Abstract:
The present invention includes a method and apparatus for setting a liner in a wellbore and then expanding a screen in the wellbore in a single trip. In one aspect of the invention, a liner and expandable screen is provided with a slip assembly to fix the liner in the wellbore. An expansion tool and work sting is run into the wellbore in the liner. After the liner is set, the expansion tool is used to expand the screen. In another embodiment, an annular area between the expansion tool and work string is utilized in order to set the slips. Thereafter, cup packers used in forming the annulus are lifted from the liner prior to expanding the screen.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention relates an apparatus and method using expandable tubulars to complete a well. More particularly, the invention relates to the installation of an expandable sand screen. More particularly still, the invention relates to a single trip installation process to set a liner hanger in a wellbore and then expand a sand screen.  
           [0003]    2. Description of the Related Art  
           [0004]    Hydrocarbon wells are typically formed with a central wellbore that is supported by steel casing. The casing lines a borehole formed in the earth during the drilling process. An annular area formed between the casing and the borehole is filled with cement to further support and form the wellbore.  
           [0005]    Some wells are produced by perforating the casing of the wellbore at selected depths where hydrocarbons are found. Hydrocarbons migrate from the formation through the perforations and into the wellbore where they are usually collected in a separate string of production tubing for transportation to the surface of the well. In other instances, a lower portion of a wellbore is left open and not lined with casing. This “open hole” completion permits hydrocarbons in an adjacent formation to migrate directly into the wellbore where they are subsequently raised to the surface, possibly through an artificial lift system.  
           [0006]    Open hole completions can provide higher production than cased hole completions and they are frequently utilized in connection with horizontally drilled boreholes. However, open hole completions leave aggregate material, including sand, free to invade the wellbore. Sand entering an open hole wellbore causes instability within the open hole which enhances the risk of complete collapse. Sand production can also result in premature failure of artificial lift and other downhole and surface equipment due to the abrasive nature of sand. In some instances, high velocity sand particles can contact and erode lining and tubing.  
           [0007]    Sand can also be a problem where casing is perforated to collect hydrocarbons. Typically, casing is perforated with a perforating assembly or “guns” that are run into a wellbore and fired to form the perforations. Thereafter, the assembly is removed and a separate assembly is installed to collect the migrating hydrocarbons. The perforations also create a passageway for aggregate material, including sand to enter the wellbore. As with an open wellbore, sand entering the cased wellbore can interfere with the operation of downhole tools, clog screens and damage components, especially if the material enters the wellbore at a high velocity.  
           [0008]    To control particle flow into a wellbore, well screens are often employed downhole. Conventional wellscreens are placed adjacent perforations or unlined portions of the wellbore to filter out particulates as production fluid enters a tubing string. One form of well screen recently developed is the expandable sand screen (ESS). In general, the ESS is constructed of different composite layers, including a filter media.  
           [0009]    A more particular description of an ESS is found in U.S. Pat. No. 5,901,789, which is incorporated by reference herein in its entirety. That patent describes an ESS which consists of a perforated base pipe, a woven filtering material, and a protective, perforated outer shroud. Both the base pipe and the outer shroud are expandable, and the woven filter is typically arranged over the base pipe in sheets that partially cover one another and slide across one another as the sand screen is expanded. The ESS is expanded by a cone-shaped object urged along its inner bore or by an expander tool having radially outward extending rollers that are fluid powered from a tubular string. Using expansion means like these, the ESS is subjected to outwardly radial forces that urge the expanding walls against the open formation or parent casing. The components of the ESS are expanded past their elastic limit, thereby increasing the inner and outer diameter of the tubular.  
           [0010]    A major advantage to the ESS in an open wellbore is that once expanded, the walls of the wellbore are supported by the ESS. Additionally, the annular area between the screen and the wellbore is mostly eliminated, and with it the need for a gravel pack. A gravel pack is used with conventional well screens to fill an annular area between the screen and wellbore and to support the walls of the open hole. With an ESS, the screen is expanded to a point where its outer wall places a stress on the walls of the wellbore, thereby providing support to the walls of the wellbore to prevent dislocation of particles. Solid expandable tubulars are oftentimes used in conjunction with an ESS to provide a zonal isolation capability. In addition to open wellbores, the ESS is effectually used with a perforated casing to control the introduction of particulate matter into the cased wellbore via the perforations.  
           [0011]    While an ESS can reduce or eliminate the inflow of particles into a wellbore, the screen must be installed and expanded in order to operate effectively. Any delay in the installation permits additional time for sand to enter the wellbore and the time period is especially critical between the formation of perforations in a casing wall and the expansion of screen against the perforations. The delays are especially critical if the newly formed wellbore is placed in an over balanced condition prior to expanding the ESS. An overbalanced condition permits fluids to enter the formations and hamper later production of hydrocarbons.  
           [0012]    In current installation procedures of ESS the operator makes two trips downhole. In the first trip, the operator sets a liner hanger to secure the ESS in the wellbore. After returning from the first trip downhole, the operator must make a second trip with an expansion tool in order to expand the ESS.  
           [0013]    There are several disadvantages to a multiple trip installation procedure. The biggest disadvantage relates to expensive downtime necessary to make both trips. Also, a delay between the first and second trips can cause well control problems due to fluid loss. For example, pressurized fluid in the wellbore used to actuate various mechanical components during the installation process can enter the formations causing formations to clog-up or collapse, restricting the flow of hydrocarbons. In addition, loss of drilling fluid increases the completion cost of the well. In other instances, a delay between perforating a casing and expanding a sand screen against the perforations increases the likelihood that solids from the formations will enter the wellbore. In addition to the foregoing, packers used to fix an ESS in a wellbore often have a relatively small inside diameter. These packer-like components remain in the wellbore and can cause access problems for remedial work required below the suspension device.  
           [0014]    There is a need therefore, for an apparatus to reduce the time needed to install an expandable sand screen in a wellbore. There is a further need to set a sand screen in a wellbore and then expand the sand screen in a single trip. There is a further need for a method and apparatus to facilitate the setting of a liner hanger in a wellbore prior to the expansion of an ESS. Still further, there is a need for an apparatus to minimize the exposure to formation solids before expanding the ESS There is a further need for a single trip ESS apparatus that uses a liner hanger that does not restrict access within the wellbore after the ESS is expanded.  
         SUMMARY OF THE INVENTION  
         [0015]    The present invention includes a method and apparatus for installing and expanding an ESS in a wellbore in a single trip. In one aspect of the invention, a liner hanger and expandable screen are provided and are run into the wellbore with an expansion tool and work string. After the hanger is set, the expansion tool is used to expand the screen. In another aspect, an annular area within the apparatus is utilized in order to set the hanger with pressurized fluid. Thereafter, cup packers used in sealing the annulus are lifted from the liner prior to expanding the screen. The expansion tool and work string are then removed leaving the expanded ESS and hanger in the wellbore. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]    So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.  
         [0017]    It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.  
         [0018]    [0018]FIG. 1 is a partial cross section view of an expansion tool assembly.  
         [0019]    [0019]FIG. 2 is a partial cross section view of a liner and sand screen assembly.  
         [0020]    [0020]FIG. 3A illustrates an upper portion of the expansion tool assembly and liner assembly.  
         [0021]    [0021]FIG. 3B illustrates a middle portion of the expansion tool assembly and liner assembly.  
         [0022]    [0022]FIG. 3C illustrates a lower portion of the expansion tool assembly and liner assembly.  
         [0023]    [0023]FIG. 4 illustrates an annular area formed between the expansion tool assembly and liner assembly.  
         [0024]    [0024]FIG. 5 illustrates the expansion tool assembly and liner assembly after a first ball has been dropped into a lower ball seat and sleeve.  
         [0025]    [0025]FIG. 6 illustrates the expansion tool assembly and liner assembly after slips have been set to fix the liner in the wellbore.  
         [0026]    [0026]FIG. 7 illustrates the lower ball seat and sleeve shifted to a second position relative to the liner assembly to reestablish a fluid pathway through the bore of the tool assembly.  
         [0027]    [0027]FIG. 8 illustrates an upper ball seat and sleeve in a second position relative to the liner assembly.  
         [0028]    [0028]FIG. 9 illustrates an upward movement of the tool assembly in relation to the liner assembly.  
         [0029]    [0029]FIG. 10 illustrates the tool assembly lifted out of the liner assembly permitting dogs to clear the top of the liner assembly.  
         [0030]    [0030]FIG. 11 is an enlarged view of FIG. 10, showing the expansion tool assembly suspended by dogs at the upper end of the liner assembly.  
         [0031]    [0031]FIG. 12 illustrates downward movement of the expansion tool assembly in relation to the liner assembly and dogs in order to expand the ESS.  
         [0032]    [0032]FIG. 13 illustrates the rotary expander tool expanding the sand screen.  
         [0033]    [0033]FIG. 14 illustrates the expansion tool assembly as it is removed from the liner assembly after the screen has been expanded. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0034]    The present invention provides a method and apparatus to install an ESS in a wellbore and to expand the screen in a single trip. The invention includes a hanger which is used to set the screen in a wellbore before the screen is expanded by an expansion tool in the same trip into the wellbore.  
         [0035]    [0035]FIG. 1 illustrates a partial cross section view of an expansion tool assembly  100  and FIG. 2 illustrates a partial cross section view of a liner and sand screen assembly  200 . While a portion of liner or non slotted tubular is shown in FIG. 1, it will be understood that the invention can be used with a section of liner above an expandable sand screen or with only a section of expandable sand screen. Further, while the Figures illustrate the invention in use with an open, noncased wellbore, it will be further understood that the methods and apparatus disclosed are equally usable in a cased wellbore with perforations formed therein. FIGS. 1 and 2 show the tool assembly  100  and the liner assembly  200  separated to illustrate the major components of each assembly. In use, the expansion tool assembly  100  is housed within assembly  200 . FIGS.  3  to  14  will fully describe the interface between the tool assembly  100  and the liner assembly  200 . In FIG. 1, the expansion tool assembly  100  includes a dust cover  110  at the upper end to seal the end of assembly  200  and to prevent wellbore contaminates from entering the liner. The assembly  100  further includes a carry nut  115  with male threads  130  that mates with female threads  205  near the top of the liner assembly  200  to secure the tool assembly  100  in the liner assembly  200 .  
         [0036]    A carrying tool  125  is located at the lower portion of the assembly  100  to facilitate removal of the tool assembly  100  from the liner assembly  200  after expanding a screen  215 . A mud motor  120  is located adjacent to a rotary expander tool  105  at the lower end of the tool assembly  100 . In operation, fluid is pumped from the surface of the well down a bore of the tool assembly  100  and into the mud motor  120 . The mud motor  120  uses the fluid to rotate the rotary expander tool  105 , thereby expanding the screen  215  disposed at the lower end of the liner assembly  200 . A hydraulic liner hanger assembly  210  is located at the upper portion of the liner assembly  200  to secure the assembly  200  in a wellbore.  
         [0037]    [0037]FIG. 3A illustrates the upper section of the expansion tool assembly  100  and the liner assembly  200 . The dust cover  110  sits on top of the liner assembly  200 . The carry nut  115  is shown threaded into the liner assembly  200 . An upper ball seat and sleeve  305  is located below the carry nut  115  and is secured to the tool assembly  100  by a first shear pin  310 . A first circumferential groove  330  is used in a later step to reestablish a fluid passageway in the bore of the assembly  100 . The liner hanger assembly  210  includes a plurality of cones  325  and slips  328  disposed about the circumference of the liner assembly  200 . The slips  328  include a tapered surface that mates with a corresponding tapered surface on the cone  325 . During the setting of the liner assembly  200  in the wellbore, the cones  325  are used to displace the slips  328  radially outward as an axial force is applied to the slip  328  in direction of the cones  325 .  
         [0038]    [0038]FIG. 3B illustrates a middle section of the expansion tool assembly  100  and the liner assembly  200 . A lower ball seat and sleeve  385  is located below the slips  328  (not shown) and is secured in the tool assembly  100  by a second pin  380 . Below the lower ball seat and sleeve  385  is a second circumferential groove  340  which is used in a later step to reestablish a fluid passageway down the bore of the assembly  100 . A plurality of swab cups  390  used to seal an annular area between the tool assembly  100  and the liner assembly  200  are located below the second shear pin  380 . Expandable dogs  350 , shown in the retracted position, are located below the swab cups  390 . The dogs  350  are used to hold a portion of the tool assembly  100  above the top surface of the liner assembly  200  as will be described herein. A third shear pin  375  is located between the swab cups  390  and the dogs  350  to temporarily hold the dogs  350  and cups  390  around the work string. FIG. 3C illustrates a lower portion of the tool assembly  100  and the liner assembly  200 . As shown, the expander tool  105  on the tool assembly  100  is housed at an upper end of the expandable sand screen  215 . The screen  215  includes a funnel shaped opening to facilitate entry into the screen  215  by the expander tool  105 .  
         [0039]    [0039]FIG. 4 illustrates an annular area formed between the expansion tool assembly  100  and liner assembly  200 . The annulus is created upon insertion of the tool assembly  100  into the liner assembly  200 . The annulus is separated into an upper annulus  355 , a middle annulus  360  and a lower annulus  365 . The carry nut  115  separates the upper annulus  355  from the middle annulus  360 . The swab cups  390  separate the middle annulus  360  from the lower annulus  365 . The middle annulus  360  serves as a fluid pathway between a first port  315  and a second port  320  which is later used to set the slips  328  that fix the liner  200  in the wellbore.  
         [0040]    [0040]FIG. 5 illustrates the expansion tool assembly  100  and liner assembly  200  after a first ball  345  has been dropped into a lower ball seat and sleeve  385 . The view further illustrates, the liner assembly  200  prior to setting the slips  328 . As shown, there is no contact between the teeth  335  on the slips  328  and a casing  475 . At a later point the tapered portion of the slips  328  will be urged up cones  325  by a plurality of longitudinal members  415  that are connected to an annular piston  395 . The piston  395  has a top O-ring  405  and a bottom O-ring  410  for creating a fluid tight seal.  
         [0041]    [0041]FIG. 6 illustrates the expansion tool assembly  100  and liner assembly  200  after the slips  328  have been set to fix the liner  200  in the wellbore. Ball  345  blocks fluid flow through the bore of the tool assembly  100 , thereby redirecting the fluid flow to a first aperture  420  formed in the sleeve  305 . The first aperture  420  is aligned with the first port  315  formed in a wall of the tool assembly  100  to form a fluid passageway to the annulus  360 . A first arrow  425  illustrates the fluid flow into the annulus  360  and a second arrow  430  illustrates fluid flow from the annulus  360  through a second port  320 . The fluid exiting the second port  320  acts on the piston  395 , thereby urging the piston  395  upward in the direction of the cones  325 . The longitudinal members  415  connecting the slips  328  to the piston  395  urges the slips  328  up the tapered portion of the cones  325 , thereby expanding the slips  328  radially outward in contact with the casing  475 . The teeth  335  formed on the outer surface of the slips  328  “bite” into the casing surface to hold the liner assembly  200  in position in the wellbore. FIG. 6 illustrates that the inner diameter of the assembly  200  is largely unobstructed by the set hanger and the bore is open to the passage of tools downhole.  
         [0042]    [0042]FIG. 7 illustrates the lower ball seat and sleeve  385  shifted to a second position relative to the liner assembly  200  to reestablish a fluid pathway through the bore of the tool assembly  100 . After the liner assembly  200  is set in the casing  475 , the fluid becomes pressurized acting against the first ball  345  which is housed in the lower ball seat and sleeve  385 . At a predetermined pressure, pin  380  is sheared allowing the ball seat and sleeve  385  to shift downward to a second position. In the second position, a first by pass port  435  formed in the sleeve  385  aligns with the second circumferential groove  340  to reestablish a fluid pathway through the bore of the tool assembly  100  as illustrated by an arrow  432 .  
         [0043]    [0043]FIG. 8 illustrates the upper ball seat and sleeve  305  in a second position relative to the liner assembly  200  to establish a fluid pathway through the bore of the tool assembly  100 . The flow path is established in order to provide a source of pressurized fluid to the expander tool  105  in order to expand the sand screen  215  at a lower end of the liner assembly  200 . The second ball  440  is dropped into the tool assembly  100  and lands on an upper seat and sleeve  305  which is held in place by pin  310 . Fluid thereafter becomes pressurized acting against the second ball  440 . At a predetermined pressure the pin  310  is sheared allowing upper ball seat and sleeve  305  to shift downward to the second position. In the second position, the ball seat and sleeve  305  aligns a second bypass port  450  with the first circumferential groove  330  to provide a fluid passage way. The fluid flow down the bore of the assembly  100  bypasses the ball  440  as illustrated by arrow  445 . In addition to reestablishing flow down the bore of the tool assembly  100 , the seat and sleeve  305  also misaligns the first aperture  420  and the first port  315 , thereby blocking fluid communication into middle annulus  360 .  
         [0044]    [0044]FIG. 9 illustrates an upper movement of the tool assembly  100  in relation to the liner assembly  200 . After the liner assembly  200  has been set in the wellbore, the expansion tool  100  with the carry nut  115  is rotated clockwise, thereby removing the male threads  130  on the carry nut  115  from the female threads  205  on the liner assembly  200 . The tool assembly  100  is then lifted axially upward in relation to the liner assembly  200  as illustrated by a directional arrow  460 . A shoulder  455  on the tool assembly  100  urges the carry nut  115  upward with the tool assembly  100  as the tool assembly  100  is partially lifted from the liner assembly  200 .  
         [0045]    [0045]FIG. 10 illustrates the tool assembly  100  lifted out of the liner assembly  200  permitting dogs  350  to clear the top of the liner assembly  200 . To prepare the tool assembly  100  to expand the screen  215 , the expansion tool assembly  100  is partially pulled from the liner assembly  200  exposing the dust cover  110 , carry nut  115 , swab cups  390  and dogs  350 . Upon removal from the liner assembly  200 , the dogs  350  expand outward. Pin  375  holds the various components together.  
         [0046]    [0046]FIG. 11 is an enlarged view of FIG. 10, showing the expansion tool assembly  100  suspended by dogs  350  at the upper end of the liner assembly  200 . After the tool assembly  100  is lifted from the liner assembly  200  and the dogs  350  expanded, it is then lowered until the expanded dogs  350  rest on top of the liner assembly  200 . As shown, the dogs  350  are outwardly biased members that are constructed and arranged to ride along a tubular surface and then to extend outward when pulled out of contact with the tubular. With the components in position shown in FIG. 11, the expander tool  105  is ready to be lowered into the ESS  215 .  
         [0047]    [0047]FIG. 12 illustrates downward movement of the expansion tool assembly  100  in relation to the liner assembly  200  and dogs  350  in order to expand the expandable sand screen  215 . A downward force is placed the tool assembly  100 , thereby exerting pressure on the pin  375 . At a predetermined pressure, the pin  375  is sheared, thereby allowing the mud motor  120  and expander tool  105  along with the carrying tool  125  to drop down into the liner assembly  200  while the dust cover  110 , the carry nut  115 , the swab cups  390  and the dogs  350  remain above the top of the liner assembly  200 . The tool assembly  100  is lowered until the expander tool  105  comes in contact with the ESS  215 .  
         [0048]    [0048]FIG. 13 illustrates the rotary expander tool  105  expanding the sand screen  215 . Fluid is pumped from the surface of the well down the bore of tool assembly  100  into the mud motor  120 . The mud motor  120  provides rotational force to the expander tool  105  while causing radially extending rollers to extend outwards, thereby expanding the sand screen  215  into the borehole. FIG. 13 illustrates expanding a sand screen  215  in a vertical open hole. However, this invention is not limited to the one shown but rather can be used in many different completion scenarios such as casing that has been perforated.  
         [0049]    [0049]FIG. 14 illustrates the expansion tool assembly  100  as it is removed from the liner assembly  200  after the ESS  215  has been expanded. As the tool assembly  100  is pulled upward, a top surface  470  of the carrying tool  125  contacts a bottom surface  465  of the dogs  350 , thereby urging the dogs  350  off the top of the liner assembly  200 . The entire tool assembly  100  is moved up out of the liner assembly  200  and then out of the wellbore. The ESS  215  allows hydrocarbons to enter the wellbore as it filters out sand and other particles. The expanded sand screen  215  is connected to production tubing at an upper end, thereby allowing the hydrocarbons travel to the surface of the well. In addition to filtering, the sand screen  215  preserves the integrity of the formation during production.  
         [0050]    While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.