Screen assembly for a resource exploration system

A screen assembly includes a tubular having a first end, a second end, and an intermediate portion including an outer surface provided with a plurality of openings extending therebetween. At least one screen arranged at the plurality of openings. At least two deformable members are mounted to the tubular between the first end and the second end. The at least two deformable members are selectively radially outwardly expandable relative to the at least one screen forming a plurality of screen compartments on the tubular, the plurality of screen compartments being substantially fluidically isolated from one another externally of the tubular.

BACKGROUND

During various downhole operations there may be a need to control sand and/or other debris entrained with downhole fluids. Sand screens may be provided about a tubular having inlet openings that receive downhole fluids. The sand screens may include one or more layers each having gradually increasing opening sizes with an outer most screen layer including openings that are smaller than an innermost screen layer. Over time, produced sand impinges on screen surface causing erosion and/or clogging of the sand screen that could lead to screen failure.

SUMMARY

A screen assembly includes a tubular having a first end, a second end, and an intermediate portion including an outer surface provided with a plurality of openings extending therebetween. At least one screen arranged at the plurality of openings. At least two deformable members are mounted to the tubular between the first end and the second end. The at least two deformable members are selectively radially outwardly expandable relative to the at least one screen forming a plurality of screen compartments on the tubular, the plurality of screen compartments being substantially fluidically isolated from one another externally of the tubular.

A resource exploration system includes a surface portion, and a downhole portion having a plurality of tubulars, and a screen assembly connected to one of the plurality of tubulars. The screen assembly includes a tubular having a first end coupled to the one of the plurality of tubulars, a second end, and an intermediate portion including an outer surface provided with a plurality of openings extending therebetween. At least one screen is arranged at the plurality of openings. At least two deformable members are mounted to the tubular between the first end and the second end. The at least two deformable members are selectively radially outwardly expandable relative to the at least one screen forming a plurality of screen compartments on the tubular.

DETAILED DESCRIPTION

A resource exploration system, in accordance with an exemplary embodiment, is indicated generally at2, inFIG. 1. Resource exploration system2should be understood to include well drilling operations, resource extraction and recovery, CO2sequestration, and the like. Resource exploration system2may include an uphole portion4operatively connected to a downhole portion6. Uphole portion4may include pumps8that aid in completion and/or extraction processes as well as fluid storage10. Fluid storage10may contain a gravel pack fluid or slurry (not shown) that is introduced into downhole portion6.

Downhole portion6may include a downhole string20formed from a plurality of tubulars, one of which is indicated at21that is extended into a wellbore24formed in formation26. Wellbore24includes an annular wall28that may be defined by formation26. It is to be understood that annular wall28may also be defined by a casing. One of tubulars21may be connected with a screen assembly30. Screen assembly30filters out or blocks various particles from entering downhole string20during select downhole operations.

With reference toFIGS. 2-4screen assembly30includes a tubular40having a first or box end42, a second or pin end43and an intermediate portion44having an outer surface46extending therebetween. Tubular40includes a plurality of openings50that extend through outer surface46. A screen54is provided on tubular40. Screen54defines an annular screen55that extends over each of the plurality of openings50. Annular screen55includes a first end portion56, a second end portion57, and an intermediate zone58. Annular screen55includes a plurality of screen openings, one of which is indicated at60. Plurality of screen openings60extend from an outer surface61of annular screen55through intermediate zone58to an inner surface62.

In accordance with an aspect of an exemplary embodiment, screen assembly30includes a plurality of deformable members depicted as swellable members63arranged on outer surface61of annular screen55. Plurality of swellable members63includes a first swellable member64, a second swellable member65, a third swellable member66and a fourth swellable member67. First swellable member64is arranged at first end portion56of annular screen55adjacent to first end42of tubular40. Fourth swellable member67is arranged at second end portion56of annular screen55adjacent second end43of tubular40. Second and third swellable members65and66are arranged along intermediate zone58of annular screen55. It is to be understood that the number of swellable members may vary.

In further accordance with an exemplary embodiment, swellable members64-67are selectively radially outwardly swellable to engage with wall28of wellbore24. Once engaged, swellable members64-67form a first screen compartment72, a second screen compartment73, and a third screen compartment74. Screen compartments72-74are fluidically isolated from one another externally of tubular40. In this manner, in the event that a portion of screen54becomes clogged or otherwise fails to pass fluids, other portions of screen54may remain operational. The development of screen compartments72-74mitigate risks associated with erosion and plugging by reducing exposure to small sections of screen54that may be covered rapidly while other areas of screen54remain open and unobstructed.

Reference will follow toFIGS. 5 and 6in describing a screen assembly85in accordance with another aspect of an exemplary embodiment. Screen assembly85includes a tubular86having a first end88, a second end89and an intermediate portion90including an outer surface92extending therebetween. Tubular86includes a plurality of openings96that extend through outer surface92. A screen110is provided on tubular86. Screen110defines an annular screen111that extends over each of the plurality of openings92. Annular screen111includes a first end portion112, a second end portion113, and an intermediate zone114. Annular screen111includes a plurality of screen openings, one of which is indicated at117. Plurality of screen openings117extend from an outer surface118of annular screen111through intermediate zone114to an inner surface119.

Annular screen111further includes a first swaged zone121and a second swaged zone122. Each swaged zone121,122represents an area of annular screen1112in which inner surface119has been compressed toward outer surface92of tubular86. In accordance with an aspect of an exemplary embodiment, inner surface119of annular screen111directly abuts outer surface92of tubular86. It is to be understood that the number of swaged zones may vary.

In further accordance with an exemplary aspect, screen assembly85includes a first swellable member128that extends about annular screen111at first swaged zone121, a second swellable member129that extends about annular screen111at second swaged zone122and a third swellable member130that extends about outer surface92of tubular86at second end portion113of annular screen111. It is to be understood that the number of swellable members may vary. In a manner similar to that described above, swellable members128-130are selectively radially outwardly expandable to abut wall28creating a number of screen compartments (not separately labeled) that are fluidically isolated from one another externally of tubular86.

Reference will now follow toFIGS. 7 and 8in describing a screen assembly138in accordance with another aspect of an exemplary embodiment. Screen assembly138includes a tubular140having a first end142, a second end143and an intermediate portion144having an outer surface146extending therebetween. Tubular140includes a plurality of openings148that extend through outer surface146. A plurality of screens, shown in the form of screen members, one of which is indicated at154is arranged in corresponding ones of the plurality of openings148in tubular140. Screen members154filter fluid flowing through plurality of openings148and may take the form of sintered beads156. It is to be understood that screen members154may also take the form of a welded mesh and/or consolidated gravel.

In accordance with an aspect of an exemplary embodiment, tubular140may include a first opening-free zone159, a second opening-free zone160, a third opening-free zone161and a fourth opening-free zone162. Each opening-free zone159-162defines a section of intermediate portion144that is devoid of openings. In further accordance with an exemplary aspect, a first swellable member164is arranged at and extends about first opening-free zone159. A second swellable member165is arranged at and extends about second opening-free zone160; a third swellable member166is arranged at and extends about third opening-free zone161, and a fourth swellable member167is arranged at and extends about fourth opening-free zone162. In a manner similar to that described above, swellable members164-167are selectively radially outwardly expandable to abut wall28creating a number of screen compartments (not separately labeled) that are fluidically isolated from one another externally of tubular140.

Reference will now follow toFIGS. 9-11in describing a screen assembly180in accordance with yet another aspect of an exemplary embodiment. Screen assembly180includes a tubular182having a first end184, a second end185and an intermediate portion186having an outer surface188extending therebetween. Tubular182includes a plurality of openings190that extend through outer surface188. A screen194extends over tubular182. Screen194may take the form of an annular screen196that extend about intermediate portion186.

In accordance with an exemplary aspect, screen assembly180includes a swellable member198that extends across and about intermediate portion186across each of the plurality of openings190. Swellable member198includes an outer surface199and a plurality of passages200defined by portions202of outer surface199. Passages200register with the plurality of openings190creating a fluid pathway into an interior portion (not separately labeled) of tubular182. In a manner similar to that described above, swellable member198selectively radially outwardly expands such that outer surface199abuts wall28. Each of the plurality of passages200forms a discrete screen compartment (not separately labeled) that is fluidically isolated from other screen compartments externally of tubular140.

Reference will now follow toFIG. 12in describing a screen assembly220in accordance with another aspect of an exemplary embodiment. Screen assembly220includes a tubular222having a first end230, a second end232and an intermediate portion234having an outer surface246extending therebetween. Tubular222includes a plurality of openings248that extend through outer surface246. A first screen254is positioned on outer surface246across openings248, a second screen256is positioned on outer surface246spaced from first screen254and a third screen258is positioned on outer surface246spaced from second screen256. It is to be understood that the number of screens may vary.

In further accordance with an exemplary aspect, screen assembly220includes a first deformable member260that extends about tubular222between first screen254and second screen256, a second deformable member262that extends about tubular222between second screen256and third screen258and a third deformable member263that extends about tubular222adjacent third screen258. It is to be understood that the number of swellable members may vary. In a manner similar to that described above, deformable members260,262, and263are selectively radially outwardly deformable creating a number of screen compartments (not separately labeled) that are fluidically isolated from one another externally of tubular222. For example, deformable members260,262, and263may be expanded upon the shifting of tubular222relative to formation26.

A screen assembly comprising: a tubular including a first end, a second end, and an intermediate portion including an outer surface provided with a plurality of openings extending therebetween; at least one screen arranged at the plurality of openings; and at least two deformable members mounted to the tubular between the first end and the second end, the at least two deformable members being selectively radially outwardly expandable relative to the at least one screen forming a plurality of screen compartments on the tubular, the plurality of screen compartments being substantially fluidically isolated from one another externally of the tubular.

The screen assembly according to any prior embodiment, wherein the at least one screen includes an annular screen extending about the tubular, the annular screen including an outer surface section and an inner surface section.

The screen assembly according to any prior embodiment, wherein at least one of the at least two deformable members is mounted to the outer surface section of the annular screen.

The screen assembly according to any prior embodiment, wherein the annular screen includes at least one swaged zone with the inner surface section of the annular screen abutting the outer surface of the tubular.

The screen assembly according to any prior embodiment wherein the at least one of the at least two deformable members is arranged on the annular screen at the at least one swaged zone.

The screen assembly according to any prior embodiment, wherein the at least two deformable members comprises portions of a deformable member extending between the first and second ends across all of the plurality of openings.

The screen assembly according to any prior embodiment, wherein the portions of the deformable member define a plurality of passages that register with corresponding ones of the plurality openings.

The screen assembly according to any prior embodiment, wherein the at least one screen includes a plurality of screen members arranged in corresponding ones of the plurality of openings.

The screen assembly according to any prior embodiment, wherein the plurality of screen members comprise at least one of a welded mesh, sintered beads and consolidated gravel.

The screen assembly according to any prior embodiment, wherein the at least two deformable members comprises at least three deformable members.

A resource exploration system comprising: an uphole portion; and a downhole portion including a plurality of tubulars, and a screen assembly connected to one of the plurality of tubulars, the screen assembly comprising: a tubular including a first end coupled to the one of the plurality of tubulars, a second end, and an intermediate portion including an outer surface provided with a plurality of openings extending therebetween; at least one screen arranged at the plurality of openings; and at least two deformable members mounted to the tubular between the first end and the second end, the at least two deformable members being selectively radially outwardly expandable relative to the at least one screen forming a plurality of screen compartments on the tubular.

The resource exploration system according to any prior embodiment, wherein the at least one screen includes an annular screen extending about the tubular, the annular screen including an outer surface section and an inner surface section.

The resource exploration system according to any prior embodiment, wherein at least one of the at least two deformable members is mounted to the outer surface section of the annular screen.

The resource exploration system according to any prior embodiment, wherein the annular screen includes at least one swaged zone with the inner surface section of the annular screen abutting the outer surface of the tubular.

The resource exploration system according to any prior embodiment, wherein at least one of the at least two deformable members is arranged on the annular screen at the at least one swaged zone.

The resource exploration system according to any prior embodiment, wherein the at least two deformable member comprises portions of a deformable member extending between the first and second ends across all of the plurality of openings.

The resource exploration system according to any prior embodiment, wherein the portions of the deformable member define a plurality of passages that register with corresponding ones of the plurality openings.

The resource exploration system according to any prior embodiment, wherein the at least one screen includes a plurality of screen members arranged in corresponding ones of the plurality of openings.

The resource exploration system according to any prior embodiment, wherein the plurality of screen members comprise at least one of a welded mesh, sintered beads and consolidated gravel.

A method of deploying a screen assembly comprising: deploying a screen assembly including at least one screen coupled to a tubular; expanding at least two deformable members radially outwardly relative to the at least one screen toward a formation; and creating a plurality of screen compartments on the tubular with the at least two deformable members.

The method of any prior embodiment, wherein creating the plurality of screen compartments includes creating a plurality of substantially fluidically isolated pockets externally of the tubular.