Liner conveyed compliant screen system

A well completion assembly and method including apparatus for setting a compliant screen assembly and a liner within a wellbore in a single trip.

BACKGROUND

Hydrocarbon producing wells are often completed in unconsolidated producing formations containing fines and sand that can flow with produced hydrocarbons (fluids or gas) from the formations. The solid particulates in the produced fluids flow stream can damage equipment and must be removed from the produced fluids. Following drilling of a wellbore through an unconsolidated formation it is often a requirement that the wellbore be completed with a device that retains the sand particles in the formation, but that allows the flow of fluids to be produced. Filters, such as for example, sand screens or compliant screens, are commonly installed in wellbores and a gravel pack operation or the conformance of the screen against the borehole geometry can be performed to assist with the filtering out the fines and sand in the produced fluids and in the stabilizing of the producing formation.

The portion of the well above the productive formation is usually lined with one or more steel casing. The annulus between the casing and the wellbore is typically filled with cement to stabilize the casing and prevent fluid flows within the annulus. The wellbore can then be drilled further to drill through the productive formation. A length of blank pipe may be run to provide a second casing (often referred to as a liner) in the wellbore below the existing casing to a location just above the productive formation. At least a portion of the annulus between the liner and the open hole below the casing is normally filled with cement to hold the liner in place and block annular flow of fluids around the liner. A screen assembly can then be run below the liner into the open hole zone to provide a flow path for produced fluids from the producing formation, through the screen and liner and to the cased portion of the well. A flow conduit for produced fluids within the cased portion of the well to the surface is typically a production tubing string.

A well completion in an open hole zone generally requires both a sand control operation and a cementing operation. These operations have typically been performed using separate stages and multiple sets of equipment run into the well at different times. For example, a liner may be placed in the well and a cementing assembly may be run into the well to perform cementing of the liner. Once cementing of the liner is completed the cementing assembly is typically removed from the well and a sand control assembly run into the well. Thus, multiple trips into the well have typically been required to place the liner and the screen within the well and to cement the liner. Each trip into the well to position equipment or perform an operation requires additional time and expense and presents a challenge.

DETAILED DESCRIPTION

The following detailed description illustrates embodiments of the present disclosure. These embodiments are described in sufficient detail to enable a person of ordinary skill in the art to practice these embodiments without undue experimentation. It should be understood, however, that the embodiments and examples described herein are given by way of illustration only, and not by way of limitation. Various substitutions, modifications, additions, and rearrangements may be made that remain potential applications of the disclosed techniques. Therefore, the description that follows is not to be taken as limiting on the scope or applications of the appended claims. In particular, an element associated with a particular embodiment should not be limited to association with that particular embodiment but should be assumed to be capable of association with any embodiment discussed herein.

Various elements of the embodiments are described with reference to their normal positions when used in a borehole. For example, a screen may be described as being below or downhole from a crossover. For vertical wells, the screen will actually be located below the crossover. For horizontal wells, the screen will be horizontally displaced from the crossover, but will be farther from the surface location of the well as measured through the well. Downhole or below as used herein refers to a position in a well farther from the surface location in the well.

An annulus, as used in the embodiments, is generally a space between two generally cylindrical elements formed when a first generally cylindrical element is positioned inside a second generally cylindrical element. For example, a liner is a cylindrical element which may be positioned in a wellbore, the wall of which is generally cylindrical forming an annulus between the liner and the wellbore. While drawings of such arrangements typically show the inner element centrally positioned in the second, it should be understood that inner element may be offset and may actually contact a surface of the outer element at some radial location, e.g. on the lower side of a horizontal well. The width of an annulus is therefore typically not the same in all radial directions.

Cementing operations in a well and equipment used for such operations are generally well known in the well completion field. In general, the equipment provides a flow path through which cement may be flowed from a work string into an annulus between a casing, liner, or other oilfield tubular element and a well. Since the well is normally filled with a fluid, e.g. drilling fluid, completion fluid, etc., the equipment also includes a return flow path for fluid displaced by cement during the cementing operation.

Sand Control operations in a well and equipment used for such operations are also generally well known in the well completion field. A complete sand control assembly may be considered to include a screen or other filter element and length of blank pipe extending from the screen, both of which are to be installed in a well, as well as equipment for placing a gravel pack activate compliant screen and/or perform a fluid displacement/treatment around the screen in the well. The equipment typically includes a work string having a packer and cross over assembly and a wash pipe extending below the cross over to the bottom of the screen. When properly positioned for a sand control operation, the packer seals the annulus between the work string and the well above the screen. A fluid, i.e mud cake breaker, acid, brine . . . is then flowed down the work string to the crossover which directs the fluids into the annulus below the packer. The fluid flows through the screen into the wash pipe back up to the crossover which directs the return flow into the annulus above the packer. Alternatively, the fluid can be pumped down the annulus through the return port by-passing the crossover, down the washpipe. It will then flow along the open hole through the crossover and up the workstring. By plugging the bottom of the compliant screen, the screen can be activated by pressurizing in the same flow path than previously described. A packer may be used between the work string and the casing, liner, etc. to prevent cement from entering the annulus between the work string and the casing, liner, etc.

A well completion in an open hole zone generally requires the running of a liner, a cementing operation, the running of a screen, and a sand control operation. These completion operations are well known but are typically performed using multiple sets of equipment run into the well at different times. For example, a liner may be placed in the well and a cementing assembly may be run into the well to perform cementing of the liner. Once cementing of the liner is completed the work string with the cementing assembly is typically removed from the well and screens run into the well. Thus, multiple trips into the well have typically been required to place the liner and the screen within the well and to cement the liner and activate the compliant screen. Each trip into the well to position equipment or perform an operation requires additional time and expense. Further the screen assembly will need to have a smaller diameter to enable it to be run through the liner, which can lead to a restriction on the productive capacity of the well and induce constraints on future intervention operations.

The one trip liner conveyed screen system of the present disclosure provides an apparatus for selectively providing flow paths through a single work string for screen positioning and screen setting, liner placement and cementing, circulation paths for cleaning and, if desired, activating annular barriers. The flow path selection can be provided by sliding seals, sleeves, or ports formed between the work string and the liner/screen assembly. The selection of the flow path can be made by lifting and lowering the work string relative to the liner/screen assembly and/or by varying the fluid pressure within the work string. The movement of the work string relative to the liner/screen assembly can be performed at the surface location of the well by lifting and lowering the work string. Alternate means for selecting flow paths can also be used. The one trip liner conveyed screen system of the present disclosure provides for the screen to have a larger diameter than a screen assembly that is required if it were to be run through the liner.

FIG. 1is a schematic illustration of an offshore oil and gas platform and the drilling of a wellbore through an oil and gas formation and is generally designated10. A semi-submersible platform12is located over a submerged hydrocarbon formation14located below the sea floor16. A subsea conduit18extends from the deck20of platform12to a wellhead installation22that includes blowout preventers24. Platform12has a hoisting apparatus26and a derrick28for raising and lowering pipe strings, such as a substantially tubular, longitudinally extending drill string or work string.

AlthoughFIG. 1depicts an offshore slanted well from a semi-submersible platform, it should be understood that the open hole completion operations of the present disclosure are equally well-suited for use on onshore wells or alternative type offshore wells, in vertical wells, horizontal wells, multilateral wells and the like.

A wellbore32extends through the various earth strata including formation14. A casing34is shown cemented within a vertical section of wellbore32by cement36. A drill string30extends from the deck20of platform12, through the wellhead installation22, including blowout preventers24, and has a drill bit38on the distal end. The open hole section40extends the wellbore32below the casing34and through formation14.

FIG. 2is an elevation view of a cross-section of an example of a subterranean formation and drilling, completion or workover rig in which a sand control operation may be performed in accordance with certain embodiments of the present disclosure.FIG. 2shows a well100during a sand control operation adjacent a portion of a subterranean formation of interest102surrounding a well bore104. The well bore104extends from the surface106. Although shown as vertical deviating to horizontal, the well bore104may include horizontal, vertical, slant, curved, and other types of well bore geometries and orientations, and the sand control operation may be applied to a subterranean zone surrounding any portion of the well bore. The well bore104can include a casing110that is cemented or otherwise secured to the well bore wall. The well bore104can be uncased or include uncased sections.

The well is shown with a work string112descending from the surface106into the well bore104. A screen120is located on the distal end of the working string112and is shown with an upper liner hanger packer122and a lower open hole packer124which define an annulus area126between the screen120and the formation102. The working string112may include coiled tubing, jointed pipe, and/or other structures that allow fluid to flow into the well bore104or formation102. The working string112can include flow control devices, bypass valves, ports, and or other tools or well devices that control a flow of fluid from the interior of the working string112into the annulus area between the two packers and screen120and the formation102. For example, the working string112may include ports to communicate a fluid128into the annulus area between the two packers and the well bore104and out into the formation102in the annulus area126.

FIGS. 3athrough 3dillustrate an embodiment of the present disclosure positioned in a well bore210extending from a surface location, not shown, to a bottom hole location212. A casing214has been placed in an upper portion of the well210and the annulus between the casing214and well210has been filled with cement216. Casing214may be nominal nine and five/eighth inch steel casing. Below the bottom of the casing214or casing shoe218, the well210remains in an open hole, i.e. uncased, condition. In many cases, the casing214is placed in an upper portion of well210and the open hole portion of the well210includes slanted, curved or otherwise deviated portions so that at the bottom hole location212, the well is horizontal or near horizontal. The present disclosure is suitable for use in wells which are vertical to the bottom hole location212or which are slanted or deviated or horizontal over portions of their length.

An assembly220according to the present disclosure is shown positioned in the well210extending from the casing214down to the bottom hole location212. The assembly220has been lowered into position on a work string222extending from the surface location of the well210. A work string for purposes of the present disclosure may be any known pipe having the necessary strength and size to be lowered into and removed from a well210to position equipment in the well, flow materials into or from the well for various known operations, etc. A work string222may comprise any suitable oilfield tubular element including drill pipe, production tubing, etc. The work string222provides a first flow path224inside the work string222and a second flow path226in the annulus between the work string222and the casing214. Fluids may be circulated from the surface down path224and back up annulus226or reverse circulated down annulus226and back up the path224.

The assembly220includes an outer assembly228and an inner assembly230. Inner assembly230is connected to the lower end of work string222throughout its use in the present disclosure so that it is run into the well210on the work string222and removed from the well210with the work string222. The inner assembly may therefore be considered part of the work string222. The outer assembly228is mechanically coupled to the inner assembly when the inner assembly230is run into the well210, but, as explained below, is thereafter mechanically coupled to the casing214and disconnected from the inner assembly230, allowing the inner assembly230to be repositioned relative to the outer assembly228by movements of the work string222from the surface location of the well210.

The outer assembly includes a packer232, which is shown inflated into sealing contact with the casing214. Packer232may be a combination packer hanger to resist axial movement of the outer assembly228in the well210, or may be only a hanger. In an embodiment, the packer232provides a fluid tight seal between outer assembly228and the casing214as well as mechanically coupling the outer assembly228to the casing214. Below the packer232is located an upper cementing port234including a sleeve valve236allowing the port234to be selectively opened or closed. In the run in position, the valve236is closed. Below port234is located a length of blank pipe238. Blank pipe238is a conventional oil field tubular element, for example steel pipe and may be referred to as a liner because a portion of it may be positioned within the casing214. In this embodiment, pipe238may have a nominal diameter of seven inches and a weight of twenty-three pounds per foot. The length of pipe238may be selected based on the distance from the casing shoe218to the producing formation or the required position of screens. The pipe238will typically pass through curved or deviated portions of the well210and may be of considerable length. The various other elements comprising the outer assembly228are connected together by various other sections of pipe238and/or collars, etc. In some applications, for example in a shallow well, it may be desirable for the pipe238to extend a considerable distance up the well210and possibly to the surface location and pipe238may replace the casing214.

Below pipe238is located a seal bore240having an inner sealing surface242. In this embodiment, the seal bore240may comprise a thick wall coupling or length of pipe having a polished inner seal bore surface242having a precise inner diameter, e.g. five inches, which is less than the minimum inner diameter of the pipe238. Alternatively, the seal bore240, and other seal bores used in the present disclosure, may be a coupling or length of pipe having an inner sealing surface242formed of an elastomeric material, e.g. one or more O-rings. As described in more detail below, the inner assembly230may carry an outer seal body to seal with the sealing surface242. If the sealing surface242is a polished metal surface, the inner assembly may carry a matching elastomeric seal body. If the sealing surface242comprises an elastomeric element, then, the inner assembly may carry a matching polished metal seal body.

Below seal bore240is located a lower cementing port244including a sleeve valve246allowing the port244to be selectively opened or closed. In the run in position, the valve246is closed. The lower cementing port244can also include a spring biased one-way valve, i.e. check valve, which allows fluids to flow out of the port244into the annulus248, but blocks flow of fluids from the annulus248into the port244. Other forms of flow direction biased one-way valves may be used if desired. Such a valve may be omitted if desired and may provide no benefit in some situations, for example if the entire interval to be cemented is horizontal. A second seal bore250is located below the port244.

An external casing packer252is located below the second seal bore250. Below the packer252is located a third seal bore254. Below seal bore254is located a valved port256. The valved port256includes a sleeve valve258, which is typically in its open position when the assembly220is run in the well. The valved port256can include an outer shroud260, which directs fluids flowing out of valved port256down hole to avoid erosion of the wall of borehole210. A fourth seal bore262is positioned below the valved port256. Below the seal bore262is located a flapper valve264. While a flapper valve264is used in this embodiment, other fluid loss control devices, e.g. a ball valve, may be used if desired.

A screen assembly266is located below the flapper valve264. The screen assembly includes a screen268that may be any conventional or premium screen or compliant screen. Other forms of filters, such as slotted pipe or perforated pipe, may be used in place of screen268if desired. Above screen268, a length of blank pipe270connects the screen268to the upper portions of the outer assembly228. The pipe270may be of smaller diameter than the liner238, as illustrated. In some embodiments, the pipe270and base pipe used in the screen268may be of the same diameter as the liner238. In alternate embodiments, the pipe270and base pipe used in the screen268may be have a larger diameter as the blank pipe238.

The inner assembly230includes a packer setting tool272at its upper end connected to work string222. The tool272is used to set the packer232and to release the outer assembly228from the work string222once the packer232is set. The inner assembly includes shifters, e.g.274, for opening and closing the sleeve valves236,246and258as the inner assembly230is moved down and up in the well210. The inner assembly230includes a crossover assembly shown generally at276. The crossover276includes a port278in fluid communication with the flow path224through work string222. It also includes a flow path280in fluid communication with the flow path226above packer232.

On a cylindrical outer surface of crossover276is carried a seal unit or seal body282extending above and below the port278. The seal unit282may be formed as a separate metal sleeve having a plurality of elastomeric rings on its outer surface. The outer diameter of the elastomeric rings may be slightly greater, e.g. 0.010 to 0.025 inch greater, than the inner diameter of the seal bores240,250,254and262. In this embodiment, the seal bores240,250,254and262have polished metal inner surfaces, e.g.242, with which such elastomeric rings may form fluid tight seals. In an alternative discussed above, the inner surfaces of seal bores240,250,254and262are formed by elastomeric elements such as O-rings. In this alternative, the seal body282may comprise only a metal sleeve having a polished outer surface having an outer diameter somewhat larger than the inner diameter of the elastomeric elements forming the inner sealing surfaces, e.g.242, of the seal bores240,250,254and262. In either case, the seal body282may form fluid tight seals with the seal bores240,250,254and262at any point along the length of the seal body282. The seal body282has sufficient length above and below the port278to form seals with seal bores240and250at the same time and with seal bores254and262at the same time.

The lowermost portion of the inner assembly230can comprise a wash pipe284which extends through flapper264and into the screen268.

InFIGS. 3a-3d, the assembly220is shown in its run in position in well210and with the packer232set. The packer232was set by dropping a ball286down the work string222. Before the ball286is dropped, the assembly220allows full fluid circulation in the well as the work string222and assembly220are run into the well. The packer setting tool272and pressure in the flow path224may be used to set the packer232. After the packer232has been set, the well may be pressure tested by increasing pressure in the annulus226.

In the run in position shown inFIG. 3, the cross over port278is located at the lowermost seal bore262below the valved port256. The seal body282contacts the seal bore262both above and below port278, blocking all flow into or out of the port278. Once the ball286is in place, the flow path224is isolated from the annulus248and annulus226. After pressure testing the packer232, the pressure in the annulus226may be increased to set packer252, as illustrated inFIGS. 4-8.

The use of the apparatus ofFIGS. 3a-3dwill be described with reference toFIGS. 4-8. After the packers232and252have been set, as shown inFIG. 4, the inner string230may be repositioned for activating the complaint screen and/or treating a portion of the well210. By lifting the work string222, the cross over port278may be positioned in fluid communication with the valved port256. This is achieved by positioning seal body282to contact the seal bores254and262above and below crossover port278respectively. A treatment fluid288, such as an acid treatment, may then be flowed from the surface down work string222and through port278and valved port256into the annulus290adjacent the screen268. The displaced liquid flows up the wash pipe284, through crossover path280and into the annulus226which can then flow back to the surface location of well210. Then, by closing a device described in theFIG. 16-20at the bottom of the compliant screen268, pressure can be applied from annulus226through crossover path280, down the wash pipe284inside the compliant screen268. The complaint screen268will be activated to conform with the borehole geometry.

In theFIG. 4configuration, the present disclosure may be used to perform pressurized treatments. In some cases it may be desirable to perform a pressurized treatment such as acidizing which requires flowing a fluid down the work string222and into the formation surrounding the screen268. In theFIG. 4configuration, any treating fluid may be flowed down the work string222and pumped into the annulus290around the screen268. By blocking return flow through the annulus226, pressure may be applied to force the fluid into the formation surrounding the screen268. The present disclosure provides a convenient system for selectively treating the production zone surrounding the screen268.

InFIG. 5, the work string222has again been lifted to move the cross over port278above the seal bore254while leaving the seal body282in sealing contact with the seal bore254below port278. In this position, fluid may be reverse circulated down the annulus226, into crossover port278and up the work string222to remove any remaining treating fluid from the annulus226and work string222.

InFIG. 6, the work string222has been moved into position for cementing the pipe238above the packer252. The work string222has been first lifted to position sleeve shifters above the sleeve valves236and246. During this lifting operation, another shifter can move the sleeve258to close the valved port256to ensure that no cement can get below the valved port256and possibly plug or otherwise harm the screen268function. The work string222is then lowered to the position shown inFIG. 6. As it is lowered, shifters open the sleeve valves236and246in the upper and lower cementing ports234and244. In this cementing position, the crossover port278is in fluid communication with the lower cementing port244. The seal body282makes sealing contact with the seal bores240and250, above and below the crossover port278respectively. In this position, cement294may be flowed down the work string222, through crossover port278and lower cementing port244into the annulus248. The cement294will then flow up the annulus248towards the upper cementing port. In this embodiment, the lower cementing port244includes a spring biased check valve. The spring bias may be adjusted to set a minimum pressure at which cement can be pumped through the valve and to provide positive closing of the check valve when pumping has stopped. It may be desirable to pump only enough cement to fill the annulus248up to about the location of the casing shoe218, which is below the port234. If excess cement is pumped, the excess may flow into the casing214, through port234and back up the annulus226. In some applications, e.g. shallow wells mentioned above, the blank pipe may extend a considerable distance up the well210and may replace casing214. In such applications, the cementing operation may extend over the length of the pipe238and possibly to the surface location of the well and the upper cementing port234and packer232may be omitted. Reservoir isolation has been provided prior to the cementing operation by means of mechanically closing the valved port256that in this embodiment functions as a fluid loss control device positioned above the screen.

After pumping of cement294is stopped, the work string222is again lifted a short distance to the position shown inFIG. 7. In this position, the cross over port278is positioned above the seal bore240and the seal body282below port278forms a seal with seal bore240. Clean fluid may then be circulated down work string222, through the port278and back up the annulus226to clean out any excess cement. If desired, the circulation may be reversed. The lower cementing port244includes a spring loaded check valve, which closes when the pumping of cement stops. The check valve prevents flow of cement back into the lower cementing port244while the work string222is being cleaned.

In this embodiment, the cementing operation is performed after the activation of the compliant screen and treatment operation. However, if desired the apparatus may be employed to selectively cement first and then perform the treatment operation and activate the compliant screen. In either case, only one trip into the well is required. In completions with multiple screens as discussed below, it may be desirable to cement around blank pipe sections between screens. In that situation, the cementing and treatment operations may be performed alternately, i.e. compliant screen activation, followed by cementing, followed by treatment, etc.

After the cement has been placed as shown inFIGS. 6 and 7, and the well and work string have been cleaned out as shown inFIG. 7, the work string222and the inner assembly230may be removed completely from the well. As the inner assembly230is removed, shifters close the valves236and246. As the inner assembly230is lifted, the wash pipe284is removed from the screen268and the flapper valve264closes as shown inFIG. 8. If another type of fluid loss control device is used, e.g. a ball valve, a shifter may be used to close the valve. The valve264may be a ceramic flapper valve, or other type of fluid loss control device that may be opened or removed for production by methods known in the art. As noted above, the movements of the work string222have closed all three of the sleeve valves236,246and258so that all ports in the outer assembly are closed and all produced fluids must flow through the screen268.

In thisFIG. 8configuration, pipe238and screen268which can be a compliant screen, have been properly installed in an open-hole well210with a single trip into the well. The well has been treated, compliant screen268has been actuated and placed in a production mode and the blank pipe238has been cemented without removing and/or replacing a work string or any part of a work string. The only surface operations required are relatively small vertical repositioning, such as lifting and lowering the work string, the pressuring up or down of the work string, and flowing of appropriate cement and clean out fluids. In certain embodiments other actuation methods can be employed, such as by electrical/accoustic signals or pressure cycle or timer or pressure hydrostatic pressure or activating balls or wiper plugs or any combination of these different activation methods that can shift ports or make other mechanical changes within the work string or within the liner/screen assembly or float shoe assembly.

InFIG. 9is shown an embodiment wherein the pipe238and compliant screen268have been properly installed in an open-hole well210with a single trip into the well. The compliant screen268has been actuated and placed in a production mode and the blank pipe238has been cemented without removing and/or replacing a work string or any part of a work string. In this embodiment the liner238and blank pipe270can be of the same size. The compliant screen268once actuated will be of a larger diameter than that of the liner238and blank pipe270as shown inFIG. 9.

FIG. 10illustrates a service tool350that can be used with the embodiment of the assembly shown inFIG. 9. The service tool can include a base pipe352and a liner hanger354. The service tool350further includes one or more circulation ports356, one or more seal assemblies358, a cross-over port360, a ball seat362, a MCS shifter364, a reduced diameter extension366and a fluid loss device FLD shifter368. The assembly220also includes a downhole shutoff collar269and a float shoe assembly271.

FIGS. 11athrough 11fshow cross-sectional views and sectional views of a compliant screen assembly300according to an embodiment, at its Run-in state302, Activation state304, and Production state306. At the run-in state302the compliant screen310is compressed against a base pipe312and the assembly has an open flow path314therethrough. Fluid flow can be circulated through the assembly300if needed to wash down through the wellbore to get to the desired setting depth. The screen assembly300can be run in the well with the liner in a single trip on a work string. Pressure can be applied to the work string to set the top hanger packer, release the running tool, set the open hole isolation packers (if hydraulic isolation packer is used) and to put the screen in the activation state304. Pressure can be bled off and then re-applied to extend the screen310to the borehole wall. During the activation state304fluid flow through the bottom of the assembly300is blocked and hydraulic pressure applied to the assembly300can expand the internal chambers316and expand the screen310. In an embodiment, the activated screen310can be conformed to the wellbore wall to stabilize and provide support to the wellbore wall. With the screen310activated and the pressure bled off, the assembly will convert to the production state306to allow fluid production from the formation, through the activated screen310and the base pipe312, through the liner and into the cased wellbore/production tubulars. In an embodiment the compliant screen assembly300can be the Endurance Hydraulic Screen® screen assembly available from Halliburton of Houston Tex. Although the Endurance Hydraulic Screen® screen assembly is shown and described herein, other versions of compliant screen systems can be used within the scope of this disclosure.

To activate the compliant screen assembly300the bottom end of the screen assembly318will typically need to be isolated. Several options are available to seal off the bottom of the screen assembly, including a simple bull plug. A downhole shutoff collar as shown inFIG. 13can be used.FIGS. 13aand 13billustrate a downhole shutoff collar that can be run at the end of the screen assembly. The downhole shutoff collar provides a fluid flow path for washing down the assembly with the ability to be shut off and seal the end of the assembly so that hydraulic pressure can be applied to activate the screen. The downhole shutoff collar coupled with a double sideport float shoe271as shown inFIG. 14will allow circulation/washdown while running the assembly into the well. A ball can be dropped from the surface to actuate the shut off and isolate the float shoe271. It will provide a liner/screen assembly pressure seal enabling the setting of the packers and the activation of the compliant screen.

FIGS. 12athrough 12dshow cross-sectional views of an expandable screen assembly300according to an embodiment. A screen element310is shown inFIG. 12Aon the exterior of a base pipe312, the base pipe defining a passageway314. InFIG. 12Bis shown a screen element310in a collapsed position, the screen forming a flattened cavity311. The base pipe312contains passageways313that allow a fluid flow as shown by arrows317to enter and pressure up the cavity311. With fluid flow315the pressure in the cavity311increases and expands the screen element310as in shown inFIG. 12C. Once the screen310is expanded the screen assembly300can be put into a production mode as shown inFIG. 12Dwhere fluid flow315from the screen310flows through the passageways313and is flow319within the base pipe312. Many alternate expandable screen assemblies are available and are not limiting as to the application to the disclosure herein.

FIGS. 13a-billustrates an elevation view of a downhole shutoff collar assembly269according to an embodiment that can be run at the end of the screen assembly. The shutoff collar assembly269provides a fluid flow path for washing down the screen assembly that can be used to facilitate the one trip method disclosed herein.

FIG. 14illustrates an elevation view of a double sideport float shoe assembly271according to an embodiment that can be run at the end of the screen assembly. The float shoe271provides a fluid flow path for washing down the screen assembly that can be used to facilitate the one trip method disclosed herein.

FIGS. 15a-billustrate a dart and a wiper plug attached to a liner hanger setting tool that can be used to facilitate the one trip method. A wiper plug and landing collar could be used to isolate the float shoe assembly271. A dart can be dropped from the surface to land on the wiper plug assembly in the hanger setting tool. Pressure can be applied to expend the wiper plug assembly to the bottom landing collar as shown inFIG. 15. The float shoe21will be isolated enabling pressure to be applied to set the hanger/packers and activate the screen assembly.

FIG. 16illustrates a landing collar with double sideport float shoe assembly271that can be used to facilitate the one trip method disclosed herein.

FIG. 17illustrates an elevation view of an eRED plug assembly according to an embodiment available from Halliburton of Houston Tex. The eRED® plug assembly contains an electronic activation element that can be actuated by a signal such as a pressure or temperature change, a timer, or other signal. The eRED® plug combined with a double sideport float shoe271can enable the circulation of fluids down through the shoe271while running in the hole. The eRED® can then be triggered to close (possible trigger: hydrostatic pressure or timer or applied pressure or combination thereof), isolate the float shoe271and allow pressure to be applied to set the hanger/packers and activate the screen.

The above operational procedures are meant to be non-limiting examples of a procedure that could be employed to achieve the desired results of the discloser herein. Alternate procedures may also be employed to likewise achieve the desired results of the discloser herein.

In some cases the liner may not need to be cemented in place, which can be accommodated by the setting of two packers on either end of the liner. These may be pressure activated or chemically activated annular barriers. If the liner requires cementing the work string and service tool can be picked up to open the return flow circulation device and place the service tool into the backflow circulating device above the open hole packer to circulate cement around the liner.

This system provides a sand control solution in a single trip with an intermediate liner while keeping the capability of isolating or/and cementing the liner if desired. This system provides a sand control solution without necessarily having to perform a gravel pack with a considerable reduction of operational risk and cost. Such method will also generally reduce rig time and the related overall cost of well construction and completion.

An embodiment of the present disclosure is a method for placing a compliant screen and liner in a well in a single trip. The method includes running into the well a work string having a liner and a compliant screen assembly and positioning the compliant screen assembly and liner within the well. The method can further include cementing the liner within the well without removing the work string from the well between cementing and positioning the liner and compliant screen assembly. The method can further include actuating a compliant screen assembly and extending an expandable element of the screen assembly without removing the work string from the well between positioning and actuating the screen assembly. The disclosed method enables a larger bore screen to be run in the open hole that otherwise would be limited by the ID of the liner.

An embodiment of the present disclosure is an apparatus for one trip completion of a well that includes a screen assembly carried on a work string, a liner carried on the work string, the compliant screen assembly and liner operable in response to positioning of the work string in the well and/or pressure within the work string without removal of the work string from the well. The apparatus can include cementing equipment carried on the work string, the cementing equipment selectively operable in response to positioning of the work string in the well and/or pressure within the work string without removal of the work string from the well. The apparatus can include compliant screen assembly activation equipment carried on the work string, the activation equipment selectively operable in response to positioning of the work string in the well and/or pressure within the work string to radially extend a screen without removal of the work string from the well.

In another embodiment having multiple screen assemblies, the assemblies may be connected by lengths of blank pipe. It may be desirable to block annular flow outside the lengths of blank pipe by, for example, open hole packers and/or cementing the annuli around such lengths of blank pipe. Cementing of such multiple lengths of pipe between multiple screen assemblies may be accomplished by providing upper and lower cementing ports and seal bores for each length of pipe which is to be cemented. The inner assembly may then be positioned to selectively open cementing valves and flow cement into the various annuli between the blank pipe lengths and the well bore wall.

An embodiment of the present disclosure is a method for completing a well in a single trip, that includes running into the well a liner, a liner hanger, at least one open-hole packer, a compliant screen assembly and float shoe on a work string. The method includes positioning the liner, liner hanger, at least one open-hole packer, compliant screen assembly and float shoe within the well while washing down through the float shoe, setting the liner hanger and the at least one open-hole packer and placing the compliant screen assembly in production mode without removing the work string from the well between setting the liner hanger and at least one open-hole packer and placing the screen assembly in production mode.

The method can include isolating an annulus between the liner and the well by cementing the liner within the well without removing the work string from the well between cementing the liner and positioning the compliant screen assembly. The method can optionally include isolating an annulus between the liner and the well by annular barrier device without removing the work string from the well between isolating the annulus between the liner and the well and positioning the compliant screen assembly. Alternate embodiments include actuating the compliant screen assembly and extending an expandable element of the screen assembly without removing the work string from the well between positioning and actuating the screen assembly. In an embodiment the expanded screen element conforms to the wall of the well, thus providing formation stabilization as well as filtering effects. They can further include setting a portion of the liner within a cased portion of the well.

An alternate embodiment includes running into the well a work string comprising a plurality of liner sections and screen sections and positioning the plurality of compliant screen sections and liner sections within the well. The individual annulus between each liner section and wellbore can be isolated either by an annular barrier device or by cementing the liner within the well without removing the work string from the well between cementing each liner section and positioning the plurality of compliant screen sections.

An alternate embodiment is a single trip completion of a well in an open hole that includes running a work string into the well, using the work string to position a liner, a liner hanger, at least one open-hole packer, a compliant screen assembly and a float shoe while circulating through the float shoe. Once positioned the completion includes setting the liner hanger and at least one open-hole packer, actuating the compliant screen assembly and placing the compliant screen assembly in production mode. Then the at least a portion of the work string is repositioned to activate a cementing functionality of the work string. The workstring is used to isolate an annulus between the liner and the well without removing the work string from the well between the cementing operation and placing the compliant screen assembly in production mode. The annulus between the liner and well can be isolated by cementing the liner within the well or by setting one or more annular barrier device. The method can further include actuating the compliant screen assembly and extending an expandable element of the compliant screen assembly without removing the work string from the well between positioning and actuating the compliant screen assembly. The liner can be set within a cased portion of the well.

Alternate embodiments can include running into the well a work string comprising a plurality of liner sections and compliant screen sections and positioning the plurality of compliant screen sections and liner sections within the well, which can further include isolating the individual annulus between each liner section and wellbore either by annular barrier device or cementing the liner within the well without removing the work string from the well between cementing each liner section and positioning the plurality of compliant screen sections.

A further embodiment is an apparatus for one trip completion of a well that includes a compliant screen assembly, liner and cementing equipment carried on a work string. The compliant screen assembly, liner and cementing equipment selectively operable in response to positioning of portions of the work string in the well and/or pressure within the work string without removal of the work string from the well. The apparatus can include compliant screen assembly activation equipment carried on the work string, the activation equipment selectively operable in response to positioning of the work string in the well and/or pressure within the work string to radially extend a screen without removal of the work string from the well. The apparatus can include a plurality of liner sections and compliant screen sections, and can optionally include sufficient ports and sleeves for isolating each individual annulus between each liner section and wellbore either by annular barrier device or cementing the liner within the well without removing the work string from the well between cementing each liner section and positioning the plurality of compliant screen sections.

The operations of the steps are described with reference to the systems/apparatus shown described herein. However, it should be understood that the operations of the steps could be performed by embodiments of systems and apparatus other than those discussed herein and are not meant to be limiting. Embodiments discussed herein could perform alternate operations different than those discussed but achieving substantially similar results.

The text above describes one or more specific embodiments of a broader disclosure. The disclosure also is carried out in a variety of alternate embodiments and thus is not limited to those described here. The foregoing description of an embodiment of the disclosure has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the disclosure be limited not by this detailed description, but rather by the claims appended hereto.