Patent Publication Number: US-2019169963-A1

Title: Selectively expandable screen for a resource exploration and recovery system

Description:
BACKGROUND 
     In the resource exploration and recovery industry, tubulars are run into boreholes for the purpose of extracting formation fluids. Often times, a tubular may support one or more expandable seal members or packers. The packers, when activated, may separate the borehole into one or more production zones. An inflow device may be arranged on the tubular at each zone. A screen may be provided at the inflow device to filter formation fluids entering into the tubular. In some cases, expandable screens are employed. Expandable screens may be formed from synthetic material that engages with side walls of the borehole. The synthetic material has a limited operating temperature, burst rating and collapse rating. Therefore, the art would appreciate an expandable screen that may withstand higher temperatures and pressures. 
     SUMMARY 
     Disclosed is a selectively expandable screen system including a tubular having an outer surface and an inner surface defining a flow path. A screen assembly is mounted at the outer surface of the tubular. The screen assembly is formed from a compressible metal material. A selectively releasable compression device is coupled to the screen assembly. The selectively releasable compression device selectively maintains the compressible metal material in a compressed configuration. 
     Also disclosed is a resource exploration and recovery system including a first system, and a second system coupled to the first system through one or more tubulars. At least one of the one or more tubulars includes an outer surface and an inner surface defining a flow path, and a screen assembly mounted at the outer surface of the tubular. The screen assembly is formed from a compressible metal material. A selectively releasable compression device is coupled to the screen assembly. The selectively releasable compression device selectively maintains the compressible metal material in a compressed configuration. 
     Further disclosed is a method of deploying a screen formed from a metal material mounted to an outer surface of a tubular. The method includes compressing the metal material toward the outer surface of the tubular, restraining the metal material with a selectively releasable compression device, moving the screen into a selected position, and releasing the selectively releasable compression device allowing the metal material to expand radially outwardly of the outer surface. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike: 
         FIG. 1  depicts a resource exploration and recovery system including a selectively expandable screen, in accordance with an aspect of an exemplary embodiment; 
         FIG. 2  depicts a cross-sectional view of the selectively expandable screen of  FIG. 1 , in accordance with an aspect of an exemplary embodiment; 
         FIG. 3  depicts a cross-sectional view of a selectively expandable screen, in accordance with an aspect of an exemplary embodiment, in a run-in configuration; 
         FIG. 4  depicts the selectively expandable screen of  FIG. 3  being deployed; 
         FIG. 5  depicts a cross-sectional view of a selectively expandable screen, in accordance with another aspect of an exemplary embodiment; 
         FIG. 6  depicts a cross-sectional view of the selectively expandable screen of  FIG. 5  after being deployed; 
         FIG. 7  depicts a cross-sectional view of a selectively expandable screen prior to being compressed, in accordance with an aspect of an exemplary embodiment; and 
         FIG. 8  depicts a cross-sectional view of the selectively expandable screen of  FIG. 7  after being compressed. 
     
    
    
     DETAILED DESCRIPTION 
     A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures. 
     A resource exploration and recovery system, in accordance with an exemplary embodiment, is indicated generally at  10 , in  FIG. 1 . Resource exploration and recovery system  10  should be understood to include well drilling operations, resource extraction and recovery, CO 2  sequestration, and the like. Resource exploration and recovery system  10  may include a first system  14  which, in some environments, may take the form of a surface system  16  operatively and fluidically connected to a second system  18  which, in some environments, may take the form of a downhole system. First system  14  may include a control system  23  that may provide power to, monitor, communicate with, and/or activate one or more downhole operations as will be discussed herein. Surface system  16  may include additional systems such as pumps, fluid storage systems, cranes and the like. 
     Second system  18  may include a tubular string  30  formed from a plurality of tubulars, one of which is indicated at  32  that is extended into a wellbore  34  formed in formation  36 . Wellbore  34  includes an annular wall  38  which may be defined by a surface of formation  36 , or a casing tubular (not shown). A first expandable member which may take the form of a first packer  44  is arranged on tubular  32 . First packer  44  may be selectively expanded into contact with annular wall  38 . A second expandable member which may take the form of a second packer  46  is arranged on tubular  32  spaced from first packer  44  along tubular string  30 . First and second packers  44  and  46  may collectively define a first zone  48 , a second zone  49  and a third zone  50  along tubular string  30 . The number, size and location of each zone  48 - 50  may vary. 
     In accordance with an aspect of an exemplary embodiment, second system  18  includes a selectively expandable screen system  60  coupled to tubular  32  at second zone  49 . It should be understood that additional selectively expandable screen systems may be arranged in first and third zones  48  and  50  or in second zone  49 . Referring to  FIG. 2 , selectively expandable screen system  60  includes a tubular  70  having an outer surface  72  and an inner surface  74  that defines a flow path  76 . A screen assembly  80  is provided at outer surface  72 . 
     Screen assembly  80  is formed from a compressible metal material  84 . in an embodiment, compressible metal material  84  is resiliently compressible. That is, after being compressed, and after being released, screen assembly  80  returns to an uncompressed state due to intrinsic material properties of compressible metal material  84 . in an embodiment, compressible metal material  84  may take the form of intermeshed metal fibers (not separately labeled). Once compressed, compressible metal material  84  may be secured by a selectively releasable compression device  94 . In an embodiment, selectively releasable compression device  94  may take the form of a plurality of wires, one of which is indicated at  100 . 
     In accordance with an aspect of an exemplary embodiment, plurality of wires  100  are made from a degradable material (not separately labeled) that may degrade when exposed to a selected fluid, for example, fluid in wellbore  34 . The fluid may take the form of formation fluids or, fluids that are introduced from first system  14 . In another embodiment, plurality of wires  100  may be frangible. Referring to  FIG. 3 -4 , tubular  70  may be formed from an expandable material. An expansion tool  106  may be directed into flow path  76  toward selectively expandable screen system  60  as shown in  FIG. 3 . A tapered end  108  of expansion tool  106  may be guided into tubular  70 . Expansion tool  106  drives tubular  70  radially outwardly, causing plurality of wires  100  to sever or break, thereby releasing compressible metal material  84  as shown in  FIG. 4 , Compressible metal material  84  resiliently expands into contact with annular wall  38 . 
     Reference will now follow to  FIGS. 5 and 6  with continued reference to  FIG. 1  in describing a selectively expandable screen system  130  in accordance with another aspect of an exemplary embodiment. Selectively expandable screen system  130  includes a tubular  134  having an outer surface  136  and an inner surface  138  that defines a flow path  140 . A screen assembly  144  is arranged at outer surface  136 . Screen assembly  144  is formed from a compressible metal material  148 . In an embodiment, compressible metal material  148  is resiliently compressible. That is, after being compressed, and after being released, screen assembly  144  returns to an uncompressed state due to intrinsic material properties of compressible metal material  148 . In an embodiment, compressible metal material  84  may take the form of intermeshed metal fibers (not separately labeled). 
     In accordance with an aspect of an exemplary embodiment, a selectively releasable compression member  160  maintains compressible metal material  148  in a compressed state as shown in  FIG. 5 . Selectively releasable compression member  160  may take the form of a tubular member  161  formed from a degradable material  162 . Degradable material  162  may degrade when exposed to a selected fluid, for example, fluid in wellbore  34 . The fluid may take the form of formation fluids or, fluids that are introduced from first system  14 , Tubular member  161  is configured to degrade after a selected time period, thereby releasing compressible metal material  148 . Compressible metal material  148  resiliently expands into contact with annular wall  38  as shown in  FIG. 6 . 
     Reference will now follow to  FIGS. 7 and 8  in describing a method of compressing compressible metal material  148  in accordance with an exemplary aspect. Compressible metal material  148  is positioned on outer surface  136  of tubular  134  as shown in  FIG. 7 . Tubular  134  and compressible metal material  148  are inserted into a compression tool  170 . Specifically, tubular  134  and compressible metal material  148  are inserted into a tapered or conical end  173  of compression tool  170 . Tubular  134  and compressible metal material  148  are shifted towards a compression portion  176  having a selected diameter. Tubular  134  and compressible metal material  148  may then be inserted into selectively releasable compression member  160 . It should be understood that compression tool  170  may also be employed to compress compressible metal material  84  of selectively expandable screen system  60 . 
     It should be understood that the exemplary embodiments describe a selectively deployable screen formed from a compressible metal material. The compressible metal material may be selectively deployed through the use of degradable materials or tools designed for the purpose. The compressible metal material may provide an increased operating temperatures and burst ratings over those achieve by expandable screen assemblies formed from synthetic materials. 
     Set forth below are some embodiments of the foregoing disclosure: 
     Embodiment 1: A selectively expandable screen system comprising a tubular having an outer surface and an inner surface defining a flow path, a screen assembly mounted at the outer surface of the tubular, the screen assembly being formed from a compressible metal material, and a selectively releasable compression device coupled to the screen assembly, the selectively releasable compression device selectively maintaining the compressible metal material in a compressed configuration. 
     Embodiment 2: The selectively expandable screen system according to any prior embodiment, wherein the selectively releasable compression device comprises a plurality of wires extending about the tubular and the compressible metal material. 
     Embodiment 3: The selectively expandable screen system according to any prior embodiment, wherein the plurality of wires are formed from a degradable material. 
     Embodiment 4: The selectively expandable screen system according to any prior embodiment, wherein the selectively releasable compression device comprises a tubular. 
     Embodiment 5: The selectively expandable screen system according to any prior embodiment, wherein the tubular is formed from a degradable material. 
     Embodiment 6: The selectively expandable screen system according to any prior embodiment, wherein the compressible metal material comprises a plurality of intermeshed metal fibers. 
     Embodiment 7: A resource exploration and recovery system comprising a first system, a second system coupled to the first system through one or more tubulars, at least one of the one or more tubulars comprising an outer surface and an inner surface defining a flow path, a screen assembly mounted at the outer surface of the tubular, the screen assembly being formed from a compressible metal material, and a selectively releasable compression device coupled to the screen assembly, the selectively releasable compression device selectively maintaining the compressible metal material in a compressed configuration. 
     Embodiment 8: The resource exploration and recovery system according to any prior embodiment, wherein the selectively releasable compression device comprises a plurality of wires extending about the tubular and the compressible metal material. 
     Embodiment 9: The resource exploration and recovery system according to any prior embodiment, wherein the plurality of wires are formed from a degradable material. 
     Embodiment 10: The resource exploration and recovery system according to any prior embodiment, wherein the selectively releasable compression device comprises a tubular. 
     Embodiment 11: The resource exploration and recovery system according to any prior embodiment, wherein the tubular is formed from a degradable material. 
     Embodiment 12: The resource exploration and recovery system according to any prior embodiment, wherein the compressible metal material comprises a plurality of intermeshed metal fibers. 
     Embodiment 13: A method of deploying a screen formed from a metal material mounted to an outer surface of a tubular, the method comprising compressing the metal material toward the outer surface of the tubular, restraining the metal material with a selectively releasable compression device, moving the screen into a selected position, and releasing the selectively releasable compression device allowing the metal material to expand radially outwardly of the outer surface. 
     Embodiment 14: The method of any prior embodiment, wherein releasing the selectively releasable compression device includes degrading the selectively releasable compression device. 
     Embodiment 15: The method of any prior embodiment, wherein releasing the selectively releasable compression device includes breaking one or more retaining wires. 
     The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should further be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity). 
     The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti -corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc. 
     While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited.