U.S. patent application number 14/803055 was filed with the patent office on 2016-01-28 for completion system.
The applicant listed for this patent is Meta Downhole Limited. Invention is credited to Roy Campbell, Neil Thomson, Peter Wood.
Application Number | 20160024894 14/803055 |
Document ID | / |
Family ID | 53900842 |
Filed Date | 2016-01-28 |
United States Patent
Application |
20160024894 |
Kind Code |
A1 |
Campbell; Roy ; et
al. |
January 28, 2016 |
Completion System
Abstract
An expandable completion system and method of completing a well
in which gravel packing of multiple completion zones is achieved by
morphing a sleeve across a gravel packed annulus to secure it to a
well bore wall by the use of fluid pressure to provide a zonal
isolation barrier between two gravel packed zones in a wellbore. An
embodiment provides gravel packing for multiple completion zones by
circulation. A further embodiment allows selective isolation
barriers to be created along the length of the completion string
after the gravel has been pumped into the annulus.
Inventors: |
Campbell; Roy; (Ellon,
GB) ; Thomson; Neil; (Aberdeen, GB) ; Wood;
Peter; (Aberdeen, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Meta Downhole Limited |
Aberdeen |
|
GB |
|
|
Family ID: |
53900842 |
Appl. No.: |
14/803055 |
Filed: |
July 18, 2015 |
Current U.S.
Class: |
166/278 ;
166/51 |
Current CPC
Class: |
E21B 33/127 20130101;
E21B 33/1277 20130101; E21B 43/04 20130101; E21B 33/1243 20130101;
E21B 33/1272 20130101; E21B 43/08 20130101 |
International
Class: |
E21B 43/04 20060101
E21B043/04; E21B 43/08 20060101 E21B043/08; E21B 33/127 20060101
E21B033/127 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 23, 2014 |
GB |
GB1413089.2 |
Aug 15, 2014 |
GB |
GB1414568.4 |
Claims
1. A method of completing a well, comprising: locating a sleeve
member on the exterior of a tubular body and sealing it thereto to
create a chamber therebetween, using the tubular body to connect
two sand screens together in an assembly; running the assembly on a
string into a wellbore and positioning the sleeve member at a
position between zones within a larger diameter structure; pumping
fluid through a port in the tubular body to access the chamber;
causing the sleeve member to move radially outwardly to morph
against an inner surface of the larger diameter structure; and
providing a gravel mixture through at least one portion of the
assembly to locate between the tubular body and the larger diameter
structure.
2. A method according to claim 1 wherein the method includes
locating multiple assemblies on the string and undertaking the
morphing of the sleeve and the provision of a gravel mixture at any
desired locations where an isolation barrier is required.
3. A method according to claim 1 wherein the method includes the
step of inserting an inner completion string into the string and
isolating the sand screens by sealing between the inner completion
string and the tubular body.
4. A method according to claim 1 wherein the step of providing a
gravel mixture includes pumping gravel slurry through the string to
exit at an end of the tubular body and circulate up an annulus
between the assembly and the larger diameter structure.
5. A method according to claim 1 wherein the step of pumping of
fluid through a port in the tubular body to access the chamber and
cause the sleeve member to move radially outwardly occurs after the
gravel slurry is pumped through the string into the annulus.
6. A method according to claim 5 wherein the sleeve moves radially
outwardly to crush the gravel and morph against the inner surface
of the large diameter structure.
7. A method according to claim 1 wherein the method comprises
causing the sleeve member to move radially outwardly to morph
against an inner surface of the larger diameter structure before
providing a gravel mixture by pumping gravel slurry through at
least one shunt tubular component of the assembly to an exit
located between the morphed sleeve member and an end of the tubular
body such that the gravel slurry circulates around an annulus
between the assembly and the larger diameter structure.
8. A method according to claim 7 wherein the at least one shunt
tubular component is provided with a valve.
9. A method according to claim 1 wherein the step of providing a
gravel mixture includes pumping gravel slurry through the string to
exit at an end of the tubular body and circulate up an annulus
between the assembly and the larger diameter structure and pumping
gravel slurry through at least one shunt tubular component of the
assembly to an exit located between the sleeve member and an end of
the tubular body such that the gravel slurry circulates around an
annulus between the assembly and the larger diameter structure.
10. A method according to claim 9 wherein the step of pumping of
fluid through a port in the tubular body to access the chamber and
cause the sleeve member to move radially outwardly occurs after the
gravel slurry is pumped into the annulus.
11. A method according to claim 10 wherein the sleeve moves
radially outwardly to crush the gravel and morph against the inner
surface of the large diameter structure.
12. An expandable completion system, comprising: an assembly
comprising two sand screens connected via a tubular body, the
assembly including connections for location in a tubular string to
be run in and secured within a larger diameter generally
cylindrical structure; wherein a sleeve member is positioned on the
exterior of the tubular body, to create a chamber therebetween; the
tubular body including a port to permit the flow of fluid into the
chamber to cause the sleeve member to move outwardly and morph
against an inner surface of the larger diameter structure wherein
the assembly is operable to provide a gravel slurry into an annulus
between the assembly and the larger diameter structure.
13. An expandable completion system according to claim 12 wherein
the sleeve member has a first end which is affixed and sealed to
the tubular body and a second end which includes a sliding seal to
permit longitudinal movement of the second end over the tubular
body.
14. An expandable completion system according to claim 12 wherein
the sand screens are slotted liners.
15. An expandable completion system according to claim 12 wherein
the system includes a plurality of assemblies.
16. An expandable completion system according to claim 15 wherein
the assemblies are separated by a tubular body, wherein a sleeve
member is positioned on the exterior of the tubular body, to create
a chamber therebetween; the tubular body including a port to permit
the flow of fluid into the chamber to cause the sleeve member to
move outwardly and morph against an inner surface of the larger
diameter structure.
17. An expandable completion system according to claim 12 wherein
the assembly(ies) comprises a string exit at an end.
18. An expandable completion system according to claim 12 wherein
the assembly(ies) comprises at least one shunt tubular having at
least one shunt exit located between the sleeve member and an end
of the tubular body.
19. An expandable completion system according to claim 18 wherein
the at least one shunt tubular is provided with a valve.
20. An expandable completion system according to claim 18 wherein
the assembly comprise string exit at an end and at least one shunt
tubular having at least one shunt exit located between the sleeve
member and an end of the tubular body.
Description
BACKGROUND
[0001] The present invention relates to an apparatus and method for
completing a well by securing a tubular within another tubular or
borehole, creating a seal across an annulus in a well bore, and
centralising or anchoring tubing within a wellbore. In particular,
though not exclusively, the invention relates to morphing a sleeve
across a gravel packed annulus to secure it to a well bore wall by
the use of fluid pressure to provide a zonal isolation barrier
between two gravel packed zones in a wellbore.
[0002] In the exploration and production of oil and gas wells, sand
production can have devastating effects as it will erode hardware;
cause blockages in the tubulars and surface equipment; and can
create downhole cavities resulting in formation subsidence and
casing collapse. Methods of completing sand-prone formations have
therefore been developed with the most widely adopted being gravel
packing. A slurry of gravel is pumped into the annulus between a
centralized screen and either perforated casing or open borehole.
The fluid in the slurry is pumped into the formation or through the
screen and back to surface leaving a gravel pack. The gravel pack
acts as a granular filter with very high permeability but prevents
the formation sand from entering the wellbore.
[0003] Completing multiple zones is very difficult as the slurry
requires to be injected into the annulus between the packers used
to isolate each zone. The slurry must entirely fill the annulus
between the packers as any void will promote sand production and
risk formation subsidence and casing collapse. The most reliable
method of ensuring even distribution is achieved at the rat-hole
where the slurry is pumped down a service string and returns up the
annulus.
[0004] Packers are typically used to isolate one section of a
downhole annulus from another section of the downhole annulus. The
annulus may be between tubular members, such as a liner, mandrel,
production tubing and casing or between a tubular member, typically
casing, and the wall of an open borehole. These packers are carried
into the well on tubing and at the desired location, elastomeric
seals are urged radially outwards or elastomeric bladders are
inflated to cross the annulus and create a seal with the outer
generally cylindrical structure i.e. another tubular member or the
borehole wall. These elastomers have disadvantages, particularly as
they may be easily eroded.
[0005] As a result, metal seals have been developed, where a
tubular metal member is run in the well and at the desired
location, an expander tool is run through the member. The expander
tool typically has a forward cone with a body whose diameter is
sized to the generally cylindrical structure so that the metal
member is expanded to contact and seal against the cylindrical
structure. These so-called expanded sleeves have an internal
surface which, when expanded, is cylindrical and matches the
profile of the expander tool. These sleeves work well in creating
an annular seal between tubular members but can have problems in
sealing against the irregular surface of an open borehole.
[0006] The present applicants have developed a technology where a
metal sleeve is forced radially outwardly by the use of fluid
pressure acting directly on the sleeve. Sufficient hydraulic fluid
pressure is applied to move the sleeve radially outwards and cause
the sleeve to morph itself onto the generally cylindrical
structure. The sleeve undergoes plastic deformation and, if morphed
to a generally cylindrical metal structure, the metal structure
will undergo elastic deformation to expand by a small percentage as
contact is made. When the pressure is released the metal structure
returns to its original dimensions and will create a seal against
the plastically deformed sleeve. During the morphing process, both
the inner and outer surfaces of the sleeve will take up the shape
of the surface of the wall of the cylindrical structure. This
morphed isolation barrier is therefore ideally suited for creating
a seal against an irregular borehole wall.
[0007] Such a morphed isolation barrier is disclosed in U.S. Pat.
No. 7,306,033, which is incorporated herein by reference. An
application of the morphed isolation barrier for FRAC operations is
disclosed in US2012/0125619, which is incorporated herein by
reference. Typically, the sleeve is mounted around a supporting
tubular body, being sealed at each end of the sleeve to create a
chamber between the inner surface of the sleeve and the outer
surface of the body. A port is arranged through the body so that
fluid can be pumped into the chamber from the throughbore of the
body.
[0008] US 2004/0074642 to Schlumberger Technology Corporation
discloses an expandable completion system and method, by expanding
a pair of spaced apart expandable sand screens in a well, the
expandable sand screens connected to one another by an unexpanded
tubing section, and gravel packing the portion of the well around
the unexpanded tubing section. Zonal isolation is achieved by
setting packers at the unexpanded tubular section prior to gravel
packing the annulus between the packer and each sand screen,
respectively. Gravel packing may also be done around the expandable
sand screen. This arrangement has the same disadvantage as the
prior art in that a gravel packing sub must be located at each
annulus between the sand screens or between a sand screen and a
packer with the potential result of uneven gravel packing.
Additionally, it is difficult to expand a sand screen reliably to
ensure a desired mesh size is achieved when expansion is completed
downhole.
[0009] It is therefore an object of the present invention to
provide an expandable completion system and method which obviates
or mitigates one or more disadvantages of the prior art.
BRIEF SUMMARY OF THE INVENTION
[0010] According to a first aspect of the present invention there
is provided a method of completing a well, comprising: [0011]
locating a sleeve member on the exterior of a tubular body and
sealing it thereto to create a chamber therebetween, [0012] using
the tubular body to connect two sand screens together in an
assembly; [0013] running the assembly on a string into a wellbore
and positioning the sleeve member at a position between zones
within a larger diameter structure; [0014] pumping fluid through a
port in the tubular body to access the chamber; [0015] causing the
sleeve member to move radially outwardly to morph against an inner
surface of the larger diameter structure; and [0016] providing a
gravel mixture through at least one portion of the assembly to
locate between the tubular body and the large diameter
structure.
[0017] In this way, gravel packing can advantageously be provided
to enhance the effectiveness of the isolation barrier created by
the morphed sleeve member.
[0018] The method may include locating multiple assemblies on the
string and undertaking the morphing of the sleeve and the provision
of a gravel mixture at any desired locations where an isolation
barrier is required. In this way, multiple zone completion is
achieved.
[0019] The large diameter structure may be an open hole borehole, a
borehole lined with a casing or liner string which may be cemented
in place downhole.
[0020] Preferably, pumping fluid through a port in the tubular body
to access the chamber involves pumping fluid through multiple ports
in the tubular body to access the chamber. This provides a faster
morphing of the sleeve.
[0021] Preferably, the method includes the step of rupturing a disc
at a valve in the port to allow fluid to enter the chamber when the
pressure reaches a desired value. This allows selective and
controlled activation of the morphing process.
[0022] The method may include the steps of running in an activation
fluid delivery tool, creating a temporary seal above and below the
port and injecting fluid from the tool into the chamber via the
port. Such an arrangement allows selective operation of the sleeve
member.
[0023] The method may include the step of inserting an inner
completion string into the string and isolating the sand screens by
sealing between the inner completion string and the tubular body.
In this way, production can be controlled from each zone.
[0024] In an embodiment, the method of providing a gravel mixture
may include pumping gravel slurry through the string to exit at an
end of the tubular body and circulate up an annulus between the
assembly and the larger diameter structure. This enables gravel
packing to be achieved by circulation in the wellbore.
[0025] The pumping of fluid through a port in the tubular body to
access the chamber and cause the sleeve member to move radially
outwardly may occur after the gravel slurry is pumped through the
string into the annulus. The sleeve may move radially outwardly to
crush the gravel and morph against the inner surface of the large
diameter structure. In such an arrangement, the gravel packing is
achieved by circulation in the wellbore with the isolation barrier
being operated after the gravel is in place.
[0026] In an embodiment, the method may comprise causing the sleeve
member to move radially outwardly to morph against an inner surface
of the larger diameter structure before providing a gravel mixture
by pumping gravel slurry through at least one shunt tubular
component of the assembly to an exit located between the morphed
sleeve member and an end of the tubular body such that the gravel
slurry circulates around an annulus between the assembly and the
larger diameter structure. This enables gravel packing to be
achieved by direct provision of the gravel slurry into the annulus
of the wellbore after a morphed annular barrier is in place and
enables the continued supply of gravel slurry regardless of
circulation in the annulus.
[0027] The gravel slurry may be operable to set when packed in the
annulus as required. By providing gravel slurry which can set, an
effective gravel packed annular barrier is formed below the morphed
sleeve annular barrier thus securing the assembly effectively.
[0028] The at least one shunt tubular may be provided with a valve.
Provision of a valve in a shunt tubular enables the effective
sealing of the shunt tubular after the gravel is packed and set
thus ensuring a complete annular barrier is formed around the
assembly.
[0029] In an embodiment, the method of providing a gravel mixture
may include pumping gravel slurry through the string to exit at an
end of the tubular body and circulate up an annulus between the
assembly and the larger diameter structure and pumping gravel
slurry through at least one shunt tubular component of the assembly
to an exit located between the sleeve member and an end of the
tubular body such that the gravel slurry circulates around an
annulus between the assembly and the larger diameter structure.
This enables gravel packing to be achieved by circulation and
direct provision in the annulus in the wellbore.
[0030] The pumping of fluid through a port in the tubular body to
access the chamber and cause the sleeve member to move radially
outwardly may occur after the gravel slurry is pumped into the
annulus. The sleeve may move radially outwardly to crush the gravel
and morph against the inner surface of the large diameter
structure. In such an arrangement, the isolation barrier is
operated after the gravel is in place.
[0031] According to a second aspect of the present invention there
is provided an expandable completion system, comprising:
[0032] an assembly comprising two sand screens connected via a
tubular body, the assembly including connections for location in a
tubular string to be run in and secured within a larger diameter
generally cylindrical structure;
[0033] wherein a sleeve member is positioned on the exterior of the
tubular body, to create a chamber therebetween;
[0034] the tubular body including a port to permit the flow of
fluid into the chamber to cause the sleeve member to move outwardly
and morph against an inner surface of the larger diameter structure
wherein the assembly is operable to provide a gravel slurry into an
annulus between the assembly and the larger diameter structure.
[0035] In this way, the completion system is easily assembled and
run in to a wellbore. The screens are not expandable and thus the
mesh size can be fixed.
[0036] The sleeve member may have a first end which is affixed and
sealed to the tubular body and a second end which includes a
sliding seal to permit longitudinal movement of the second end over
the tubular body. In this way, as the sleeve is morphed,
longitudinal contraction of the sleeve member occurs which reduces
the thinning of the sleeve member during morphing.
[0037] The large diameter structure may be an open hole borehole, a
borehole lined with a casing or liner string which may be cemented
in place downhole.
[0038] Preferably, there is a plurality of ports arranged through
the tubular body. In this way, rapid morphing of the sleeve member
can be achieved. The ports may be arranged circumferentially around
the body. The ports may be arranged longitudinally along the
body.
[0039] The port may include a barrier. In this way, fluid is
prevented from entering the chamber until activation is required.
The barrier may be a rupture disc which allows fluid to flow
through the port at a predetermined fluid pressure. Alternatively
the barrier may be a valve. Preferably the valve is a one-way check
valve. In this way, fluid is prevented from exiting the
chamber.
[0040] The sand screens may be of any configuration known to those
skilled in the art. In this way standard sand screens can be used.
The sand screen may be a slotted liner or any other arrangement
used to filter production fluid entering the tubular string.
[0041] Preferably, the system includes a plurality of assemblies.
The assemblies may be separated by a tubular body, wherein a sleeve
member is positioned on the exterior of the tubular body, to create
a chamber therebetween; the tubular body including a port to permit
the flow of fluid into the chamber to cause the sleeve member to
move outwardly and morph against an inner surface of the larger
diameter structure. In this way a multiple zone completion system
is formed.
[0042] In an embodiment, the assembly comprises a string exit at an
end. Gravel slurry may be pumped through the string to exit at the
string exit. Such an assembly enables the gravel slurry to be
output at the string end and circulate up an annulus between the
assembly and the larger diameter structure due to circulation in
the wellbore. The gravel packing may be supplied such that on
actuation the sleeve member is operable to move outwardly to crush
gravel and morph against an inner surface of the larger
diameter.
[0043] In an embodiment, the assembly comprises at least one shunt
tubular having at least one shunt exit located between the sleeve
member and an end of the tubular body. Gravel slurry may be pumped
through the shunt tubular such that it exits at the shunt exit and
circulates around an annulus between the assembly and the larger
diameter structure. This assembly gravel packing to be achieved by
direct provision of the gravel slurry into the annulus of the
wellbore. The provision of gravel slurry through the shunt tubular
may occur after the sleeve member is actuated such that a morphed
annular barrier is in place and such an assembly enables the
continued supply of gravel slurry regardless of circulation in the
annulus.
[0044] The at least one shunt tubular may be provided with a valve.
Provision of a valve in a shunt tubular enables the effective
sealing of the shunt tubular after the gravel is packed and set
thus ensuring a complete annular barrier is formed around the
assembly.
[0045] In an embodiment, the assembly may comprise string exit at
an end and at least one shunt tubular having at least one shunt
exit located between the sleeve member and an end of the tubular
body. Such an arrangement enables gravel slurry to be provided
through the string exit and through the shunt tubular to achieve an
annular gravel pack in an expedient manner.
[0046] In the description that follows, the drawings are not
necessarily to scale. Certain features of the invention may be
shown exaggerated in scale or in somewhat schematic form, and some
details of conventional elements may not be shown in the interest
of clarity and conciseness. It is to be fully recognized that the
different teachings of the embodiments discussed below may be
employed separately or in any suitable combination to produce the
desired results.
[0047] Accordingly, the drawings and descriptions are to be
regarded as illustrative in nature, and not as restrictive.
Furthermore, the terminology and phraseology used herein is solely
used for descriptive purposes and should not be construed as
limiting in scope. Language such as "including," "comprising,"
"having," "containing," or "involving," and variations thereof, is
intended to be broad and encompass the subject matter listed
thereafter, equivalents, and additional subject matter not recited,
and is not intended to exclude other additives, components,
integers or steps. Likewise, the term "comprising" is considered
synonymous with the terms "including" or "containing" for
applicable legal purposes.
[0048] All numerical values in this disclosure are understood as
being modified by "about". All singular forms of elements, or any
other components described herein including (without limitations)
components of the apparatus are understood to include plural forms
thereof.
[0049] The terms `seal` and `isolation` are used with the
recognition that some leakage may occur and that such leakage may
be acceptable. Thus, some embodiments of the present invention may
allow for leakage without departing from the scope of the invention
and systems that provide for such leakage fall within the scope of
the present invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0050] Embodiments of the present invention will now be described,
by way of example only, with reference to the accompanying drawings
of which:
[0051] FIGS. 1a-1c are schematic illustrations of a sequence for
completing a well; FIG. 1a is a cross-sectional view of an assembly
according to the present invention located in a wellbore; FIG. 1b
shows gravel being pumped into the wellbore and circulated
therethrough; and FIG. 1c is a cross-sectional view of the assembly
of FIG. 1a with a morphed sleeve having crushed the gravel and
sealed against the wall of the wellbore; and
[0052] FIGS. 2a-2c are schematic illustrations of a sequence for
setting two sleeve members in an open borehole during a completion
according to an embodiment of the present invention; FIG. 2a is a
cross-sectional view of a tubular string with two assemblies
according to the present invention and the deployment of gravel;
FIG. 2b shows the tubular string in the borehole with an activation
fluid delivery tool inserted therein; and FIG. 2c is a
cross-sectional view of the tubular string with morphed sleeves and
an inner completion string.
[0053] FIGS. 3a-3c are schematic illustrations of a sequence for
setting a sleeve member in an open borehole during a completion
according to an embodiment of the present invention. FIG. 3a is a
cross-sectional view of an assembly according to the present
invention located in a wellbore; FIG. 3b is a cross-sectional view
of the assembly of FIG. 3a with a morphed sleeve sealed against the
wall of the wellbore; and FIG. 3c shows gravel being pumped into
the wellbore.
DETAILED DESCRIPTION OF THE INVENTION
[0054] Reference is initially made to FIG. 1a of the drawings which
illustrates an assembly, generally indicated by reference numeral
10, including first 20 and second 22 sand screens located on either
side of a tubular body 12, with a sleeve member 14, chamber 16 and
port 18, according to an embodiment of the present invention.
[0055] Sand screens 20,22 are of any configuration known to those
skilled in the art. They are of generally cylindrical construction
with multiple apertures passing therethrough in the form of a mesh,
slots or holes. The aperture dimensions are selected to prevent the
passage of sand into the bore 24 of the assembly 10. A first end 26
of the first sand screen 20 and a second end 28 of the second sand
screen 22 are connected into a tubular string 30 such as casing,
liner or production tubing that is intended to be permanently set
or completed in a well bore. The string may be a drill pipe or any
other tubular string designed to be run in a well bore. A first end
32 of the second sand screen 22 and a second end 34 of the first
sand screen 20 are connected via a tubular body 12.
[0056] Tubular body 12 is a cylindrical tubular section having an
inner diameter preferably matching the inner diameter of the first
20 and second 22 sand screens. Body 12 includes a throughbore 36
which is co-linear with the throughbore 24 of the string 30.
[0057] A port 18 is provided through the side wall 38 of the body
12 to provide a fluid passageway between the throughbore 36 and the
outer surface 40 of the body 12. While only a single port 18 is
shown, it will be appreciated that a set of ports may be provided.
These ports may be equidistantly spaced around the circumference of
the body 12 and/or be arranged along the body to access the chamber
16.
[0058] In an embodiment, at the port 18 there is located a check
valve 54. The check valve 54 is a one-way valve which only permits
fluid to pass from the throughbore 36 into the chamber 16. The
check valve 54 can be made to close when the pressure within the
chamber 16 reaches a predetermined level, this being defined as the
morphed pressure value. Thus, when the pressure in the sleeve 14
reaches the morphed pressure value, the valve 54 will close. Also
arranged at the port 18 is a rupture disc 56. The rupture disc 56
is rated to a desired pressure at which fluid access to the chamber
is desired. In this way, the rupture disc 56 can be used to control
when the setting of the sleeve 14 is to begin. The disc 56 can be
operated by increasing pressure in the throughbore 36 with the
pressure to rupture the disc being selected to be greater than the
fluid pressure required to activate any other tools or functions in
the well bore.
[0059] Tubular body 12 is located coaxially within a sleeve member
14. Sleeve member 14 is a steel cylinder being formed from
typically 316L or Alloy 28 grade steel but could be any other
suitable grade of steel or any other metal material or any other
suitable material which undergoes elastic and plastic deformation.
Ideally the material exhibits high ductility i.e. high strain
before failure. The sleeve member 14 is appreciably thin-walled of
lower gauge than the tubing body 12 and is preferably formed from a
softer and/or more ductile material than that used for the tool
body 12. The sleeve member 14 may be provided with a non-uniform
outer surface 40 such as ribbed, grooved or other keyed surface in
order to increase the effectiveness of the seal created by the
sleeve member 14 when secured within another casing section or
borehole 60.
[0060] Sleeve member 14 which surrounds the tubular body 12 is
affixed thereto via welded or clamped connections 42, 44,
respectively. Such attachments 42, 44 are pressure-tight
connectors. An O-ring seal (not shown) may also be provided between
the inner surface 46 of the sleeve member 14 and the outer surface
40 of the tubular body 12 to act as a secondary seal or back-up to
the seal provided by the welded connections. In an embodiment of
the present invention, the first attachment means 42 is provided by
a mechanical clamp to fix the first end 48 of sleeve member 14 to
the tubular body 12. The second end 50 of the sleeve member 14 is
connected to the outer surface 40 of the tubular body 12 via a
sliding seal arrangement. In this way, the second end 50 of the
sleeve member 14 can move longitudinally along the outer surface 40
of the tubular body 12 while maintaining a seal between the
surfaces to hold pressure within the chamber 16. This sliding seal
is arranged so that the second end 50 of the sleeve member 14 is
permitted to move towards the first end 48. Thus when the sleeve
member 14 is caused to move in a radially outward direction, during
morphing, the sleeve contracts which causes simultaneous movement
of the sliding seal. This has the advantage in reducing thinning of
the material of the sleeve 14 by the radial outward expansion.
[0061] The attachments 42, 44 together with the inner surface 46 of
the sleeve member 14 and the outward surface 40 of the body 12
define the chamber 16. The port 18 is arranged to access the
chamber 16 and permit fluid communication between the through-bore
24 and the chamber 16.
[0062] Thus, the assembly 10 is constructed by taking two sand
screens 20,22, connecting them on either side of a tubular body 12
and locating a sleeve member 14 over the tubular body 12. A first
end 48 of the sleeve member 14 is attached to the tubular body 12
via the attachment 42 and the second end 50 of the sleeve member 14
is also attached to the tubular body, via attachment 44. Assembly
10 is then connected into a string 30 as is known in the art and
run into the wellbore 60. The assembly 10 may be attached to the
bottom of a casing or liner string. The assembly 10 is run into a
position where a barrier is required and in the embodiment shown in
FIG. 1a, this is inside a wellbore 60 between a first zone 62 and a
second zone 64 of the formation 66.
[0063] When the assembly 10 is in position in the wellbore 60, a
gravel slurry 70 is pumped down the bore 24 of the string 30. This
is illustrated in FIG. 1b. The gravel 70 may be pumped directly
through the bore 24 or may be pumped through an inner string and
gravel packing sub (not shown) used to deliver the gravel to the
end 52 of the string 30 without damaging the inner surface 58 of
the string 30. The gravel 70 passes out of the end 52 of the string
30 and circulates up the annulus 68 between the outer surface 40 of
the body 12 and the inner surface 72 of the wellbore 60. The end 52
of the string 30 may be located in the rat-hole. This method of
circulating the gravel 70 ensures that there are no voids left in
the annulus 68. It also negates the requirement to install valves,
which may be referred to as shunt valves, in the tubing string to
inject gravel at points along the tubing string.
[0064] When the gravel 70 is in position in the annulus 68,
pressure in the through-bore 36 of the body 12 is increased. This
is typically fluid pressure delivered from a fluid delivery system
inserted through the string 30 as will be described with reference
to FIG. 2b. Pressure in the through-bore 36 thus increases to a
point where the disc 56 ruptures and allows fluid under pressure to
pass through the check valve 54 at the port 18. As detailed
previously, multiple ports 18 may be located upon the tubular body
12 to increase the rate of fluid pressure entering the chamber 16.
As the chamber 16 is cylindrical in nature and the material of the
sleeve member 14 is more elastic than that of the tubular body 12,
as pressure increases in the chamber 16, the sleeve member 14 will
be forced radially outwardly from the tubular body across the
annulus 68 between the outer surface 40 of the tubular body 12 and
the inner surface 72 of the wellbore 60. This expansion of the
sleeve member 14 by fluid pressure will initially force the gravel
70 out from the annulus 68 at the sleeve member 14 and then crush
the gravel 70 trapped between the sleeve member 14 and the inner
surface 72. The pressure will be sufficient to crush the gravel 70
into small particles such as a powder so that the morphed sleeve 14
creates a seal against the inner surface 72 of the wellbore 60. The
crushed gravel 70 may form part of this seal. This is illustrated
in FIG. 1c. This morphing process is known and operates by
elastically and then plastically deforming the sleeve member 14. At
a morphed fluid pressure value, the check valve 54 closes therefore
sealing the chamber 16. The seal between the assembly 10 and the
inner surface 72 thus forms a barrier in the wellbore 60 so that
fluid flow through the annulus 68 is prevented. Fluid flow from the
formation 64 is then directed through the first sand screen 20 for
production from the lower, second zone 64 and through the second
sand screen 22 for production from the upper, first zone 62. Each
zone 62,64 has therefore been completed with its own gravel pack
74,76 respectively.
[0065] In an alternative embodiment, the sleeve member 14 may be
expanded while the gravel 70 is still being pumped. When the sleeve
member 14 has been morphed against the inner surface 72, a rupture
disc 78 located on the sleeve member 14 towards the first end 48 is
burst, allowing gravel 70 to enter the chamber 16. This gravel 70
which enters the chamber 16 can support the sleeve member 14 in the
morphed position and therefore increase the strength of the
isolation barrier. The rupture disc 78 may alternatively be in the
form of a check valve, letting the gravel 70 enter but not escape
from the chamber 16.
[0066] Reference will now be made to FIG. 2 of the drawings which
provides an illustration of a further method for completing a well
according to an embodiment of the present invention. Like parts to
those in the earlier Figures have been given the same reference
numerals to aid clarity.
[0067] In use, the assembly 10 is conveyed into the borehole by any
suitable means, such as incorporating the assembly 10 into a casing
or liner string 30 or on an end of a drill pipe and running the
string into the wellbore 60 until it reaches the location within
the open borehole 80 at which operation of the assembly 10 is
intended. This location is normally within the borehole at a
position where the sleeve 14a is to be expanded in order to, for
example, isolate the section of borehole 80b located above the
sleeve 14a from that below 80d in order to provide an isolation
barrier between the zones 80b, 80d. Additionally a further assembly
10b can be run on the same string 76 so that zonal isolation can be
performed in a zone 80b.
[0068] The string 30 is run-in the wellbore 60 and hung from casing
82. Gravel 70 is then pumped through the string 30 and exits at the
end 52 where a gravel packing sub 84 is located. The gravel slurry
70 fills the rat hole 86 and travels up the annulus 68 between the
outer surface 40 of the string 30 and the inner surface 72 of the
wellbore 60. This is as illustrated in FIG. 2a.
[0069] Reference is now made to FIG. 2b which shows an activation
fluid delivery tool 88 run into the string 30. Tool 88 can be run
into the string 30 from surface by means of a coiled tubing 90 or
other suitable method. The tool 88 is provided with upper and lower
seal means 92, which are operable to radially expand to seal
against the inner surface 58 of the body 12 at a pair of spaced
apart locations in order to isolate an internal portion of body 12
located between the seals 92; it should be noted that said isolated
portion includes the fluid port 18. Tool 88 is also provided with
an aperture 96 in fluid communication with the interior of the
string 30.
[0070] To operate the tool 88, seal means 92 are actuated from the
surface to isolate the portion of the tool body 12. Activation
fluid is then pumped under pressure through the coiled tubing such
that the pressurised fluid flows through tool aperture 96 and then
via port 18 into chamber 16 and acts on the sleeve members 14a,14b
in the same manner as described hereinbefore. Use of such a tool
allows setting of selective assemblies 10 in a wellbore.
[0071] A detailed description of the operation of such a fluid
delivery tool 88 is described in GB2398312 in relation to the
packer tool 112 shown in FIG. 27 of that patent with suitable
modifications thereto, where the seal means 92 could be provided by
suitably modified seal assemblies 214, 215 of GB2398312, the
disclosure of which is incorporated herein by reference. The entire
disclosure of GB2398312 is incorporated herein by reference.
[0072] The increase in pressure of fluid causes the sleeve 14a,14b
to move radially outwardly crushing the gravel 70 and seal against
a portion of the inner circumference of the borehole 80. The
pressure within the chamber 16 continues to increase such that the
sleeve 14a,14b initially experiences elastic expansion followed by
plastic deformation. The sleeve 14a,14b expands radially outwardly
beyond its yield point, undergoing plastic deformation until the
sleeve 14a,14b morphs against the surface 72 of the borehole 80 as
shown in FIG. 2c. Accordingly, the sleeve 14a,14b has been
plastically deformed and morphed by pressure from the chamber
contents without any mechanical expansion means being required.
Note that gravel 70 is now separated into gravel packs 74, 76
contained between barriers created by the sleeve members
14a,14b.
[0073] Fluid may be pumped into the chamber 16 at any desired
pressure as the check valve 54 can be set to allow a calculated
volume of fluid which is sufficient to morph the sleeve to enter
the chamber before closing. When closed, the check-valve will trap
any fluid remaining in the chamber 16. The pressure may be
increased sufficiently to assist in crushing the gravel 70 and then
bled-off before closing the port 18.
[0074] The sleeve 14a,14b will have taken up a fixed shape under
plastic deformation with an inner surface 46 matching the profile
of the surface 72 of the borehole 60 and the crushed gravel 70. An
outer surface of the sleeve will also match the profile of the
surface 72 of the borehole 60 and the crushed gravel 70. A seal
which effectively isolates the annulus 94 of the borehole 80 above
the sleeve 14a from the annulus 98 below the sleeve 14a is created.
If two sleeves 14a,14b are set together then zonal isolation can be
achieved for the annulus 94 between the sleeves 14a,14b. At the
same time the sleeves 14a,14b have effectively centered, secured
and anchored the tubing string 30 to the borehole 60.
[0075] Also shown in FIG. 2c is an inner completion string 100. The
inner completion string 100 includes spaced apart seals 102 to
isolate the respective sand screens 62, 64 from each other. Valves
104 can then be opened sequentially for the selected production
flow from each zone 80d, 80b.
[0076] Reference will now be made to FIGS. 3a-3c of the drawings
which provide an illustration of a further method for completing a
well according to an embodiment of the present invention. Like
parts to those in the earlier Figures have been given the same
reference numerals to aid clarity.
[0077] Reference is initially made to FIG. 3a which illustrates an
assembly as previously described with reference to FIG. 1a,
generally indicated by reference numeral 10, including first 20 and
second 22 sand screens located on either side of a tubular body 12,
with a sleeve member 14, chamber 16 and port 18. The assembly of
FIG. 3a further comprises a shunt tubular assembly 110 which is
arranged so as to run adjacent to, and in parallel with, tubular 12
traversing through sleeve member 14 as a discreet sealed continuous
tubular member, according to an embodiment of the present
invention.
[0078] The shunt tubular assembly 110 is shown as having a single
shunt tube however it will be appreciated that several shunt tubes
may be provided running in parallel to one another. The shunt tube
110 runs along the outside of the sand screens 20, 22 and is a
narrow bore tube constructed of a metal based material. The bore of
the shunt tube 110 can be seen to run continuously through the
sleeve 14 to allow the shunt tube 110 to flow continuously along
the tubular 12. Dedicated crossover connections using components
(not shown) such as those known in the art would be required
between the sleeve 14 and shunt tube 110 to ensure a sealed and
effective crossover between components that allows the sleeve 14 to
function effectively whilst continuous flow through the shunt tube
110 is also possible.
[0079] In use, the assembly 10 is conveyed into the borehole by any
suitable means, such as incorporating the assembly 10 into a casing
or liner string 30 or on an end of a drill pipe and running the
string into the wellbore 60 until it reaches the location where the
barrier is required and in the embodiment shown in FIG. 3a, this is
inside wellbore 60 between a first zone 62 and a second zone 64 of
the formation. This location is within the borehole at the position
where the sleeve 14 is to be expanded in order to, isolate the
section of borehole 62 located above the sleeve 14 from that below
64 in order to provide an isolation barrier between the zones 62,
64.
[0080] When the sleeve 14 is in position in the annulus 68,
pressure in the through-bore 36 of the body 12 is increased. This
is typically fluid pressure delivered from a fluid delivery system
inserted through the string 30 as will be described with reference
to FIG. 3b. Pressure in the through-bore 36 thus increases to a
point where the disc 56 ruptures and allows fluid under pressure to
pass through the check valve 54 at the port 18. As detailed
previously, multiple ports 18 may be located upon the tubular body
12 to increase the rate of fluid pressure entering the chamber 16.
As the chamber 16 is cylindrical in nature and the material of the
sleeve member 14 is more elastic than that of the tubular body 12,
as pressure increases in the chamber 16, the sleeve member 14 will
be forced radially outwardly from the tubular body across the
annulus 68 between the outer surface 40 of the tubular body 12 and
the inner surface 72 of the wellbore 60. The pressure will be
sufficient that the morphed sleeve 14 creates a seal against the
inner surface 72 of the wellbore 60. This is illustrated in FIG.
3b. This morphing process is known and operates by elastically and
then plastically deforming the sleeve member 14. At a morphed fluid
pressure value, the check valve 54 closes therefore sealing the
chamber 16. The seal between the assembly 10 and the inner surface
72 thus forms a barrier in the wellbore 60 so that fluid flow
through the annulus 68 is prevented. Note that the shunt 112 is
held against the tubular body 12 during the morphing process and is
not moved radially outwards.
[0081] When the sleeve 14 is morphed in position in the wellbore
60, a gravel slurry 70 is pumped down the bore 111 of the shunt
112. This is illustrated in FIG. 3c. The gravel 70 passes out of
the shunt exits 116, which may be a plurality of exit holes or
slits as appropriate, and which are arranged beyond the morphed
sleeve 14. The gravel 70 then circulates around the annulus 68
between the outer surface 40 of the body 12 and the inner surface
72 of the wellbore 60. This method of circulating the gravel 70
circulates locally to the morphed sleeve 14 and ensures that there
are no voids left in the annulus 68.
[0082] Once the gravel 70 has circulated the annulus 68 around the
assembly 10 the gravel 70 is allowed to set after which value 112
provided in the shunt 110 is closed thus sealing the shunt tube 110
completely. This method of gravel provision ensures a complete
annular barrier is formed around the tubular 12 adjacent to the
annular barrier of morphed seal 14 without the morphed seal 14
being required to crush gravel during the sealing process.
[0083] In a further embodiment (not shown) gravel may be provided
to annulus 68 via shunt tube 110 and via string 30 such that it
enters the annulus via shunt exits 112 and string end 52 enabling
it to circulate up and round the annulus 68 as well as around
sleeve 14 during installation. Such an arrangement would enable
gravel 70 to circulated locally around the sleeve 14 as well as by
means of circulation in the wellbore and subsequent morphing of the
sleeve 14 would act to crush gravel which would go on to form part
of the annular seal around the assembly.
[0084] The principle advantage of the present invention is that it
provides an expandable completion system and method of completing a
well in which gravel packing for multiple completion zones can be
easily achieved.
[0085] A further advantage of at least one embodiment of the
present invention is that it provides an expandable completion
system and method of completing a well in which gravel packing for
multiple completion zones can be achieved by circulation.
[0086] A still further advantage of at least one embodiment of the
present invention is that it provides an expandable completion
system and method of completing a well in which selective isolation
barriers can be created along the length of the completion string
after the gravel has been pumped into the annulus.
[0087] It will be apparent to those skilled in the art that
modifications may be made to the invention herein described without
departing from the scope thereof. For example, sliding sleeves may
be incorporated on the tubular string to access the chambers and/or
the sand screens.
* * * * *