US20160024894A1

US20160024894A1 - Completion System

Info

Publication number: US20160024894A1
Application number: US14/803,055
Authority: US
Inventors: Roy Campbell; Neil Thomson; Peter Wood
Original assignee: Meta Downhole Ltd
Current assignee: Meta Downhole Ltd
Priority date: 2014-07-23
Filing date: 2015-07-18
Publication date: 2016-01-28
Also published as: WO2016012782A1; GB2528583B; GB201512910D0; GB2528583A

Abstract

An expandable completion system and method of completing a well in which gravel packing of multiple completion zones is achieved by morphing a sleeve across a gravel packed annulus to secure it to a well bore wall by the use of fluid pressure to provide a zonal isolation barrier between two gravel packed zones in a wellbore. An embodiment provides gravel packing for multiple completion zones by circulation. A further embodiment allows selective isolation barriers to be created along the length of the completion string after the gravel has been pumped into the annulus.

Description

BACKGROUND

The present invention relates to an apparatus and method for completing a well by securing a tubular within another tubular or borehole, creating a seal across an annulus in a well bore, and centralising or anchoring tubing within a wellbore. In particular, though not exclusively, the invention relates to morphing a sleeve across a gravel packed annulus to secure it to a well bore wall by the use of fluid pressure to provide a zonal isolation barrier between two gravel packed zones in a wellbore.
In the exploration and production of oil and gas wells, sand production can have devastating effects as it will erode hardware; cause blockages in the tubulars and surface equipment; and can create downhole cavities resulting in formation subsidence and casing collapse. Methods of completing sand-prone formations have therefore been developed with the most widely adopted being gravel packing. A slurry of gravel is pumped into the annulus between a centralized screen and either perforated casing or open borehole. The fluid in the slurry is pumped into the formation or through the screen and back to surface leaving a gravel pack. The gravel pack acts as a granular filter with very high permeability but prevents the formation sand from entering the wellbore.
Completing multiple zones is very difficult as the slurry requires to be injected into the annulus between the packers used to isolate each zone. The slurry must entirely fill the annulus between the packers as any void will promote sand production and risk formation subsidence and casing collapse. The most reliable method of ensuring even distribution is achieved at the rat-hole where the slurry is pumped down a service string and returns up the annulus.
Packers are typically used to isolate one section of a downhole annulus from another section of the downhole annulus. The annulus may be between tubular members, such as a liner, mandrel, production tubing and casing or between a tubular member, typically casing, and the wall of an open borehole. These packers are carried into the well on tubing and at the desired location, elastomeric seals are urged radially outwards or elastomeric bladders are inflated to cross the annulus and create a seal with the outer generally cylindrical structure i.e. another tubular member or the borehole wall. These elastomers have disadvantages, particularly as they may be easily eroded.
As a result, metal seals have been developed, where a tubular metal member is run in the well and at the desired location, an expander tool is run through the member. The expander tool typically has a forward cone with a body whose diameter is sized to the generally cylindrical structure so that the metal member is expanded to contact and seal against the cylindrical structure. These so-called expanded sleeves have an internal surface which, when expanded, is cylindrical and matches the profile of the expander tool. These sleeves work well in creating an annular seal between tubular members but can have problems in sealing against the irregular surface of an open borehole.
The present applicants have developed a technology where a metal sleeve is forced radially outwardly by the use of fluid pressure acting directly on the sleeve. Sufficient hydraulic fluid pressure is applied to move the sleeve radially outwards and cause the sleeve to morph itself onto the generally cylindrical structure. The sleeve undergoes plastic deformation and, if morphed to a generally cylindrical metal structure, the metal structure will undergo elastic deformation to expand by a small percentage as contact is made. When the pressure is released the metal structure returns to its original dimensions and will create a seal against the plastically deformed sleeve. During the morphing process, both the inner and outer surfaces of the sleeve will take up the shape of the surface of the wall of the cylindrical structure. This morphed isolation barrier is therefore ideally suited for creating a seal against an irregular borehole wall.
Such a morphed isolation barrier is disclosed in U.S. Pat. No. 7,306,033, which is incorporated herein by reference. An application of the morphed isolation barrier for FRAC operations is disclosed in US2012/0125619, which is incorporated herein by reference. Typically, the sleeve is mounted around a supporting tubular body, being sealed at each end of the sleeve to create a chamber between the inner surface of the sleeve and the outer surface of the body. A port is arranged through the body so that fluid can be pumped into the chamber from the throughbore of the body.
US 2004/0074642 to Schlumberger Technology Corporation discloses an expandable completion system and method, by expanding a pair of spaced apart expandable sand screens in a well, the expandable sand screens connected to one another by an unexpanded tubing section, and gravel packing the portion of the well around the unexpanded tubing section. Zonal isolation is achieved by setting packers at the unexpanded tubular section prior to gravel packing the annulus between the packer and each sand screen, respectively. Gravel packing may also be done around the expandable sand screen. This arrangement has the same disadvantage as the prior art in that a gravel packing sub must be located at each annulus between the sand screens or between a sand screen and a packer with the potential result of uneven gravel packing. Additionally, it is difficult to expand a sand screen reliably to ensure a desired mesh size is achieved when expansion is completed downhole.
It is therefore an object of the present invention to provide an expandable completion system and method which obviates or mitigates one or more disadvantages of the prior art.

BRIEF SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided a method of completing a well, comprising:

- locating a sleeve member on the exterior of a tubular body and sealing it thereto to create a chamber therebetween,
- using the tubular body to connect two sand screens together in an assembly;
- running the assembly on a string into a wellbore and positioning the sleeve member at a position between zones within a larger diameter structure;
- pumping fluid through a port in the tubular body to access the chamber;
- causing the sleeve member to move radially outwardly to morph against an inner surface of the larger diameter structure; and
- providing a gravel mixture through at least one portion of the assembly to locate between the tubular body and the large diameter structure.

In this way, gravel packing can advantageously be provided to enhance the effectiveness of the isolation barrier created by the morphed sleeve member.
The method may include locating multiple assemblies on the string and undertaking the morphing of the sleeve and the provision of a gravel mixture at any desired locations where an isolation barrier is required. In this way, multiple zone completion is achieved.
The large diameter structure may be an open hole borehole, a borehole lined with a casing or liner string which may be cemented in place downhole.
Preferably, pumping fluid through a port in the tubular body to access the chamber involves pumping fluid through multiple ports in the tubular body to access the chamber. This provides a faster morphing of the sleeve.
Preferably, the method includes the step of rupturing a disc at a valve in the port to allow fluid to enter the chamber when the pressure reaches a desired value. This allows selective and controlled activation of the morphing process.
The method may include the steps of running in an activation fluid delivery tool, creating a temporary seal above and below the port and injecting fluid from the tool into the chamber via the port. Such an arrangement allows selective operation of the sleeve member.
The method may include the step of inserting an inner completion string into the string and isolating the sand screens by sealing between the inner completion string and the tubular body. In this way, production can be controlled from each zone.
In an embodiment, the method of providing a gravel mixture may include pumping gravel slurry through the string to exit at an end of the tubular body and circulate up an annulus between the assembly and the larger diameter structure. This enables gravel packing to be achieved by circulation in the wellbore.
The pumping of fluid through a port in the tubular body to access the chamber and cause the sleeve member to move radially outwardly may occur after the gravel slurry is pumped through the string into the annulus. The sleeve may move radially outwardly to crush the gravel and morph against the inner surface of the large diameter structure. In such an arrangement, the gravel packing is achieved by circulation in the wellbore with the isolation barrier being operated after the gravel is in place.
In an embodiment, the method may comprise causing the sleeve member to move radially outwardly to morph against an inner surface of the larger diameter structure before providing a gravel mixture by pumping gravel slurry through at least one shunt tubular component of the assembly to an exit located between the morphed sleeve member and an end of the tubular body such that the gravel slurry circulates around an annulus between the assembly and the larger diameter structure. This enables gravel packing to be achieved by direct provision of the gravel slurry into the annulus of the wellbore after a morphed annular barrier is in place and enables the continued supply of gravel slurry regardless of circulation in the annulus.
The gravel slurry may be operable to set when packed in the annulus as required. By providing gravel slurry which can set, an effective gravel packed annular barrier is formed below the morphed sleeve annular barrier thus securing the assembly effectively.
The at least one shunt tubular may be provided with a valve. Provision of a valve in a shunt tubular enables the effective sealing of the shunt tubular after the gravel is packed and set thus ensuring a complete annular barrier is formed around the assembly.
In an embodiment, the method of providing a gravel mixture may include pumping gravel slurry through the string to exit at an end of the tubular body and circulate up an annulus between the assembly and the larger diameter structure and pumping gravel slurry through at least one shunt tubular component of the assembly to an exit located between the sleeve member and an end of the tubular body such that the gravel slurry circulates around an annulus between the assembly and the larger diameter structure. This enables gravel packing to be achieved by circulation and direct provision in the annulus in the wellbore.
The pumping of fluid through a port in the tubular body to access the chamber and cause the sleeve member to move radially outwardly may occur after the gravel slurry is pumped into the annulus. The sleeve may move radially outwardly to crush the gravel and morph against the inner surface of the large diameter structure. In such an arrangement, the isolation barrier is operated after the gravel is in place.
According to a second aspect of the present invention there is provided an expandable completion system, comprising:
an assembly comprising two sand screens connected via a tubular body, the assembly including connections for location in a tubular string to be run in and secured within a larger diameter generally cylindrical structure;
wherein a sleeve member is positioned on the exterior of the tubular body, to create a chamber therebetween;
the tubular body including a port to permit the flow of fluid into the chamber to cause the sleeve member to move outwardly and morph against an inner surface of the larger diameter structure wherein the assembly is operable to provide a gravel slurry into an annulus between the assembly and the larger diameter structure.
In this way, the completion system is easily assembled and run in to a wellbore. The screens are not expandable and thus the mesh size can be fixed.
The sleeve member may have a first end which is affixed and sealed to the tubular body and a second end which includes a sliding seal to permit longitudinal movement of the second end over the tubular body. In this way, as the sleeve is morphed, longitudinal contraction of the sleeve member occurs which reduces the thinning of the sleeve member during morphing.
The large diameter structure may be an open hole borehole, a borehole lined with a casing or liner string which may be cemented in place downhole.
Preferably, there is a plurality of ports arranged through the tubular body. In this way, rapid morphing of the sleeve member can be achieved. The ports may be arranged circumferentially around the body. The ports may be arranged longitudinally along the body.
The port may include a barrier. In this way, fluid is prevented from entering the chamber until activation is required. The barrier may be a rupture disc which allows fluid to flow through the port at a predetermined fluid pressure. Alternatively the barrier may be a valve. Preferably the valve is a one-way check valve. In this way, fluid is prevented from exiting the chamber.
The sand screens may be of any configuration known to those skilled in the art. In this way standard sand screens can be used. The sand screen may be a slotted liner or any other arrangement used to filter production fluid entering the tubular string.
Preferably, the system includes a plurality of assemblies. The assemblies may be separated by a tubular body, wherein a sleeve member is positioned on the exterior of the tubular body, to create a chamber therebetween; the tubular body including a port to permit the flow of fluid into the chamber to cause the sleeve member to move outwardly and morph against an inner surface of the larger diameter structure. In this way a multiple zone completion system is formed.
In an embodiment, the assembly comprises a string exit at an end. Gravel slurry may be pumped through the string to exit at the string exit. Such an assembly enables the gravel slurry to be output at the string end and circulate up an annulus between the assembly and the larger diameter structure due to circulation in the wellbore. The gravel packing may be supplied such that on actuation the sleeve member is operable to move outwardly to crush gravel and morph against an inner surface of the larger diameter.
In an embodiment, the assembly comprises at least one shunt tubular having at least one shunt exit located between the sleeve member and an end of the tubular body. Gravel slurry may be pumped through the shunt tubular such that it exits at the shunt exit and circulates around an annulus between the assembly and the larger diameter structure. This assembly gravel packing to be achieved by direct provision of the gravel slurry into the annulus of the wellbore. The provision of gravel slurry through the shunt tubular may occur after the sleeve member is actuated such that a morphed annular barrier is in place and such an assembly enables the continued supply of gravel slurry regardless of circulation in the annulus.
The at least one shunt tubular may be provided with a valve. Provision of a valve in a shunt tubular enables the effective sealing of the shunt tubular after the gravel is packed and set thus ensuring a complete annular barrier is formed around the assembly.
In an embodiment, the assembly may comprise string exit at an end and at least one shunt tubular having at least one shunt exit located between the sleeve member and an end of the tubular body. Such an arrangement enables gravel slurry to be provided through the string exit and through the shunt tubular to achieve an annular gravel pack in an expedient manner.
In the description that follows, the drawings are not necessarily to scale. Certain features of the invention may be shown exaggerated in scale or in somewhat schematic form, and some details of conventional elements may not be shown in the interest of clarity and conciseness. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce the desired results.
Accordingly, the drawings and descriptions are to be regarded as illustrative in nature, and not as restrictive. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as “including,” “comprising,” “having,” “containing,” or “involving,” and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers or steps. Likewise, the term “comprising” is considered synonymous with the terms “including” or “containing” for applicable legal purposes.
All numerical values in this disclosure are understood as being modified by “about”. All singular forms of elements, or any other components described herein including (without limitations) components of the apparatus are understood to include plural forms thereof.
The terms ‘seal’ and ‘isolation’ are used with the recognition that some leakage may occur and that such leakage may be acceptable. Thus, some embodiments of the present invention may allow for leakage without departing from the scope of the invention and systems that provide for such leakage fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings of which:

FIGS. 1 a-1 c are schematic illustrations of a sequence for completing a well; FIG. 1 a is a cross-sectional view of an assembly according to the present invention located in a wellbore; FIG. 1 b shows gravel being pumped into the wellbore and circulated therethrough; and FIG. 1 c is a cross-sectional view of the assembly of FIG. 1 a with a morphed sleeve having crushed the gravel and sealed against the wall of the wellbore; and

FIGS. 2 a-2 c are schematic illustrations of a sequence for setting two sleeve members in an open borehole during a completion according to an embodiment of the present invention; FIG. 2 a is a cross-sectional view of a tubular string with two assemblies according to the present invention and the deployment of gravel; FIG. 2 b shows the tubular string in the borehole with an activation fluid delivery tool inserted therein; and FIG. 2 c is a cross-sectional view of the tubular string with morphed sleeves and an inner completion string.

FIGS. 3 a-3 c are schematic illustrations of a sequence for setting a sleeve member in an open borehole during a completion according to an embodiment of the present invention. FIG. 3 a is a cross-sectional view of an assembly according to the present invention located in a wellbore; FIG. 3 b is a cross-sectional view of the assembly of FIG. 3 a with a morphed sleeve sealed against the wall of the wellbore; and FIG. 3 c shows gravel being pumped into the wellbore.

DETAILED DESCRIPTION OF THE INVENTION

Reference is initially made to FIG. 1 a of the drawings which illustrates an assembly, generally indicated by reference numeral 10, including first 20 and second 22 sand screens located on either side of a tubular body 12, with a sleeve member 14, chamber 16 and port 18, according to an embodiment of the present invention.
Sand screens 20,22 are of any configuration known to those skilled in the art. They are of generally cylindrical construction with multiple apertures passing therethrough in the form of a mesh, slots or holes. The aperture dimensions are selected to prevent the passage of sand into the bore 24 of the assembly 10. A first end 26 of the first sand screen 20 and a second end 28 of the second sand screen 22 are connected into a tubular string 30 such as casing, liner or production tubing that is intended to be permanently set or completed in a well bore. The string may be a drill pipe or any other tubular string designed to be run in a well bore. A first end 32 of the second sand screen 22 and a second end 34 of the first sand screen 20 are connected via a tubular body 12.
Tubular body 12 is a cylindrical tubular section having an inner diameter preferably matching the inner diameter of the first 20 and second 22 sand screens. Body 12 includes a throughbore 36 which is co-linear with the throughbore 24 of the string 30.
A port 18 is provided through the side wall 38 of the body 12 to provide a fluid passageway between the throughbore 36 and the outer surface 40 of the body 12. While only a single port 18 is shown, it will be appreciated that a set of ports may be provided. These ports may be equidistantly spaced around the circumference of the body 12 and/or be arranged along the body to access the chamber 16.
In an embodiment, at the port 18 there is located a check valve 54. The check valve 54 is a one-way valve which only permits fluid to pass from the throughbore 36 into the chamber 16. The check valve 54 can be made to close when the pressure within the chamber 16 reaches a predetermined level, this being defined as the morphed pressure value. Thus, when the pressure in the sleeve 14 reaches the morphed pressure value, the valve 54 will close. Also arranged at the port 18 is a rupture disc 56. The rupture disc 56 is rated to a desired pressure at which fluid access to the chamber is desired. In this way, the rupture disc 56 can be used to control when the setting of the sleeve 14 is to begin. The disc 56 can be operated by increasing pressure in the throughbore 36 with the pressure to rupture the disc being selected to be greater than the fluid pressure required to activate any other tools or functions in the well bore.
Tubular body 12 is located coaxially within a sleeve member 14. Sleeve member 14 is a steel cylinder being formed from typically 316L or Alloy 28 grade steel but could be any other suitable grade of steel or any other metal material or any other suitable material which undergoes elastic and plastic deformation. Ideally the material exhibits high ductility i.e. high strain before failure. The sleeve member 14 is appreciably thin-walled of lower gauge than the tubing body 12 and is preferably formed from a softer and/or more ductile material than that used for the tool body 12. The sleeve member 14 may be provided with a non-uniform outer surface 40 such as ribbed, grooved or other keyed surface in order to increase the effectiveness of the seal created by the sleeve member 14 when secured within another casing section or borehole 60.
Sleeve member 14 which surrounds the tubular body 12 is affixed thereto via welded or clamped connections 42, 44, respectively. Such attachments 42, 44 are pressure-tight connectors. An O-ring seal (not shown) may also be provided between the inner surface 46 of the sleeve member 14 and the outer surface 40 of the tubular body 12 to act as a secondary seal or back-up to the seal provided by the welded connections. In an embodiment of the present invention, the first attachment means 42 is provided by a mechanical clamp to fix the first end 48 of sleeve member 14 to the tubular body 12. The second end 50 of the sleeve member 14 is connected to the outer surface 40 of the tubular body 12 via a sliding seal arrangement. In this way, the second end 50 of the sleeve member 14 can move longitudinally along the outer surface 40 of the tubular body 12 while maintaining a seal between the surfaces to hold pressure within the chamber 16. This sliding seal is arranged so that the second end 50 of the sleeve member 14 is permitted to move towards the first end 48. Thus when the sleeve member 14 is caused to move in a radially outward direction, during morphing, the sleeve contracts which causes simultaneous movement of the sliding seal. This has the advantage in reducing thinning of the material of the sleeve 14 by the radial outward expansion.
The attachments 42, 44 together with the inner surface 46 of the sleeve member 14 and the outward surface 40 of the body 12 define the chamber 16. The port 18 is arranged to access the chamber 16 and permit fluid communication between the through-bore 24 and the chamber 16.
Thus, the assembly 10 is constructed by taking two sand screens 20,22, connecting them on either side of a tubular body 12 and locating a sleeve member 14 over the tubular body 12. A first end 48 of the sleeve member 14 is attached to the tubular body 12 via the attachment 42 and the second end 50 of the sleeve member 14 is also attached to the tubular body, via attachment 44. Assembly 10 is then connected into a string 30 as is known in the art and run into the wellbore 60. The assembly 10 may be attached to the bottom of a casing or liner string. The assembly 10 is run into a position where a barrier is required and in the embodiment shown in FIG. 1 a, this is inside a wellbore 60 between a first zone 62 and a second zone 64 of the formation 66.
When the assembly 10 is in position in the wellbore 60, a gravel slurry 70 is pumped down the bore 24 of the string 30. This is illustrated in FIG. 1 b. The gravel 70 may be pumped directly through the bore 24 or may be pumped through an inner string and gravel packing sub (not shown) used to deliver the gravel to the end 52 of the string 30 without damaging the inner surface 58 of the string 30. The gravel 70 passes out of the end 52 of the string 30 and circulates up the annulus 68 between the outer surface 40 of the body 12 and the inner surface 72 of the wellbore 60. The end 52 of the string 30 may be located in the rat-hole. This method of circulating the gravel 70 ensures that there are no voids left in the annulus 68. It also negates the requirement to install valves, which may be referred to as shunt valves, in the tubing string to inject gravel at points along the tubing string.
When the gravel 70 is in position in the annulus 68, pressure in the through-bore 36 of the body 12 is increased. This is typically fluid pressure delivered from a fluid delivery system inserted through the string 30 as will be described with reference to FIG. 2 b. Pressure in the through-bore 36 thus increases to a point where the disc 56 ruptures and allows fluid under pressure to pass through the check valve 54 at the port 18. As detailed previously, multiple ports 18 may be located upon the tubular body 12 to increase the rate of fluid pressure entering the chamber 16. As the chamber 16 is cylindrical in nature and the material of the sleeve member 14 is more elastic than that of the tubular body 12, as pressure increases in the chamber 16, the sleeve member 14 will be forced radially outwardly from the tubular body across the annulus 68 between the outer surface 40 of the tubular body 12 and the inner surface 72 of the wellbore 60. This expansion of the sleeve member 14 by fluid pressure will initially force the gravel 70 out from the annulus 68 at the sleeve member 14 and then crush the gravel 70 trapped between the sleeve member 14 and the inner surface 72. The pressure will be sufficient to crush the gravel 70 into small particles such as a powder so that the morphed sleeve 14 creates a seal against the inner surface 72 of the wellbore 60. The crushed gravel 70 may form part of this seal. This is illustrated in FIG. 1 c. This morphing process is known and operates by elastically and then plastically deforming the sleeve member 14. At a morphed fluid pressure value, the check valve 54 closes therefore sealing the chamber 16. The seal between the assembly 10 and the inner surface 72 thus forms a barrier in the wellbore 60 so that fluid flow through the annulus 68 is prevented. Fluid flow from the formation 64 is then directed through the first sand screen 20 for production from the lower, second zone 64 and through the second sand screen 22 for production from the upper, first zone 62. Each zone 62,64 has therefore been completed with its own gravel pack 74,76 respectively.
In an alternative embodiment, the sleeve member 14 may be expanded while the gravel 70 is still being pumped. When the sleeve member 14 has been morphed against the inner surface 72, a rupture disc 78 located on the sleeve member 14 towards the first end 48 is burst, allowing gravel 70 to enter the chamber 16. This gravel 70 which enters the chamber 16 can support the sleeve member 14 in the morphed position and therefore increase the strength of the isolation barrier. The rupture disc 78 may alternatively be in the form of a check valve, letting the gravel 70 enter but not escape from the chamber 16.
Reference will now be made to FIG. 2 of the drawings which provides an illustration of a further method for completing a well according to an embodiment of the present invention. Like parts to those in the earlier Figures have been given the same reference numerals to aid clarity.
In use, the assembly 10 is conveyed into the borehole by any suitable means, such as incorporating the assembly 10 into a casing or liner string 30 or on an end of a drill pipe and running the string into the wellbore 60 until it reaches the location within the open borehole 80 at which operation of the assembly 10 is intended. This location is normally within the borehole at a position where the sleeve 14 a is to be expanded in order to, for example, isolate the section of borehole 80 b located above the sleeve 14 a from that below 80 d in order to provide an isolation barrier between the zones 80 b, 80 d. Additionally a further assembly 10 b can be run on the same string 76 so that zonal isolation can be performed in a zone 80 b.
The string 30 is run-in the wellbore 60 and hung from casing 82. Gravel 70 is then pumped through the string 30 and exits at the end 52 where a gravel packing sub 84 is located. The gravel slurry 70 fills the rat hole 86 and travels up the annulus 68 between the outer surface 40 of the string 30 and the inner surface 72 of the wellbore 60. This is as illustrated in FIG. 2 a.
Reference is now made to FIG. 2 b which shows an activation fluid delivery tool 88 run into the string 30. Tool 88 can be run into the string 30 from surface by means of a coiled tubing 90 or other suitable method. The tool 88 is provided with upper and lower seal means 92, which are operable to radially expand to seal against the inner surface 58 of the body 12 at a pair of spaced apart locations in order to isolate an internal portion of body 12 located between the seals 92; it should be noted that said isolated portion includes the fluid port 18. Tool 88 is also provided with an aperture 96 in fluid communication with the interior of the string 30.
To operate the tool 88, seal means 92 are actuated from the surface to isolate the portion of the tool body 12. Activation fluid is then pumped under pressure through the coiled tubing such that the pressurised fluid flows through tool aperture 96 and then via port 18 into chamber 16 and acts on the sleeve members 14 a,14 b in the same manner as described hereinbefore. Use of such a tool allows setting of selective assemblies 10 in a wellbore.
A detailed description of the operation of such a fluid delivery tool 88 is described in GB2398312 in relation to the packer tool 112 shown in FIG. 27 of that patent with suitable modifications thereto, where the seal means 92 could be provided by suitably modified seal assemblies 214, 215 of GB2398312, the disclosure of which is incorporated herein by reference. The entire disclosure of GB2398312 is incorporated herein by reference.
The increase in pressure of fluid causes the sleeve 14 a,14 b to move radially outwardly crushing the gravel 70 and seal against a portion of the inner circumference of the borehole 80. The pressure within the chamber 16 continues to increase such that the sleeve 14 a,14 b initially experiences elastic expansion followed by plastic deformation. The sleeve 14 a,14 b expands radially outwardly beyond its yield point, undergoing plastic deformation until the sleeve 14 a,14 b morphs against the surface 72 of the borehole 80 as shown in FIG. 2 c. Accordingly, the sleeve 14 a,14 b has been plastically deformed and morphed by pressure from the chamber contents without any mechanical expansion means being required. Note that gravel 70 is now separated into gravel packs 74, 76 contained between barriers created by the sleeve members 14 a,14 b.
Fluid may be pumped into the chamber 16 at any desired pressure as the check valve 54 can be set to allow a calculated volume of fluid which is sufficient to morph the sleeve to enter the chamber before closing. When closed, the check-valve will trap any fluid remaining in the chamber 16. The pressure may be increased sufficiently to assist in crushing the gravel 70 and then bled-off before closing the port 18.
The sleeve 14 a,14 b will have taken up a fixed shape under plastic deformation with an inner surface 46 matching the profile of the surface 72 of the borehole 60 and the crushed gravel 70. An outer surface of the sleeve will also match the profile of the surface 72 of the borehole 60 and the crushed gravel 70. A seal which effectively isolates the annulus 94 of the borehole 80 above the sleeve 14 a from the annulus 98 below the sleeve 14 a is created. If two sleeves 14 a,14 b are set together then zonal isolation can be achieved for the annulus 94 between the sleeves 14 a,14 b. At the same time the sleeves 14 a,14 b have effectively centered, secured and anchored the tubing string 30 to the borehole 60.
Also shown in FIG. 2 c is an inner completion string 100. The inner completion string 100 includes spaced apart seals 102 to isolate the respective sand screens 62, 64 from each other. Valves 104 can then be opened sequentially for the selected production flow from each zone 80 d, 80 b.
Reference will now be made to FIGS. 3 a-3 c of the drawings which provide an illustration of a further method for completing a well according to an embodiment of the present invention. Like parts to those in the earlier Figures have been given the same reference numerals to aid clarity.
Reference is initially made to FIG. 3 a which illustrates an assembly as previously described with reference to FIG. 1 a, generally indicated by reference numeral 10, including first 20 and second 22 sand screens located on either side of a tubular body 12, with a sleeve member 14, chamber 16 and port 18. The assembly of FIG. 3 a further comprises a shunt tubular assembly 110 which is arranged so as to run adjacent to, and in parallel with, tubular 12 traversing through sleeve member 14 as a discreet sealed continuous tubular member, according to an embodiment of the present invention.
The shunt tubular assembly 110 is shown as having a single shunt tube however it will be appreciated that several shunt tubes may be provided running in parallel to one another. The shunt tube 110 runs along the outside of the sand screens 20, 22 and is a narrow bore tube constructed of a metal based material. The bore of the shunt tube 110 can be seen to run continuously through the sleeve 14 to allow the shunt tube 110 to flow continuously along the tubular 12. Dedicated crossover connections using components (not shown) such as those known in the art would be required between the sleeve 14 and shunt tube 110 to ensure a sealed and effective crossover between components that allows the sleeve 14 to function effectively whilst continuous flow through the shunt tube 110 is also possible.
In use, the assembly 10 is conveyed into the borehole by any suitable means, such as incorporating the assembly 10 into a casing or liner string 30 or on an end of a drill pipe and running the string into the wellbore 60 until it reaches the location where the barrier is required and in the embodiment shown in FIG. 3 a, this is inside wellbore 60 between a first zone 62 and a second zone 64 of the formation. This location is within the borehole at the position where the sleeve 14 is to be expanded in order to, isolate the section of borehole 62 located above the sleeve 14 from that below 64 in order to provide an isolation barrier between the zones 62, 64.
When the sleeve 14 is in position in the annulus 68, pressure in the through-bore 36 of the body 12 is increased. This is typically fluid pressure delivered from a fluid delivery system inserted through the string 30 as will be described with reference to FIG. 3 b. Pressure in the through-bore 36 thus increases to a point where the disc 56 ruptures and allows fluid under pressure to pass through the check valve 54 at the port 18. As detailed previously, multiple ports 18 may be located upon the tubular body 12 to increase the rate of fluid pressure entering the chamber 16. As the chamber 16 is cylindrical in nature and the material of the sleeve member 14 is more elastic than that of the tubular body 12, as pressure increases in the chamber 16, the sleeve member 14 will be forced radially outwardly from the tubular body across the annulus 68 between the outer surface 40 of the tubular body 12 and the inner surface 72 of the wellbore 60. The pressure will be sufficient that the morphed sleeve 14 creates a seal against the inner surface 72 of the wellbore 60. This is illustrated in FIG. 3 b. This morphing process is known and operates by elastically and then plastically deforming the sleeve member 14. At a morphed fluid pressure value, the check valve 54 closes therefore sealing the chamber 16. The seal between the assembly 10 and the inner surface 72 thus forms a barrier in the wellbore 60 so that fluid flow through the annulus 68 is prevented. Note that the shunt 112 is held against the tubular body 12 during the morphing process and is not moved radially outwards.
When the sleeve 14 is morphed in position in the wellbore 60, a gravel slurry 70 is pumped down the bore 111 of the shunt 112. This is illustrated in FIG. 3 c. The gravel 70 passes out of the shunt exits 116, which may be a plurality of exit holes or slits as appropriate, and which are arranged beyond the morphed sleeve 14. The gravel 70 then circulates around the annulus 68 between the outer surface 40 of the body 12 and the inner surface 72 of the wellbore 60. This method of circulating the gravel 70 circulates locally to the morphed sleeve 14 and ensures that there are no voids left in the annulus 68.
Once the gravel 70 has circulated the annulus 68 around the assembly 10 the gravel 70 is allowed to set after which value 112 provided in the shunt 110 is closed thus sealing the shunt tube 110 completely. This method of gravel provision ensures a complete annular barrier is formed around the tubular 12 adjacent to the annular barrier of morphed seal 14 without the morphed seal 14 being required to crush gravel during the sealing process.
In a further embodiment (not shown) gravel may be provided to annulus 68 via shunt tube 110 and via string 30 such that it enters the annulus via shunt exits 112 and string end 52 enabling it to circulate up and round the annulus 68 as well as around sleeve 14 during installation. Such an arrangement would enable gravel 70 to circulated locally around the sleeve 14 as well as by means of circulation in the wellbore and subsequent morphing of the sleeve 14 would act to crush gravel which would go on to form part of the annular seal around the assembly.
The principle advantage of the present invention is that it provides an expandable completion system and method of completing a well in which gravel packing for multiple completion zones can be easily achieved.
A further advantage of at least one embodiment of the present invention is that it provides an expandable completion system and method of completing a well in which gravel packing for multiple completion zones can be achieved by circulation.
A still further advantage of at least one embodiment of the present invention is that it provides an expandable completion system and method of completing a well in which selective isolation barriers can be created along the length of the completion string after the gravel has been pumped into the annulus.
It will be apparent to those skilled in the art that modifications may be made to the invention herein described without departing from the scope thereof. For example, sliding sleeves may be incorporated on the tubular string to access the chambers and/or the sand screens.

Claims

1. A method of completing a well, comprising:

locating a sleeve member on the exterior of a tubular body and sealing it thereto to create a chamber therebetween,

using the tubular body to connect two sand screens together in an assembly;

running the assembly on a string into a wellbore and positioning the sleeve member at a position between zones within a larger diameter structure;

pumping fluid through a port in the tubular body to access the chamber;

causing the sleeve member to move radially outwardly to morph against an inner surface of the larger diameter structure; and

providing a gravel mixture through at least one portion of the assembly to locate between the tubular body and the larger diameter structure.

2. A method according to claim 1 wherein the method includes locating multiple assemblies on the string and undertaking the morphing of the sleeve and the provision of a gravel mixture at any desired locations where an isolation barrier is required.

3. A method according to claim 1 wherein the method includes the step of inserting an inner completion string into the string and isolating the sand screens by sealing between the inner completion string and the tubular body.

4. A method according to claim 1 wherein the step of providing a gravel mixture includes pumping gravel slurry through the string to exit at an end of the tubular body and circulate up an annulus between the assembly and the larger diameter structure.

5. A method according to claim 1 wherein the step of pumping of fluid through a port in the tubular body to access the chamber and cause the sleeve member to move radially outwardly occurs after the gravel slurry is pumped through the string into the annulus.

6. A method according to claim 5 wherein the sleeve moves radially outwardly to crush the gravel and morph against the inner surface of the large diameter structure.

7. A method according to claim 1 wherein the method comprises causing the sleeve member to move radially outwardly to morph against an inner surface of the larger diameter structure before providing a gravel mixture by pumping gravel slurry through at least one shunt tubular component of the assembly to an exit located between the morphed sleeve member and an end of the tubular body such that the gravel slurry circulates around an annulus between the assembly and the larger diameter structure.

8. A method according to claim 7 wherein the at least one shunt tubular component is provided with a valve.

9. A method according to claim 1 wherein the step of providing a gravel mixture includes pumping gravel slurry through the string to exit at an end of the tubular body and circulate up an annulus between the assembly and the larger diameter structure and pumping gravel slurry through at least one shunt tubular component of the assembly to an exit located between the sleeve member and an end of the tubular body such that the gravel slurry circulates around an annulus between the assembly and the larger diameter structure.

10. A method according to claim 9 wherein the step of pumping of fluid through a port in the tubular body to access the chamber and cause the sleeve member to move radially outwardly occurs after the gravel slurry is pumped into the annulus.

11. A method according to claim 10 wherein the sleeve moves radially outwardly to crush the gravel and morph against the inner surface of the large diameter structure.

12. An expandable completion system, comprising:

an assembly comprising two sand screens connected via a tubular body, the assembly including connections for location in a tubular string to be run in and secured within a larger diameter generally cylindrical structure;

wherein a sleeve member is positioned on the exterior of the tubular body, to create a chamber therebetween;

the tubular body including a port to permit the flow of fluid into the chamber to cause the sleeve member to move outwardly and morph against an inner surface of the larger diameter structure wherein the assembly is operable to provide a gravel slurry into an annulus between the assembly and the larger diameter structure.

13. An expandable completion system according to claim 12 wherein the sleeve member has a first end which is affixed and sealed to the tubular body and a second end which includes a sliding seal to permit longitudinal movement of the second end over the tubular body.

14. An expandable completion system according to claim 12 wherein the sand screens are slotted liners.

15. An expandable completion system according to claim 12 wherein the system includes a plurality of assemblies.

16. An expandable completion system according to claim 15 wherein the assemblies are separated by a tubular body, wherein a sleeve member is positioned on the exterior of the tubular body, to create a chamber therebetween; the tubular body including a port to permit the flow of fluid into the chamber to cause the sleeve member to move outwardly and morph against an inner surface of the larger diameter structure.

17. An expandable completion system according to claim 12 wherein the assembly(ies) comprises a string exit at an end.

18. An expandable completion system according to claim 12 wherein the assembly(ies) comprises at least one shunt tubular having at least one shunt exit located between the sleeve member and an end of the tubular body.

19. An expandable completion system according to claim 18 wherein the at least one shunt tubular is provided with a valve.

20. An expandable completion system according to claim 18 wherein the assembly comprise string exit at an end and at least one shunt tubular having at least one shunt exit located between the sleeve member and an end of the tubular body.