suitable
material that holds them in compression until a chemical is
utilized to dissolve or degrade this particular coating may be
utilized. In this embodiment, the spheres elastically expand
outward when the confining pressure produced by the coating is
removed. Other suitable chemical expansion systems are contemplated
by the present invention.
[0019] In a thermal expansion system embodiment, any suitable
materials that expand or swell when they are heated may be
utilized. For example, elastic spring-like materials, bimetallic
springs that bend when they are heated, or shape memory alloys that
transform into a different shape when heated may be utilized. Other
suitable thermal expansion systems are contemplated by the present
invention.
[0020] In an electrical actuation system embodiment, suitable
materials that change dimensions when subjected to electric
current, such as piezoelectric materials, may be utilized. Other
suitable electrical expansion systems are contemplated by the
present invention.
[0021] In a mechanical expansion system embodiment, a plurality of
spheres or other particles that push radially outward and expand
screen element 110 when subjected to axial compression from a
piston or other suitable element may be utilized. Other suitable
mechanical expansion systems are contemplated by the present
invention.
[0022] Screen element 110 may be any suitable screen of any
suitable size and configuration and may be formed from any suitable
material. For example, screen element 110 may be formed from a
suitable carbon steel and include a fine screen or coarse screen
(or both) inside of a suitable sleeve (sometimes referred to as a
"shroud") having suitable apertures formed therein. Screen element
110 may also have any suitable length and may be formed from one or
more sections. Screen element 110 is disposed around the outside of
intermediate expansion system 108 and may or may not directly
couple to intermediate expansion system 108. As described in
greater detail below, after expansion of base pipe 106 and
intermediate expansion system 108, screen element 110 engages and
applies a force to the wall of wellbore 101.
[0023] System 100 may also include a pump 118 operable to dispose a
completion fluid 120 into an annular space 122 between the wall of
wellbore 101 and screen element 110. Any suitable pump is
contemplated by the present invention. Completion fluid 120 may be
any suitable completion fluid.
[0024] In operation of one embodiment of the invention, and with
reference to FIGS. 1 and 2, wellbore 101 is first drilled by any
suitable method within formation 102 and the upper portion thereof
may be cased with a casing (not explicitly illustrated). A suitable
liner hanger (not explicitly illustrated) is utilized to position
expandable screen assembly 104 within wellbore 101. Work string 112
with expander 114 coupled thereto is then run-in-hole and
completion fluid 120 is circulated down into wellbore 101.
Completion fluid 120 fills annular space 122.
[0025] Work string 112 is then utilized to apply weight to expander
114, which translates downward and starts radially expanding base
pipe 106. Expander 114 plastically deforms base pipe 106. As base
pipe 106 is radially expanded outwards towards the wall of wellbore
101, intermediate expansion system 108 and screen element 110 may
also be expanded radially.
[0026] After base pipe 106 has been expanded as desired, then
intermediate expansion system 108 is expanded via actuation system
116. Intermediate expansion system 108 expands screen element 110
further towards the wall of wellbore 101 so that it applies a force
to the wall of wellbore 101. In other embodiments, intermediate
expansion system 108 may be radially expanded by actuation system
116 before base pipe 106 is expanded. Any suitable amount of
expansion of base pipe 106, intermediate expansion system 108, and
screen element is contemplated by the present invention.
[0027] Thus, system 100 includes expandable screen assembly 104
that increases the overall expansion of screen element 110 to
ensure that screen element 110 contacts the wall of wellbore 101
and exert adequate force thereto for sand control and efficient
production from wellbore 101.
[0028] Although embodiments of the invention and their advantages
are described in detail, a person of ordinary skill in the art
could make various alterations, additions, and omissions without
departing from the spirit and scope of the present invention as
defined by the appended claims.
* * * * *