Abstract:
In general, a method is provided for completing a subterranean wellbore, and an apparatus for using the method. The method comprises positioning an expandable sand-control device in the wellbore thereby forming an annulus between the sand-control device and the wellbore; depositing a filter media in the annulus; and after the depositing step, radially expanding the sand-control device to decrease the volume of the annulus. The sand-control device can be a sand screen or slotted or perforated liner having radially extending passageways in the walls thereof, the passageways designed to substantially prevent movement of the particulate material through the passageways and into the sand-control device. Where a slotted liner is desired, the passageways can be plugged during positioning and later unplugged for production. Another embodiment of the method and apparatus presented herein comprises positioning a well-completion device into the wellbore, thereby forming an annulus between the well-completion device and the wellbore, the well-completion device having a flexible, permeable membrane sleeve surrounding an expandable sand-control device; and thereafter radially expanding the sand-control device to decrease the volume of the annulus, thereby also expanding the membrane sleeve. The well-completion device can further include a layer of filter media encased between the membrane sleeve and the sand-control device. The filter media may be of any type known in the industry. Preferably, the membrane sleeve, when expanded, substantially fills the annular space extending between the wellbore and the sand-control device by deforming to substantially contour the wellbore.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a divisional of commonly owned application Ser. No. 09/698,322 filed Oct. 27, 2000 now U.S. Pat. No. 6,543,545, entitled “Expandable Sand-control device and Specialized Completion System and Method,” the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     FIELD OF INVENTION 
     The present invention relates to sand-control apparatus and methods in a subterranean hydrocarbon well. More particularly, the present invention relates to methods and apparatus for using an expandable sand control device in conjunction with a specialized gravel pack fluid system. 
     BACKGROUND 
     The control of the movement of sand and gravel into a wellbore and production string has been the subject of much importance in the oil production industry. Gravel pack operations are typically performed in subterranean wells to prevent fine particles of sand or other debris from being produced along with valuable fluids extracted from a geological formation. If produced, the fine sand tends to erode production equipment, clog filters, and present disposal problems. It is therefore economically and environmentally advantageous to ensure that the fine sand is not produced. During gravel packing, the annulus between the well bore wall and the production tubing, which can include a screen or slotted liner assembly, is filled with selected natural or man-made packing material, or “gravel.” Such packing materials can include naturally occurring or man-made materials such as sand, gravel, glass, metal or ceramic beads, sintered bauxite and other packing materials known in the art. The gravel prevents the fine sand from the formation from packing off around the production tubing and screen, and the screen prevents the large grain sand from entering the production tubing. 
     One difficulty in packing operations, especially in open-hole wellbores, is completely filling the often irregular annular space between the production tubing and the wellbore wall. Where packing is incomplete, “voids” are left around the production tubing. These voids, or areas which are incompletely packed with gravel, allow sand fines to be produced along the area of sand screen or slotted liner. The fines can clog the production assembly or erode production equipment. 
     Consequently, a more effective method of packing a wellbore is needed. 
     SUMMARY 
     In general, a method is provided for completing a subterranean wellbore, and an apparatus for using the method. The method comprises positioning an expandable sand-control device in the wellbore thereby forming an annulus between the sand-control device and the wellbore; depositing a filter media in the annulus; and after the depositing step, radially expanding the sand-control device to decrease the volume of the annulus. The sand-control device can be a sand screen or slotted or perforated liner having radially extending passageways in the walls thereof, the passageways designed to substantially prevent movement of the particulate material through the passageways and into the sand-control device. Where a slotted liner is desired, the passageways can be plugged during positioning and later unplugged for production. 
     The filter media is typically a particulate material and can be deposited as a slurry comprising liquid material and particulate material, or as a cement slurry. The step of expanding the sand-control device further includes squeezing at least a portion of the liquid of the slurry through the sand-control device passageways thereby forming a pack in the wellbore annulus. The liquid material can be water-based, oil-based or emulsified and can include gelling agents. Further, the particulate can be resin coated with a delayed form system. The form system can include particulate material. The foam can also include decomposable material which can be decomposed after placement of the form in the annulus. 
     Another embodiment of the method and apparatus presented herein comprises positioning a well-completion device into the wellbore, thereby forming an annulus between the well-completion device and the wellbore, the well-completion device having a flexible, permeable membrane sleeve surrounding an expandable sand-control device; and thereafter radially expanding the sand-control device to decrease the volume of the annulus, thereby also expanding the membrane sleeve. The well-completion device can further include a layer of filter media encased between the membrane sleeve and the sand-control device. The filter media may be of any type known in the industry. Preferably, the membrane sleeve, when expanded, substantially fills the annular space extending between the wellbore and the sand-control device by deforming to substantially contour the wellbore. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Drawings of the preferred embodiment of the invention are attached hereto, so that the invention may be better and more fully understood, in which: 
     FIG. 1 is a schematic elevational cross-sectional view of a typical subterranean well and tool string utilizing the invention; 
     FIG. 2 is a schematic elevational detail, in cross-section, of the depositing the filter media and expanding the expandable sand-control device of the invention; 
     FIG. 3 is a detail of a slotted or perforated liner which can be used with the invention; and; 
     FIGS. 4A and 4B are views of alternate embodiments of the invention. 
    
    
     Numeral references are employed to designate like parts throughout the various figures of the drawing. Terms such as “left,” “right,” “clockwise,” “counterclockwise,” “horizontal,” “vertical,” “up” and “down” when used in reference to the drawings, generally refer to orientation of the parts in the illustrated embodiment and not necessarily during use. The terms used herein are meant only to refer to the relative positions and/or orientations, for convenience, and are not meant to be understood to be in any manner otherwise limiting. Further, dimensions specified herein are intended to provide examples and should not be considered limiting. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to FIG. 1, a tubing string  10  is shown run in well  16  at least to the zone of interest  12  of the formation  14 . The well  16  can be on-shore or offshore, vertical or horizontal, consolidated or unconsolidated and can be cased or an open-hole. It is expected that the invention will be primarily utilized in open-hole horizontal wells, but it is not limited to such use. The tubing string  10  extends from the well surface  18  into the well bore  20 . The well bore  20  extends from the surface  18  into the subterranean formation  14 . The well bore  20 , having well bore wall  26 , extends through a cased portion  22  and into an un-cased open-hole portion  24  which includes the zone of interest  12  which is to be produced. 
     In the cased portion  22  of the well, the well bore  20  is supported by a casing  26 . The well bore typically is cased, as shown, continuously from the well surface but can also be intermittently cased as circumstances require, including casing portions of the wellbore downhole from the zone of interest  12 . The well is illustrated for convenience as vertical, but as explained above, it is anticipated that the invention may be utilized in a horizontal well. 
     The tubing string  10  extends longitudinally into the well bore  20  and through the cased portion  22 . The tubing string can carry packers, tester, circulating and multi-position valves, cross-over assemblies, centralizers and the like to control the flow of fluids through the tubing string and placement of the string in the well bore. 
     Adjacent the lower end  28  of the tubing string  10  a sand control device  30  is connected. The sand control device  30  can be of many types which are generally known in the art, including one or more sand screens. Preferably POROPLUS (a trademark) sand screens are used and reusable, retrievable screens are preferred. Apparatus and methods for constructing and deploying screens are used in conjunction with the invention. Exemplary sand-control screens and methods of deployment are disclosed in U.S. Pat. Nos. 5,931,232 and 5,850,875, and in U.S. Patent Application Ser. No. 09/627,196 filed Jul. 27, 2000, all of which are assigned to the assignee of this application and are incorporated herein by reference for all purposes. 
     The sand control device  30  can also be a slotted or perforated liner or sleeve, such as seen in FIG. 3, and such as are known in the art, having radially extending passageways  31  to fluidly connect the interior of the slotted liner  30  with the formation. In the case of a slotted or perforated liner it may be desirable to plug the passageways  31  in the liner with plugs  33  during run-in of the tools and completion of the packing procedure. The passageways  31  can later be unplugged, or the plugs  33  removed, to allow fluid flow into the tubing string. Removal of the plugs  33  can be accomplished mechanically or chemically as is known in the art. 
     Mounted on the tubing string  10  are a hanger  32  and an open-hole packer  34 . The packers are shown in their expanded or “set” positions. The packers are run into the hole in a retracted or unexpanded condition. The hanger  32  engages the casing  26  of the cased portion  22  of the well and typically provides a seal through which fluids and particulate cannot pass. The hanger  32  can be a retrievable direct hydraulic hanger with a control line access feature  36 . The hanger can be of any type generally known in the art and can be an inflatable, compression or other type of hanger, and can be actuated hydraulically, by wireline or otherwise as will be evident to those of ordinary skill in the art. Similarly, the open-hole packer  34  may be of any type known in the art such as a “hook wall” packer or a non-rotating inflatable packer. The packer can be retrievable if desired. Additional or fewer packers and hangers can be employed without departing from the spirit of the invention. A lower packer  34  may only be necessary when it is desired to seal off a non-producing zone downhole from the zone of interest  12 . 
     The tubing string  10 , as shown in FIG. 1, can additionally carry other drill string tools for controlling and measuring fluid flow and well characteristics and for manipulating the tubing string. Illustrated are a valve  40 , a cross-over kit  42  having a control line  36 , and disconnects  44 . These tools are generally known in the art and additional tools, such as collars, measuring devices, and samplers can be added to the tool string as desired. 
     The tubing string  10  or work string  50  also carries an expansion tool assembly  52 . The expansion tool assembly is run into the well in a retracted position so as not to interfere with movement of the tubing and work strings, as seen in FIG.  1 . The expansion tool is activated to an expanded position  54 , as seen in FIG. 2, and drawn through the expandable sand-control device  30 . The expansion cone, or other expansion device, such as is known in the art, can be hydraulically actuated by a downhole force generator or can be forced along the tubing string by weight applied to the work string. The expansion of the expandable sand-control device can occur from top-down or from bottom-up, as desired. Preferably the expansion tool assembly is retrievable. 
     The tubing string preferably carries centralizers  48  which act to maintain the tubing string in a spaced relation with the well bore wall  26 . This is of particular importance where the well bore is horizontal. The details of construction of the centralizers  48  varies according to the requirements of the application and include segmented “fin” devices, round disks as well as the centralizers shown. The centralizers aid in cuttings removal and protect the expandable sand-control device  30  during run-in and drilling operations, as well. 
     A working string  50  can be deployed interior of the tubing string  10  and sand-control device  30 . Working string  50  can carry a plurality of well tools as are known in the art. Such tools can include a measuring while drilling assembly  62 , a shoe  64 , a downhole motor  66 , a drill bit  68  and a receptacle  70  for the downhole motor and bit, as shown. Preferably these tools are retrievable. Additional tools and types of tools can be utilized as well without departing from the spirit of the invention. Those skilled in the art will recognize a vast choice of tool combinations depending on the requirements of the formation and desires of the practitioner. 
     The measuring while drilling assembly  62  preferably includes a logging while drilling function and may include an acoustic telemetry system to provide real-time data acquisition of well characteristics. Other data acquisition instruments can also be employed. 
     Disconnects  44  allow sections of the tubing and work strings to be released for retrieval to the surface for reuse. Additionally the disconnects can allow portions of the strings, such as downhole motor  66  and drill bit assembly  68  to be retracted into receptacle  70  used for that purpose. Disconnects  44  are of types generally known in the art and may be mechanically, hydraulically or explosively actuated. 
     A tool assembly, such as the one shown in FIGS. 1 and 2, is drilled into place in formation  14  using a downhole motor  66  and drill bit  68  assembly. The tool assembly can include a downhole motor  66  with bit  68 , a measuring while drilling tool assembly  62 , a receptacle housing  70 , an expanding screen or slotted liner device  30 , blank tubing  72  and an expansion tool assembly  52 . Depending on the tool assembly configuration, the expansion tool  52  can be run-in as part of the assembly or on a separate trip. Also depending on the configuration, an inner tubing string, or work string  50  or the tubing string  10  with expandable sand-control device  30  can be used as the fluid conduit during drilling, wellbore fluid and filter media placement. 
     The bottom hole assembly is made up and run in the wellbore  20 . The open-hole portion  24  will be drilled with the downhole motor  66  and drill bit  68  assembly along the desired well bore trajectory and to the desired depth. Once the zone of interest  12  is passed or reached, the wellbore can be cleaned to remove cuttings, as is known in the art. Once cleaned, a wellbore fluid can be placed in the well bore annulus  72  between the tubing string  10  and the well bore wall  26 . The use of well bore fluids is well known in the art. Preferably the hanger  32  is set in the cased portion  22  of the well, as shown. Alternately, a packer may be used. The hanger anchors the sand-control device  30  in place. 
     The work string  50  can be released at disconnect  44  to allow recovery of the measurement while drilling tool  62  and latching of the downhole motor  66  and drill bit  68  assembly into the receptacle housing  70 . The receptacle housing  70  seals the motor  66  from the sand-control device  30  if desired. The recovery of the work string may occur before or after insertion of the filter media  74  into the annulus  72  depending on the system configuration. 
     The filter media  74  is placed across the annulus  72 , particularly along the length of the annulus surrounding the sand-control device  30 . The filter media  72  can be inserted into the annulus  72  by any method known in the art, such as pumping the filter media  74  from the surface  18  through the annulus  76  between the work string  50  and the tubing string  10  and thereafter through ports  80  into annulus  72 . The ports may be located at various places along the tubing string. Alternately, the filter media can be pumped out of the shoe  64  at the lower end of the hole. In such a case, the lower isolation packer  34  would be unnecessary. In cases where the tubing string  10  is run in on a separate trip from the drilling string  30 , the filter media  74  can be pumped into the annulus  72  during running of the tubing string  10  or after the desired depth is reached by the string. Further, the filter media  74  can be pumped in as the welbore fluid is removed. The method and direction of pumping, or inserting, the filter media  74  is not critical to the invention. Various methods of placing the filter media  74  into the annulus  72  will be readily apparent to those of skill in the art. Preferably, the drilling operation, filter pumping operation and sand-control device expansion operation can be accomplished with a single trip of the combined tubing string and concentric work string. However, multiple trips may be necessary or desired depending on the configuration employed. 
     The filter media  74  of the process can take several forms. Some of the fluids covered by the invention are a suspension of particulates in fluid, a particulate slurry and foamed systems. 
     The filter media  74  can be a suspension of particulates in fluid. The particulates in this application could be of any size appropriate for controlling sand production from the reservoir. In addition, the proppant, or particulate, specific gravity preferably ranges from 1.1 to 2.8. The specific gravity and other characteristics of the particulate will vary, however, and are determined by the required downhole hydrostatic pressure. The use of lightweight particulate is preferable where the major mechanism for inducing a squeezing of the ‘void filling fluid’, or filter media, is caused by expansion of the sand-control device. Particulate, or proppant, loading preferably ranges between 0.1 to 20 ppg, but is not limited to this range. The carrier fluid for the particulate can be water-based, hydrocarbon-based, or an emulsified system. Examples of water based system include, but are not limited to, clear brines or those that include the use of gelling agents such as HEC, xanthan, viscous surfactant gel or synthetic polymers. In addition, the water-based system bay be weighted by the addition of salts such as calcium chloride or other conventional brines as used in the oil field. Examples of hydrocarbon based systems include, but are not limited to, the use of gelled oils and drill-in fluids. Emulsified systems (water external or oil external) can also be used. 
     Another filter media system  74  can be applied is a solid particulate/cement slurry mixture that after liquid removal by the squeezing action of the expansion of the sand-control device, and after the passage of time, creates a porous media through which hydrocarbons and other fluids can be produced while controlling fines migration. Particulate concentrations can range from 5 to 22 ppg, but will vary based on application conditions. The density of the particulates can range from 1.1 to 2.8, but may also vary. Testing with such a system containing 20/40 sized sand indicated that a permeability of 40 Darcy and an unconfined compressive strength of 900 psi could be developed with this system. Such a system, with these permeability and strength factors, is desirable in most well formations. 
     A system in which a particulate coated with a resin material is also covered by this invention. The resin material may be activated by well temperature, time, stress induced by liquid removal, or through the use of an activator that is injected after the liquid removal process. Resins and activators are well known in the art. 
     The filter media can be a foamed system, with or without particulates, that creates an open-faced permeable foam after liquid removal. A chemical treatment, after dehydration, may be necessary to enhance the permeability of the foam. A typical system for this application could be a foamed cement to which a mixture of crosslinked-gel particulate and carbonate particles of appropriate size have been added to the slurry. The crosslinked gel particles have a chemical breaker added to them. After liquid removal the crosslinked gel particles are broken by the in-situ breaker leading to the creation of a porous media. The permeability of the porous media can be further enhanced by pumping an acid to dissolve the crosslinked gel and the calcium carbonate particles. This invention also covers the use of alternative materials that can decompose by contact with conventional brines or oil soluble systems such as oil soluble resin or gilsonite that can be dissolved by contact with hydrocarbons. Degradable semi-solid gel particulate material can also be used in the filter system to act as a means to increase the porosity of the filter media after the carrier fluid is removed by squeezing. This will enhance the permeability and prevent excessive losses in permeability caused by the dehydration process. Various types of foam and particulate mixtures, and methods for improving permeability and porosity, will be recognized by those of skill in the art. 
     Surface modifying agents can be added to the solid material in the filtration media. These surface modifying agents can improve the filtration properties of the particulate material by stopping fines migration at the open hole, filter interface and prevent plugging of the filter media itself. Surface modifying agents can also be added to the particulate material in the filtration media to provide cohesive bonds between particles when the suspending fluid is at least partially removed by the squeezing effect of the sand-control device expansion. The cohesive strength in the pack will prevent movement of particles in the pack during production operations which will reduce any chance for well tool erosion. 
     Alternately, the permeable filter media is placed external of the sand-control device  30  prior to running and expanding in the subterranean wellbore. An open-cell, permeable, expandable, foamed material is molded or cast into a cylinder shape  90 , sleeve or jacket. This foamed sleeve  90  is then slid over the expandable sand-control device  30  to encapsulate its outer wall before its downhole placement. The wall thickness of the sleeve is preferably from ¼ inch to 1 inch, depending on the diameters of the screen and wellbore. The permeable sleeve  90  can be tightly fit or glued to the device surface to prevent it from sliding off of the device during operation. The outer surface of the foamed sleeve  90  can be coated with high tensile strength “film”  92  or material to protect the sleeve from tearing or ripping during handling and installation of the expandable screen downhole. 
     The deformability of the foam allows it to fill up the void space or gaps between the screen and the formation as the screen is expanded against the open-hole wall  26 . The foamed sleeve  90  can also be impregnated with synthetic beads, sands or proppant, to maintain permeability of the porous medium under compression. 
     The foamed sleeve  90  can also be impregnated with treatment chemical that can be slowly released, such as a breaker that can break up or dissolve the filter cake remaining after drilling operation. The treatment chemical can be mud breakers, such as oxidizers, enzymes or hydrolysable esters that are capable of producing a pH change in the fluid, scale inhibitors, biocides, corrosion inhibitors, and paraffin inhibitors that can be slowly released during production. 
     Another concept includes the use of a flexible, expandable, and permeable membrane  94 , which is prepared in the shape of a sleeve or jacket to provide similar function as described in the above concept. The permeable sleeve, which can be pulled over the expandable screen covering its outer wall, acts as pouch containing the filter medium  74  (i.e. lightweight beads, sands, proppant, etc.). As the screen is expanded, the filter medium in the deformable membrane fills up the annulus space  72 . This permeable membrane can be prepared from materials such as metals, polymers, or composites, so that it can tolerate both physical and chemical requirements of downhole conditions. 
     After placement of the filter media  74  in the wellbore annulus  72 , the sand-control device  30  is expanded. As shown in FIG. 2, wherein the work string  50  has already been retrieved, the sand-control device  30  can be expanded from bottom-up. The expansion can occur top-down as well depending on the well tool configuration. 
     The sand-control device  30  is adjacent the zone of interest  12 . The retractable expansion tool  52  is activated to its expanded position, as seen in FIG. 2, to expand the sand-control device. The sand-control device  30  is radially expanded from its unexpanded, or initial position or radial size  80 , to its expanded position  82 . During expansion, liquid L from the filter media  74  flows along lines F into the sand-control device  30  and then into the tubing string  10 . If the expansion assembly is operated from the top-down, it may be desirable for the expansion assembly to have a bypass port  81  through which the fluid F may travel up into the tubing string  10 . As at least a portion of the fluid F is squeezed from the filter media  74 , the particulate material P is tightly packed into the annulus  72 . The filter media particulate P cannot flow into the sand-control device  30 . The screen or slotted holes of the sand-control device  30  are selectively sized and shaped to prevent migration of the particulate P into the device  30 . The filter media particulate P remaining in the annulus  72  acts as a filter during production of hydrocarbons H from the well formation  14 . Fines, or small sand particles S, are trapped or filtered by the remaining media and prevented from flowing into the sand-control device  30 . 
     The filter media is pumped into the annulus  72  to fill up the annular space. However, conventional methods of packing often leave undesirable voids, or areas which are not filled with packing media. Preferably, in the current invention, as the filter media is squeezed between the wellbore wall  26  and the tubing string  10  during expansion of the sand-control device  30 , any voids not previously filled are eliminated and filled-in with the filter media. 
     The filter media can prevent fines from migrating to the sand-control device, thereby preventing clogging and erosion of the well tools and sand-control device, and can prevent the formation from collapsing thereby reducing the production of fines. The tight packing of the media against the wellbore wall can also prevent shale spalling. Shale spalling could result in plugging of the media and sand-control device. 
     Preferably, when the filter media  74  is pumped into the annulus  72 , the filter media fills the annulus at least a set distance into the cased portion  22  of the well as shown. 
     It will be seen therefore, that the apparatus and method addressed herein are well-adapted for use in flow testing an unconsolidated well formation. After careful consideration of the specific and exemplary embodiments of the present invention described herein, a person of skill in the art will appreciate that certain modifications, substitutions and other changes may be made without substantially deviating from the principles of the present invention. The detailed description is illustrative, the spirit and scope of the invention being limited only by the appended claims.