US20230265745A1

US20230265745A1 - Sand screen assemblies for a subterranean wellbore

Info

Publication number: US20230265745A1
Application number: US18/011,853
Authority: US
Inventors: Michael J. Foster; Kevin Whaley
Original assignee: BP Corp North America Inc
Current assignee: BP Corp North America Inc
Priority date: 2020-06-24
Filing date: 2021-06-18
Publication date: 2023-08-24
Also published as: WO2021262553A1; EP4172463A1

Abstract

A sand screen assembly for a subterranean wellbore includes a base pipe having a central axis and including a flow port extending radially therethrough. The sand screen assembly also includes a screen element disposed about the base pipe and radially spaced from the base pipe to define an annulus radially positioned between the screen element and the base pipe. In addition, the sand screen assembly includes a manifold formed about the based pipe. The flow port is in fluid communication with the manifold and axially overlaps with the manifold. Further, the sand screen assembly includes a phase change material disposed within the manifold. The phase change material is configured to melt at a temperature below a melting temperature of the base pipe and flow into the flow port.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a 35 U.S.C. § 371 national stage application of PCT/US2021/038116 filed Jun. 18, 2021, entitled “Sand Screen Assemblies for a Subterranean Wellbore,” which claims benefit of U.S. provisional patent application Serial No. 63/043,607 filed Jun. 24, 2020, and entitled “Sand Screen Assemblies for a Subterranean Wellbore,” each of which is hereby incorporated herein by reference in its entirety for all purposes.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND

To obtain hydrocarbons from subterranean formations, wellbores are drilled from the surface to access the potentially hydrocarbon-bearing subterranean formation. After drilling a wellbore to the desired depth, a completion string containing various completion and production devices is installed in the wellbore to enable the subsequent production of hydrocarbons from the subterranean formation to the surface. To prevent the free migration of sands or other fines from the subterranean formation into the completion and production devices (that is, along with any produced hydrocarbons), a fluid flow restriction device, usually including one or more screens, is often placed within the wellbore, and proppant (which is generally referred to herein as “gravel”) may be injected in a slurry and deposited into the annular space between the wellbore sidewall (or an inner surface of a casing pipe) and the screens. The resulting “gravel pack” in the annular space forms a barrier to filter out the fines and sand from the produced fluids such that the fines and/or sand are prevented from passing through the screens and being produced to the surface. In some instances, a screen or screens may be utilized within a wellbore without a gravel pack.

BRIEF SUMMARY OF THE DISCLOSURE

Embodiments of sand screen assemblies for subterranean wellbores are disclosed herein. In one embodiment, a sand screen assembly comprises a base pipe having a central axis and including a flow port extending radially therethrough. The sand screen assembly also comprises a screen element disposed about the base pipe and radially spaced from the base pipe to define an annulus radially positioned between the screen element and the base pipe. In addition, the sand screen assembly comprises a manifold formed about the based pipe. The flow port is in fluid communication with the manifold and axially overlaps with the manifold. Further, the sand screen assembly comprises a phase change material disposed within the manifold. The phase change material is configured to melt at a temperature below a melting temperature of the base pipe and flow into the flow port.
Embodiments of methods of selectively stopping a flow of fluids through sand screen assemblies are disclosed herein. In one embodiment, a method of selectively stopping a flow of fluids through a sand screen assembly comprises (a) inserting a phase change material within the sand screen assembly. The phase change material is configured to melt at a temperature below a melting temperature of the sand screen assembly. The method also comprises (b) inserting the sand screen within a subterranean wellbore after (a). In addition, the method comprises (c) flowing fluid through a flow port of the sand screen after (b). Further, the method comprises (d) melting the phase change material. Still further, the method comprises (e) flowing the phase change material into the flow port. Moreover, the method comprises (f) re-solidifying the phase change material within the flow port after (d) and (e). The method also comprises (g) restricting fluid flow through the flow port after and as a result of (f).
Embodiments described herein comprise a combination of features and characteristics intended to address various shortcomings associated with certain prior devices, systems, and methods. The foregoing has outlined rather broadly the features and technical characteristics of the disclosed embodiments in order that the detailed description that follows may be better understood. The various characteristics and features described above, as well as others, will be readily apparent to those skilled in the art upon reading the following detailed description, and by referring to the accompanying drawings. It should be appreciated that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes as the disclosed embodiments. It should also be realized that such equivalent constructions do not depart from the spirit and scope of the principles disclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

For a detailed description of various exemplary embodiments, reference will now be made to the accompanying drawings in which:

FIG. 1 is a schematic view of an embodiment of a system for producing wellbore fluids from a wellbore in accordance with principles described herein;

FIG. 2 is an enlarged side cross-sectional view of an embodiment of a sand screen assembly for use within the system of FIG. 1 in accordance with principles described herein;

FIG. 3 is a cross-sectional view of the sand screen assembly of FIG. 2 taken along section A-A shown in FIG. 2 ;

FIG. 4 is a cross-sectional view of the sand screen assembly of FIG. 2 taken along section B-B in FIG. 2 ;

FIG. 5 is a side cross-sectional view of the sand screen assembly of FIG. 2 with a phase change material blocking one or more flow ports therein;

FIG. 6 is a side cross-sectional view of another embodiment of a sand screen assembly for use within the system of FIG. 1 in accordance with principles described herein;

FIG. 7 is a cross-sectional view of an embodiment of a sand screen assembly in accordance with the principles described herein for use within the system of FIG. 1 and taken along a section analogous to section B-B shown in FIG. 2 ; and

FIG. 8 is a flowchart illustrating an embodiment of a method for stopping the flow of fluids through a sand screen assembly in accordance with the principles described herein.

DETAILED DESCRIPTION

The following discussion is directed to various exemplary embodiments. However, one of ordinary skill in the art will understand that the examples disclosed herein have broad application, and that the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.
The drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness.
In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection of the two devices, or through an indirect connection that is established via other devices, components, nodes, and connections. In addition, as used herein, the terms “axial” and “axially” generally mean along or parallel to a given axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the given axis. For instance, an axial distance refers to a distance measured along or parallel to the axis, and a radial distance means a distance measured perpendicular to the axis. Further, when used herein (including in the claims), the words “about,” “generally,” “substantially,” “approximately,” and the like mean within a range of plus or minus 10% of the recited value. Thus, for example, a recited angle of “about 80 degrees” refers to an angle ranging from 72 degrees to 88 degrees. Any reference to up or down in the description and the claims is made for purposes of clarity, with “up”, “upper”, “upwardly”, “uphole”, or “upstream” meaning toward the surface of the wellbore or borehole and with “down”, “lower”, “downwardly”, “downhole”, or “downstream” meaning toward the terminal end of the wellbore or borehole, regardless of the wellbore or borehole orientation.
As previously described, in some subterranean wellbores, a flow restriction device, such as, for instance a screen, which may also be generally referred to herein as a “sand screen,” may be installed within the wellbore to filter out sands and/or other fines from other wellbore fluids (e.g., water, oil, gases, condensate, etc.). In addition, as previously described above, gravel may also be injected into an annular space surrounding the sand screen to form a gravel pack between the sand screen and either a wellbore sidewall or an inner surface of a casing pipe or other tubular in the wellbore. The gravel pack may further act as a barrier to filter out the sands and/or other fines from the wellbore fluids before they are produced to the surface.
In some instances, it may be desirable to selectively shut off flow from one or more of the sand screens installed within the wellbore. For instance, it may be desirable to shut off flow through one or more of the sand screens if one or more of the production zones of the subterranean formation begins producing an unacceptable amount water and/or sand, or no longer produces a minimum quantity of wellbore fluids. However, it may be difficult to selectively shut off flow through a sand screen that is installed within the wellbore. For instance, mechanically actuated valves or other such components may not reliably actuate within the harsh wellbore environment, which is not only remote from the surface, but is also at elevated temperature and pressures. Accordingly, embodiments disclosed herein include systems and methods for selectively shutting off fluid flow into a production flow bore from one or more sand screen assemblies located within a subterranean wellbore. In some embodiments, the disclosed systems and methods may selectively shut off (or at least restrict) flow into one or more sand screen assemblies within a subterranean wellbore by selectively flowing or moving a phase change material that is pre-installed within the sand screen assemblies into one or more flow ports of the sand screen assemblies during production operations.
Referring now to FIG. 1 , an embodiment of a system 10 for producing hydrocarbon fluids from a subterranean formation 3 via a wellbore 8 extending from the surface 5 into the subterranean formation 3 is shown. In this embodiment, wellbore 8 is shown as a vertical wellbore so as to simplify the drawings and description, however, it should be appreciated that in other embodiments, one or more portions of wellbore 8 may be deviated (e.g., angled) relative to the vertical direction. Production system 10 includes an elongate tubular casing or liner pipe 20 installed in wellbore 8 and an elongate tubular production string 50 extending from a surface structure 12 at the surface 5 into wellbore 8 through casing 20. In general, surface structure 12 may be any suitable structure or equipment for drilling, servicing, or producing a subterranean wellbore 8.
Casing 20 is installed (e.g., cemented) within wellbore 8 to ensure integrity of the wellbore 9 and prevent that fluid communication between surface 5 and the annulus between wellbore sidewall 9 and casing 20. Casing 20 has a first or uphole end 20 a at or proximate the surface 5 and a second or downhole end 20 b distal the surface 5. As shown in FIG. 1 , downhole end 20 b is spaced from a bottom or downhole end 7 of wellbore 8. In other words, casing 20 does not extend to downhole end 7 of wellbore 8. Thus, wellbore 8 may be described as being divided into a first or cased section 13 of wellbore 8 and a second or uncased section 15 of wellbore 8, wherein the cased section 13 is the portion or section of wellbore 8 within which casing 20 installed and the uncased section 15 is the portion or section of wellbore 8 that has no casing 20 installed. In some embodiments, casing 20 includes a plurality of tubular members coupled together (e.g., threadably engaged) end-to-end to extend between ends 20 a, 20 b.
Production string 50 has a central or longitudinal axis 55 and extends through casing 20 and into the uncased section 15 of wellbore 8. Production string 50 may include any suitable tubular member or assembly, such as, for instance, a plurality of threadably engaged tubular pipes, continuous or semi-continuous tubing (e.g., coiled tubing, e-line, slick-line, etc.), or some combination thereof.
A plurality of axially-spaced sand screen assemblies 100 a, 100 b are disposed along a lower portion of production string 50 to allow the flow of fluids in uncased section 15 to flow into a central bore of lower production string 50 (the central bore of production string 50 is not specifically shown in FIG. 1 ). The screen assemblies 100 a, 100 b may be coupled to or integrated with production string 50. In the embodiment of FIG. 1 , system 10 includes a first or uphole screen assembly 100 a and a second or downhole screen assembly 100 b positioned downhole of uphole screen assembly 100 a within wellbore 8. In this embodiment, each screen assembly 100 a, 100 b is disposed within the uncased section 15 of borehole 8. However, in some embodiments, one or more screen assemblies (e.g., screen assemblies 100 a, 100 b) may be disposed within the cased section 13 of borehole 8. Both uphole screen assembly 100 a and downhole screen assembly 100 b include a plurality of perforations 102 configured to allow the passage of fluids therethrough during operations.
Referring still to FIG. 1 , a plurality of annular sealing assemblies 30, 32 (e.g., packers) are installed within wellbore 8 so as to control the flow of fluids therethrough during operations. For instance, a packing or sealing assembly 30 is installed between production string 50 and casing 20 at or proximate to downhole end 20 b and is configured to prevent or restrict the flow of fluids from the uncased section 15 into the annular space between the production string 50 and casing 20. In addition, another sealing assembly 32 is installed along production string 50 between the uphole screen assembly 100 a and downhole screen assembly 100 b so as to prevent or restrict a flow of fluids within the wellbore 8 between the screen assemblies 100 a, 100 b. A first or uphole annular space or region 40 is defined within the uncased region 15 between uphole screen assembly 100 a and wellbore sidewall 9, and a second or downhole annular space or region 42 is defined within the uncased region 15 between downhole screen assembly 100 b and wellbore sidewall 9. The uphole annular space 40 is separated from the downhole annular space 42 by the sealing assembly 32. Thus, during production operations, fluids that enter the wellbore 8 at uphole annular space 40 may enter production string 50 via uphole screen assembly 100 a, and fluids that enter wellbore 8 at downhole annular space 42 may enter production string 50 via downhole screen assembly 100 b.
In some embodiments, one or both of the uphole annular space 40 and the downhole annular space 42 is filled (wholly or partially) with gravel (not shown). As previously described above, the gravel and/or the perforations 102 of screen assemblies 100 a, 100 b filter out sand and other fines that are produced into annular spaces 40, 42 along with other wellbore fluids (e.g., oil, gas, water, etc.). In some embodiments, one or both of the annular spaces 40, 42 may not include gravel therein.
During production operations, it may eventually become desirable to prevent or restrict the flow of wellbore fluids into the production string 50 via one or both of the screen assemblies 100 a, 100 b. For instance, at some point, water (or more than an acceptable amount of water) may be produced into one or both of the annular spaces 40, 42, or the amount of sands and/or other fines that may be produced with the wellbore fluids 40, 42 may reach a sufficient level or amount that interferes with overall production from wellbore 8. Regardless of the reason, a wellbore operator may wish to prevent flow into one or both of the screen assemblies 100 a, 100 b, without ceasing or preventing production from wellbore 8 entirely. Accordingly, as will be described in more detail below, each of the screen assemblies 100 a, 100 b is configured to selectively prevent or restrict flow of wellbore fluids therethrough during operations by flowing a pre-installed phase change material within the screen assembly 100 a, 100 b into one or more of the internal flow ports so as to prevent further flow of wellbore fluids therethrough. Further details of embodiments of screen assemblies 100 a, 100 b will now be described below.
Referring now to FIG. 2 , an embodiment of a screen assembly 100 is shown. In general, screen assembly 100 can be used as the uphole screen assembly 100 a and/or downhole screen assembly 100 b of system 10 of FIG. 1 . In this embodiment, screen assembly 100 includes a central or longitudinal axis 105, a base tubular or pipe 110, a screen element 120 disposed about base pipe 110, a first or upper end ring or cap 130 extending radially between pipe 110 and screen element 120, and a second or lower end ring or cap 140 extending radially between pipe 110 and screen element 120. When screen assembly 100 is disposed in wellbore 8 (e.g., screen assemblies 100 a, 100 b as shown in FIG. 1 ), axis 105 is generally oriented parallel to axis 55. Each of the foregoing components will now be described in more detail below.
Base pipe 110 is an elongate tubular member that may be integrated with or coupled along production string 50 (see e.g., screen assemblies 100 a, 100 b shown in FIG. 1 ). Base pipe 110 includes a first or uphole end 110 a, a second or downhole end 110 b axially opposite uphole end 110 a, a radially outer surface 110 c extending axially between ends 110 a, 110 b, and a radially inner surface 110 d extending axially between ends 110 a, 110 b. The radially inner surface 110 d defines an inner passage or throughbore 112 that extends axially between ends 110 a, 110 b. During production operations, throughbore 112 is in fluid communication with (and/or may make up part of) the inner flow bore of production string 50 (see e.g., FIG. 1 ). Thus, fluids entering or flowing within throughbore 112 are communicated to the surface 5 via production string 50.
Referring now to FIGS. 2 and 4 , base pipe 110 includes a plurality of flow ports 114 extending radially therethrough between radially outer surface 110 c and radially inner surface 110 d. Flow ports 114 enable fluid communication between the environment outside base pipe 110 and throughbore 112. As best shown in FIG. 4 , in this embodiment, flow ports 114 are axially located more proximate downhole end 110 b than uphole 110 a; however, the locations of flow ports 114 along base pipe 110 may be varied in some embodiments. In this embodiment, flow ports 114 are arranged in a plurality of axially-spaced circumferential rows, wherein the flow ports 114 in each circumferential row are uniformly circumferentially spaced about axis 105 as shown in FIG. 4 .
Referring still to FIG. 2 , screen element 120 is an elongate tubular member coaxially aligned with and disposed about base pipe 110. Screen element 120 has an inner diameter that is greater than an outer diameter of base pipe 110, and thus, an annulus or annular space 125 is radially disposed therebetween. As best shown in FIG. 3 , in some embodiments, a plurality of spacing elements 116 are disposed within annulus 125 so as to maintain the radial spacing between base pipe 110 and screen element 120 while still allowing or facilitating the flow of fluids within annulus 125 during operations. In some embodiments, the spacing elements 116 may comprise rib-wire that extends generally axially through the annulus 125.
Referring again to FIG. 2 , screen element 120 includes a first or uphole end 120 a, a second or downhole end 120 b opposite uphole end 120 a, a radially outer surface 120 c extending axially between ends 120 a, 120 b, and a radially inner surface 120 d extending axially between ends 120 a, 120 b. The plurality of perforations 102 extend radially through screen element 120, and thereby enable fluid communication between the environment outside screen element 120 and annular space 125. In this embodiment, perforations 102 comprises a plurality of axially and circumferentially spaced perforations 102 extending radially between the radially outer surface 120 c and radially inner surface 120 d. In general, perforations 102 can be punched, drilled, or otherwise formed in screen element 120. In other embodiments, screen element 120 may comprise a cylindrical weave of wire or other suitable material, wherein the spaces between the wire define the perforations (e.g., perforations 102). The screen element 120 is sized and positioned such that the downhole end 120 b of screen element 120 is positioned uphole of the flow ports 114 in base pipe 110. Thus, the flow parts 114 are axially spaced from the screen element 120, and in particular, are positioned axially downhole of the screen element 120 in this embodiment.
Upper end cap 130 is disposed about radially outer surface 110 c of base pipe 110 and axially abuts with uphole end 120 a of screen element 120. More specifically, upper end cap 130 extends radially from base pipe 110 to uphole end 120 a, and thus, closes off an uphole end of annular space 125. Suitable seals, welds, or other sealing connection mechanisms are employed between screen element 120, base pipe 110, and upper end cap 130 to prevent fluid flow between upper end cap 130 and base pipe 110 and to prevent fluid flow between upper end cap 130 and screen element 120.
Referring still to FIG. 2 , lower end cap 140 is disposed about radially outer surface 110 c of base pipe 110 and radially engages screen element 120 at or proximate to downhole end 120 b (e.g., along radially outer surface 120 c). More specifically, lower end cap 140 extends radially outward from base pipe 110 and then axially upward to downhole end 120 b, and thus, closes off a downhole end of annular space 125. Suitable seals, welds, or other sealing connection mechanisms are employed between screen element 120, base pipe 110, and lower end cap 140 to prevent fluid flow between lower end cap 140 and base pipe 110 and to prevent fluid flow between lower end cap 140 and screen element 120.
As noted above, lower end cap 140 extends radially outward from base pipe 110 and then axially upward to downhole end 120 b. Consequently, lower end cap 140 and base pipe 110 define an annular manifold or flow chamber 142 disposed about base pipe 110 and positioned generally downhole of screen element 120. The manifold 142 is generally axially aligned and overlapping with the plurality of flow ports 114 extending through base pipe 110. Manifold 142 is in fluid communication with and axially downhole of annulus 125, and is in fluid communication with and radially adjacent flow ports 114. Accordingly, fluid flowing into annulus 125 via perforations 120 may generally flow axially downhole through annulus 125 and into manifold 142, where it is then directed through flow ports 114 and into throughbore 112. As with upper end cap 130, suitable welds, seals, or other sealing connection mechanisms are employed between lower end cap 140, screen element 120, and base pipe 110 so as to prevent fluid flow between lower end cap 140 and base pipe 110 and to prevent fluid flow between lower end cap 140 and screen element 120
Referring now to FIGS. 1, 2, and 4 , a phase change material 150 is disposed within manifold 142. Phase change material 150 may be pre-installed within manifold 142 before coupling screen assembly 100 along production string 50 and/or insertion of screen assembly 100 within borehole 8. Upon installation of screen assembly 100 within borehole 8 and during production operations (e.g., whereby wellbore fluids are produced into the throughbore 112 of screen assembly 100 via perforations 102, annulus 125, manifold 142, and flow ports 114 as previously described above), the phase change material 150 is in a solid state and arranged (e.g., positioned and maintained) within the manifold 142 so as not to block or substantially restrict the flow of fluid through manifold 142 and into flow ports 114. Thus, phase change material 150 is configured to remain in a solid state under normal or expected conditions (e.g., temperature, pressure, PH, etc.) while within the wellbore 8 during production operations. However, when additional thermal energy or heat (i.e., above and beyond the thermal energy associated with normal downhole conditions within the wellbore 8) is applied to the phase change material 150, the phase change material 150 changes phase from solid to liquid (or may at least partially change phase from solid to liquid) so as to move or flow within manifold 142 during operations. Upon removal of the additional thermal energy, the phase change material 150 transition back to a solid material. Accordingly, the phase change material 150 transitions between solid and liquid phases at a temperature (i.e., the phase change material 150 may have a melting temperature) that is less than the melting temperature of the materials forming other components of sand screen assembly 100 (e.g., base pipe 110, screen element 120, end caps 130, 140, etc.), but greater than the downhole temperatures during normal production operations. In general, phase change material 150 can comprise any suitable composition with the foregoing characteristics. One exemplary suitable composition for phase change material 150 is an alloy material including bismuth, such as those described in U.S. Pat. No. 6,923,263, the contents of which is incorporated herein by reference in its entirety. In some embodiments, the phase change material 150 comprises a bismuth based alloy such as those manufactured and sold by BiSN Ltd. located in Warrington, United Kingdom.
Referring now to FIG. 8 , an embodiment of a method 200 for selectively ceasing or stopping the flow of production fluids through one or more flow ports of a screen assembly is shown. Method 200 will be described in connection with the screen assembly 100 (e.g., screen assembly 100 a, 100 b) previously described and shown in FIGS. 1-5 . Method 200 begins in block 201 in which the phase change material 150 is positioned or inserted into screen assembly 100. For example, the phase change material 150 can be positioned within manifold 142. Next, in block 202, screen assembly 100 is inserted into the wellbore 8 and lowered to the desired position in the uncased section 15 with production string 50 for production operations. One or more annular sealing assemblies 30, 32 may be actuated to isolate the screen assembly 100 from one or more other production zones within the uncased section 15. Moving now to block 203, production operations are performed. In particular, production fluid (e.g., wellbore fluids) flows through perforations 102 into annulus 125 and manifold 143, and then flows through flow ports 114 into throughbore 112. As previously described, base pipe 110 is coupled to or integrated within production string 50 so that when fluids enter into throughbore 112, they may then flow upward or uphole toward the surface 5. However, as is previously described above, at some point, it may become desirable or necessary to close off or restrict the flow of wellbore fluids into the production string 50 via the screen assembly 100 (e.g., due to water production, sand production, etc.). At such time, phase change material 150 is at least partially melted in the sand screen assembly 100 according to block 204. More specifically, additional thermal energy may be applied to the phase change material 150 within manifold 142 so as to transition the phase change material 150 from a solid to a liquid (or partial liquid) as previously described. The additional thermal energy may be applied by inserting a heater or heating element (e.g., resistive heating element, chemically driven heating device, nuclear driven heating device, etc.) into throughbore 112 and positioning it proximate phase change material 150. In some embodiments, an exothermic chemical reaction may be induced within the manifold (e.g., via a combination of injected fluids and/or wellbore fluids). In some embodiments one or more heating elements 152 may be pre-installed within manifold that may provide additional thermal energy to phase change material 150 during operations as shown in FIG. 6 . The heating elements 152 may have their own on-board power source (e.g., batteries), or may receive electrical or other power source from the surface 5 via wire, cables, or other conductors (not shown).
Referring again to FIG. 8 , regardless of the method and manner used to apply additional thermal energy to the phase change material 150, the phase change material 150 may partially or wholly melt within the manifold 142 as previously described above. Without being limited to this or any other theory, in block 205, the pressure differential that exists between the annulus 125 and throughbore 112 during production operations flows the melted or semi-melted phase change material 150 into the flow ports 114 (see e.g., the representative progression from FIG. 4 to FIG. 5 ). Next in block 206, the additional thermal energy is removed or ceased, so that the phase change material 150 begins to transition back to a solid (i.e., re-solidify); however, at this point, the phase change material 150 (or some portion thereof) is now plugged within the flow ports 114 so that once the phase change material 150 re-solidifies, fluid flow through the flow ports 114 is now restricted and/or prevented according to block 207.
The additional thermal energy applied to the phase change material may be ceased by powering down a heating element (e.g., whether within the throughbore 112, manifold 142, or elsewhere), the natural (or selective) end or reduction in a exothermic chemical reaction, or by simply moving the heating element or source away from the phase change material 150 and flow ports 114. For instance, when a heating element or device is inserted within the throughbore 112 to provide additional thermal energy to phase change material 150, the heating element may be advanced axially past the phase change material at a constant and predetermined rate so as to heat and melt (or partially melt) the phase change material 150 as previously described, and so that the heating element is advanced axially away or past the flow ports 114 phase change material 150 so as to re-solidify the phase change material 150 once it has flowed into and blocked the flow ports 114, it begins to re-solidify. In some embodiments, the heating element is move axially within throughbore 112 until it is aligned with the phase change material 150. Thereafter, the heating element is paused or stopped within the throughbore while outputting thermal energy so to facilitate the above-described melting. After a predetermined period of time, the heating element is then advanced axially (e.g., uphole, downhole, etc.) away from the phase change material 150 and flow ports 114 so as to allow the phase change material 150 to re-solidify within the flow ports 114 as previously described.
While the phase change material 150 has been shown (e.g., in FIGS. 2 and 4 ) in an annular shape or arrangement within manifold 142 during production operations, it should be appreciated that the arrangement, shape, position, distribution, etc. of the phase change material 150 may be greatly varied in different embodiments. For instance, reference is now made to FIG. 7 , which shows one such alternative arrangement of phase change material 150 within manifold 142. More specifically, in the embodiment of FIG. 7 , the phase change material 150 is locally disposed about the flow ports 114 within manifold 142. Specifically, the phase change material 150 is arranged in a plurality of separate volumes 154 that are disposed overtop and about each flow port 114. Each volume 154 may include a flow port or opening 156 to allow fluids to flow therethrough (and therefore into flow ports 114) during normal production operations as previously described above. Upon the application of additional thermal energy (e.g., via any one or more of the methods previously described above), the volumes 154 of phase change material 150 may be melted (or partially melted) so as to flow into the flow ports 114, and thereafter re-solidify in the manner previously described above.
In some embodiments, the volumes 154 of phase change material 150 may be inserted (at least partially) within the flow ports 114 themselves during normal productions operations through screen assembly 100 (i.e., before melting the phase change material 150 to close off flow through flow ports 114). For instance, the volumes 154 may be partially disposed within the flow ports 114 and partially disposed within manifold 142 (and/or throughbore 112), or may be wholly disposed within flow ports 114. However, prior to melting the phase change material 150, fluids may freely flow through the openings 156 through volumes 154 within flow ports 114.
Referring again to FIG. 2 , in some embodiments the phase change material 150 comprises (or be replaced with) a swellable material that may increase in size so as to selectively block off the flow ports 114 when desired. For instance, in some embodiments, the swellable material (e.g., a swellable foam) that may increase in volume upon being contacted by an activation fluid (e.g., oil, water, or combination thereof) that is flowed across the swellable material either from the surface 5 or from the formation 3. In addition, in some embodiments, the phase change material 150 comprises a metallic material (e.g., aluminum) that is selectively dissolved or melted via contact with an activating fluid (e.g., acid) flowed into the wellbore (e.g., from the surface 5) so as to cause the dissolved (or partially dissolved) phase change material 150 to flow into and therefore block the flow ports 114.
Embodiments disclosed herein include systems (and related methods) for selectively shutting off fluid flow into a product flow bore from one or more sand screens. Specifically, in some embodiments, the disclosed systems and methods selectively shut off (or at least restrict) flow into one or more sand screens within a subterranean wellbore by selectively flowing or moving a phase change material that is pre-installed within the sand screen during operations. Accordingly, the embodiments disclosed herein may allow for the selective prevention or restriction of fluid flow through one or more sand screen assemblies without affecting the flow through other sand screens or other inflow devices, ports, etc. disposed within the wellbore.
While exemplary embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the systems, apparatus, and processes described herein are possible and are within the scope of the disclosure. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. Unless expressly stated otherwise, the steps in a method claim may be performed in any order. The recitation of identifiers such as (a), (b), (c) or (1), (2), (3) before steps in a method claim are not intended to and do not specify a particular order to the steps, but rather are used to simplify subsequent reference to such steps.

Claims

1. A sand screen assembly for a subterranean wellbore, the sand screen assembly comprising:

a base pipe having a central axis and including a flow port extending radially therethrough;

a screen element disposed about the base pipe and radially spaced from the base pipe to define an annulus radially positioned between the screen element and the base pipe;

a manifold formed about the based pipe, wherein the flow port is in fluid communication with the manifold and axially overlaps with the manifold; and

a phase change material disposed within the manifold, wherein the phase change material is configured to melt at a temperature below a melting temperature of the base pipe and flow into the flow port.

2. The sand screen assembly of claim 1, wherein the phase change material is entirely disposed within the manifold.

3. The sand screen assembly of claim 2, wherein the phase change material has an annular shape.

4. The sand screen assembly of claim 1, wherein the phase change material is disposed about the flow port.

5. The sand screen assembly of claim 4, wherein the phrase change material comprises an opening configured to allow fluid to flow therethrough and into the flow port.

6. The sand screen assembly of claim 1, wherein the screen element comprises a plurality of perforations extending radially therethrough, wherein the perforations are in fluid communication with the annulus and the manifold.

7. The sand screen assembly of claim 2, comprising a plurality of rib wires disposed within the annulus, wherein the rib wires are configured to maintain the radially spacing of the base pipe and the screen element.

8. The sand screen assembly of claim 1, wherein the phase change material comprises a bismuth alloy.

9. The sand screen assembly of claim 1, wherein the screen element has an uphole end and a downhole end, wherein the manifold is positioned axially proximal the downhole end of the screen element.

10. The sand screen assembly of claim 1, wherein the flow port is axially spaced from the sand element.

11. A method of selectively stopping a flow of fluids through a sand screen assembly, the method comprising:

(a) inserting a phase change material within the sand screen assembly, wherein the phase change material is configured to melt at a temperature below a melting temperature of the sand screen assembly;

(b) inserting the sand screen within a subterranean wellbore after (a);

(c) flowing fluid through a flow port of the sand screen after (b);

(d) melting the phase change material;

(e) flowing the phase change material into the flow port;

(f) re-solidifying the phase change material within the flow port after (d) and (e); and

(g) restricting fluid flow through the flow port after and as a result of (f).

12. The method of claim 9, wherein (d) comprises:

(d1) inserting a heating element within a throughbore of the sand screen; and

(d2) positioning the heating element in the throughbore proximal the phase change material.

13. The method of claim 11, wherein (d) comprises:

(d1) activating a heating element positioned proximal the phase change material; and

(d2) generating thermal energy with the heating element.

14. The method of claim 11, wherein the sand screen assembly comprises:

a base pipe having a central axis and including the flow port extending radially therethrough;

a manifold formed about the based pipe, wherein the flow port is in fluid communication with the manifold and axially overlaps with the manifold.

15. The method of claim 14, wherein the flow port is axially aligned with the manifold.

16. The method of claim 15, wherein the flow port is positioned axially downhole of the screen element.

17. The method of claim 15, wherein (a) comprises positioning the phase change material in the manifold.

18. The method of claim 14, wherein the annulus has an uphole end and a downhole end axially opposite the uphole end, wherein the flow port is axially positioned proximal the downhole end of the annulus.

19. The method of claim 11, wherein (c) comprises:

(c1) flowing the fluid through a plurality of perforations in a screen element of the sand screen assembly;

(c2) flowing the fluid through into a manifold of the sand screen assembly after (c1); and

(c3) flowing the fluid through the flow port after (c2).

20. The method of claim 11, comprising flowing the fluid through the phase change material during (c) and before (d)-(g).