SAND CONTROL SCREEN ASSEMBLY AND METHOD FOR USE OF SAME
TECHNICAL FIELD OF THE INVENTION
[0001] This invention relates, in general, to controlling the production of particulate materials
from a hydrocarbon formation and, in particular, to a sand control screen assembly having a
swellable material layer that is operable to radially extend a plurality of telescoping perforations
having particulate filtering capability into contact with the formation.
BACKGROUND OF THE INVENTION
[0002] Without limiting the scope of the present invention, its background is described with
reference to the production of hydrocarbons through a wellbore traversing an unconsolidated or
loosely consolidated formation, as an example.
[0003] It is well known in the subterranean well drilling and completion art that particulate
materials such as sand may be produced during the production of hydrocarbons from a well
traversing an unconsolidated or loosely consolidated subterranean formation. Numerous
problems may occur as a result of the production of such particulate materials. For example, the
particulate materials cause abrasive wear to components within the well, such as tubing, pumps
and valves. In addition, the particulate materials may partially or fully clog the well creating the
need for an expensive workover. Also, if the particulate materials are produced to the surface,
they must be removed from the hydrocarbon fluids by processing equipment at the surface.
[0004] One method for preventing the production of such particulate materials to the surface is
gravel packing the well adjacent the unconsolidated or loosely consolidated production interval.
In a typical gravel pack completion, a sand control screen is lowered into the wellbore on a work
string to a position proximate the desired production interval. A fluid slurry including a liquid
carrier and a particulate material, such as gravel, is then pumped down the work string and into
the well annulus formed between the sand control screen and the perforated well casing or open
hole production zone.
[0005] The liquid carrier either flows into the formation or returns to the surface by flowing
through the sand control screen or both. In either case, the gravel is deposited around the sand
control screen to form a gravel pack, which is highly permeable to the flow of hydrocarbon
fluids but blocks the flow of the particulate carried in the hydrocarbon fluids. As such, gravel
packs can successfully prevent the problems associated with the production of particulate
materials from the formation.
[0006] It has been found, however, that a complete gravel pack of the desired production
interval is difficult to achieve particularly in long or inclined/horizontal production intervals.
These incomplete packs are commonly a result of the liquid carrier entering a permeable portion
of the production interval causing the gravel to form a sand bridge in the annulus. Thereafter,
the sand bridge prevents the slurry from flowing to the remainder of the annulus which, in turn,
prevents the placement of sufficient gravel in the remainder of the annulus.
[0007] In certain open hole completions where gravel packing may not be feasible, attempts
have been made to use expandable sand control screens. Typically, expandable sand control
screens are designed to not only filter particulate materials out of the formation fluids, but also
provide radial support to the formation to prevent the formation from collapsing into the
wellbore. It has been found, however, that conventional expandable sand control screens are not
capable of contacting the wall of the wellbore along their entire length as the wellbore profile is
not uniform. More specifically, due to the process of drilling the wellbore and heterogeneity of
the downhole strata, washouts or other irregularities commonly occur which result in certain
locations within the wellbore having larger diameters than other areas or having non circular
cross sections. Thus, when the expandable sand control screens are expanded, voids are created
between the expandable sand control screens and the irregular areas of the wellbore. In
addition, it has been found that the expansion process undesirably weakens such sand control
screens.
[0008] More recently, attempts have been made to install sand control screens that include
telescoping screen members. Typically, hydraulic pressure is used to extend the telescoping
screen members radially outwardly toward the wellbore. This process requires providing fluid
pressure through the entire work string that acts on the telescoping members to shift the
members from a position partially extending into to production string to the radially extended
position. It has been found, however, that in substantially horizontal production intervals, the
telescoping screen members may not properly deploy, particularly along the portion of the
production siring resting on the bottom surface of the wellbore. Failure to fully extend all the
telescoping screen members results in a non uniform inner bore which may prevent the passage
of tools therethrough.
[0009] Therefore, a need has arisen for a sand control screen assembly that prevents the
production of particulate materials from a well that traverses a hydrocarbon bearing
subterranean formation without the need for performing a gravel packing operation. A need has
also arisen for such a sand control screen assembly that provides radial support to the formation
without the need for expanding metal tubulars. Further, a need has arisen for such a sand
control screen assembly that is suitable for operation in open hole completions and horizontal
production intervals.
SUMMARY OF THE INVENTION
[0010] The present invention disclosed herein comprises a sand control screen assembly that
prevents the production of particulate materials from a well that traverses a hydrocarbon bearing
subterranean formation. The sand control screen assembly of the present invention achieves this
result without the need for performing a gravel packing operation. In addition, the sand control
screen assembly of the present invention provides radial support to the formation without the
need for expanding metal tubulars and is suitable for operation in open hole completions and
horizontal production intervals.
[0011] In one aspect, the present invention is directed to a sand control screen assembly
including a base pipe having a plurality of openings that allow fluid flow therethrough and a
swellable filter media disposed exteriorly of the base pipe and surrounding the plurality of
openings. The swellable filter media is radially extendable between a first configuration and a
second configuration in response to contact with an activating fluid. The swellable filter media
is operable to allow fluid flow therethrough and prevent particulate flow of a predetermined size
therethrough.
[0012] In one embodiment, the activating fluid is a hydrocarbon. In another embodiment, the
swellable filter media is formed from a material selected from the group consisting of elastic
polymers, EPDM rubber, styrene butadiene, natural rubber, ethylene propylene monomer
rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate rubber, hydrogenized
acrylonitrile-butadiene rubber, acrylonitrile butadiene rubber, isoprene rubber, chloroprene
rubber and polynorbomene. In this embodiment, the swellable material may contain pores
having diameters of less than 1 mm. In yet another embodiment, the swellable filter media is
operable to swell into contact with a surface of a formation when the sand control screen
assembly is disposed in a well and the swellable filter media is in the second configuration. In
one embodiment, the swellable filter media may include filter medium layer and a swellable
material layer. In another embodiment, the swellable filter media may include a filter medium
layer positioned between two swellable material layers.
[0013] In another aspect, the present invention is directed to a sand control screen assembly that
includes base pipe having at least one opening in a sidewall portion thereof and a swellable
material layer disposed exteriorly of the base pipe and having at least one opening
corresponding to the at least one opening of the base pipe. A telescoping perforation is operably
associated with the at least one opening of the base pipe and is at least partially disposed within
the at least one opening of the swellable material layer. A filter medium is disposed within the
telescoping perforation. In operation, radial expansion of the swellable material layer, in
response to contact with an activating fluid, causes the telescoping perforation to radially
outwardly extend.
[0014] In one embodiment, a face plate located at the distal end of the telescoping perforation
substantially transverse to a longitudinal axis of the telescoping perforation. In this
embodiment, the face plate may be positioned on the exterior surface of the swellable material
layer. In another embodiment, the filter medium is recessed radially inwardly from the distal
end of the telescoping perforation. In this embodiment, the filter medium further may be a
multi-layer woven wire mesh. In yet another embodiment, the telescoping perforation may be a
telescoping tubular perforation. In a further embodiment, the activating fluid may be a
hydrocarbon and the swellable material may be selected from the group consisting of elastic
polymers, EPDM rubber, styrene butadiene, natural rubber, ethylene propylene monomer
rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate rubber, hydrogenized
acrylonitrile-butadiene rubber, acrylonitrile butadiene rubber, isoprene rubber, chloroprene
rubber and polynorbomene.
[0015] In a further aspect, the present invention is directed to a sand control screen assembly
that includes a base pipe having a plurality of openings in a sidewall portion thereof and
defining an internal flow path. A swellable material layer is disposed exteriorly of the base pipe
and has a plurality of openings that correspond to the openings of the base pipe. A plurality of
telescoping perforations is operably associated with the openings of the base pipe and at least
partially disposed within the corresponding openings of the swellable material layer. The
telescoping perforations provide fluid flow paths between a fluid source disposed exteriorly of
the base pipe and the interior flow path. A filter medium is disposed within each of the
telescoping perforations. In operation, radial expansion of the swellable material layer, in
response to contact with an activating fluid, causes the telescoping perforation to radially
outwardly extend.
[0016] In a further aspect, the present invention is directed to a method for making a sand
control screen assembly. The method includes providing a base pipe having an interior flow
path, disposing a swellable material layer on the exterior of the base pipe, forming
corresponding openings in the base pipe and the swellable material layer and operably
associating a plurality of telescoping perforations having filter media with the openings of the
base pipe and at least partially disposing the telescoping perforations within the corresponding
openings of the swellable material layer such that upon radial expansion of the swellable
material layer, the telescoping perforations are radially outwardly extendable.
[0017] The method may also include forming the openings after the swellable material layer is
disposed on the exterior of the base pipe, drilling holes through the swellable material layer and
the base pipe and threadably coupling the telescoping perforations with the openings of the base
pipe.
[0018] In another aspect, the present invention is directed to a method of installing a sand
control screen assembly in a subterranean well. The method includes running the sand control
screen assembly to a target location within the subterranean well, contacting a swellable
material layer disposed exteriorly on a base pipe with an activating fluid, the swellable material
layer and the base pipe having corresponding openings, radially expanding the swellable
material layer in response to contact with the activating fluid and radially outwardly extending
telescoping perforations having filter media that are operably associated with the openings of the
base pipe and at least partially disposed within the corresponding openings of the swellable
material layer, in response to the radial expansion of the swellable material layer.
BRIEF DESCRIPTION OF THE DRAWINGS
{0019] For a more complete understanding of the features and advantages of the present
invention, reference is now made to the detailed description of the invention along with the
accompanying figures in which corresponding numerals in the different figures refer to
corresponding parts and in which:
[0020] Figure 1A is a schematic illustration of a well system operating a plurality of sand
control screen assemblies in a run in configuration according to an embodiment of the present
invention;
[0021] Figure 1B is a schematic illustration of the well system operating a plurality of sand
control screen assemblies in an operating configuration according to an embodiment of the
present invention;
[0022] Figure 2A is a schematic illustration of a well system operating a plurality of sand
control screen assemblies in a run in configuration according to an embodiment of the present
invention;
[0023] Figure 2B is a schematic illustration of a well system operating a plurality of sand
control screen assemblies in an operating configuration according to an embodiment of the
present invention;
[0024] Figure 3 is a cross sectional view taken along line 3-3 of the sand control screen
assembly of figure 1A;
[0025] Figure 4 is a cross sectional view taken along line 4-4 of the sand control screen
assembly of figure 1B;
[0026] Figure 5 is a side view of a sand control screen assembly in a run in configuration
according to an embodiment of the present invention;
[0027] Figure 6 is a side view of a sand control screen assembly in an operating configuration
according to an embodiment of the present invention;
[0028] Figure 7A is a side view of a portion of a sand control screen assembly depicting the top
of a telescoping perforation according to an embodiment of the present invention;
[0029] Figure 7B is a cross sectional view taken along line 7B-7B of the telescoping perforation
of figure 7A;
[0030] Figure 8 is a side view of a sand control screen assembly in a run in configuration
according to an embodiment of the present invention;
[0031] Figure 9 is a side view of a sand control screen assembly in an operating configuration
according to an embodiment of the present invention;
[0032] Figure 10 is a side view of a sand control screen assembly in a run in configuration
according to an embodiment of the present invention;
[0033] Figure 11 is a side view of a sand control screen assembly in an operating configuration
according to an embodiment of the present invention;
[0034] Figure 12 is a side view of a sand control screen assembly in an operating configuration
according to an embodiment of the present invention;
[0035] Figure 13 is a side view of a sand control screen assembly in an operating configuration
according to an embodiment of the present invention;
[0036] Figure 14 is a flow diagram of a process for making a sand control screen assembly
according to an embodiment of the present invention; and
[0037] Figure 15 is a flow diagram of a process for installing and operating a sand control
screen assembly according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0038] While the making and using of various embodiments of the present invention are
discussed in detail below, it should be appreciated that the present invention provides many
applicable inventive concepts which can be embodied in a wide variety of specific contexts.
The specific embodiments discussed herein are merely illustrative of specific ways to make and
use the invention, and do not delimit the scope of the present invention.
[0039] Referring initially to figure 1A, therein is depicted a well system including a plurality of
sand control screen assemblies embodying principles of the present invention that are
schematically illustrated and generally designated 10. In the illustrated embodiment, a wellbore
12 extends through the various earth strata. Wellbore 12 has a substantially vertical section 14,
the upper portion of which has installed therein a casing string 16. Wellbore 12 also has a
substantially horizontal section 18 that extends through a hydrocarbon bearing subterranean
formation 20. As illustrated, substantially horizontal section 18 of wellbore 12 is open hole.
[0040] Positioned within wellbore 12 and extending from the surface is a tubing string 22.
Tubing string 22 provides a conduit for formation fluids to travel from formation 20 to the
surface. Positioned within tubing string 22 is a plurality of sand control screen assemblies 24.
The sand control screen assemblies 24 are shown in a run in or unextended configuration.
[0041] Referring next to figure 1B, therein is depicted the well system of figure 1A with sand
control screen assemblies 24 in their radially expanded configuration. As explained in greater
detail below, when the swellable material layer of sand control screen assemblies 24 come in
contact with an activating fluid, such as a hydrocarbon fluid, the swellable material layer
radially expands which in turn causes telescoping perforations of sand control screen assemblies
24 to radially outwardly extend. Preferably, as illustrated in figure 1B, swellable material layer
and telescoping perforations come in contact with formation 20 upon expansion.
[0042] Referring to figures 2A - 2B, therein is depicted a well system including a plurality of
sand control screen assemblies 24 embodying principles of the present invention that are
schematically illustrated and generally designated 30. In addition to those elements located in
figure 2A common to figures 1A - 1B, the tubing string 22 may further be divided up into a
plurality of intervals using zone isolation devices and/or swellable zone isolation devices 26 or
other sealing devices, such as packers, between adjacent sand control screen assemblies 24 or
groups of sand control screen assemblies 24. The zone isolation devices 26 may swell between
the tubing string 22 and the wellbore 12 in horizontal section 18, as depicted in figure 2B, to
provide zone isolation for those adjacent sand control screen assemblies 24 or groups of sand
control screen assemblies 24 located between one or more zone isolation devices 26.
[0043] These zone isolation devices 26 may be made from materials that swell upon contact by
a fluid, such as an inorganic or organic fluid. Some exemplary fluids that may cause the zone
isolation devices 26 to swell and isolate include water and hydrocarbons.
[0044] In addition, even though figures 1A - 2B depict the sand control screen assemblies of the
present invention in a horizontal section of the wellbore, it should be understood by those skilled
in the art that the sand control screen assemblies of the present invention are equally well suited
for use in deviated or vertical wellbores. Accordingly, it should be understood by those skilled
in the art that the use of directional terms such as above, below, upper, lower, upward,
downward and the like are used in relation to the illustrative embodiments as they are depicted
in the figures, the upward direction being toward the top of the corresponding figure and the
downward direction being toward the bottom of the corresponding figure.
[0045] Referring to figure 3, therein is depicted a cross sectional view of a sand control screen
assembly in its run in configuration that embodies principles of the present invention and is
generally designated 40. Sand control screen assembly 40 includes base pipe 44 that defines an
internal flow path 42. Base pipe 44 has a plurality of openings 45 that allow fluid to pass
between the exterior of base pipe 44 and internal flow path 42. Sand control screen assembly 40
includes a concentric layer of swellable material 46 that circumferentially surrounds base pipe
44. Swellable material 46 has a plurality of openings 47 that correspond to openings 45 of base
pipe 44. In the illustrated embodiment, sand control screen assembly 40 includes a plurality of
telescoping perforations 48. The proximal ends of the telescoping perforations 48 are connected
to the base pipe 44 by means of threading, welding, friction fit or the like. The distal ends of the
telescoping perforations 48 terminate at a face plate 50 that is positioned exterior of or
embedded in the exterior surface of swellable material 46. Telescoping perforations 48 provide
a fluid conduit or passageway between the distal ends and the proximal ends of the telescoping
perforations 48 that passes through swellable material 46 and base pipe 44. Disposed within
each telescoping perforation 48 is a filter media 52.
[0046] The filter media 52 may comprise a mechanical screening element such as a fluid-
porous, particulate restricting, metal screen having a plurality of layers of woven wire mesh that
may be diffusion bonded or sintered together to form a porous wire mesh screen designed to
allow fluid flow therethrough but prevent the flow of particulate materials of a predetermined
size from passing therethrough. Alternatively, filter media 52 may be formed from other types
of sand control medium, such as gravel pack material, metallic beads such as stainless steel
beads or sintered stainless steel beads and the like.
[0047] Referring additionally now to figure 4, therein is depicted a cross sectional view of sand
control screen assembly 40 in its operating configuration. In the illustrated embodiment,
swellable material 46 has come in contact with an activating fluid, such as a hydrocarbon fluid,
that has caused swellable material 46 to radially expand into contact with the surface of the
wellbore 54, which in the illustrated embodiment is the formation face. In addition, the radial
expansion of swellable material 46 has caused telescoping perforations 48 to radially outwardly
extend into contact with the surface of the wellbore 54. In this embodiment, a stand off region
56 is provided between filter media 52 and wellbore 54 such that filter media 52 does not come
into physical contact with the surface of the formation.
[0048] Referring next to figure 5, therein is depicted a side view of a sand control screen
assembly in its run in configuration that embodies principles of the present invention and is
generally designated 100. In this embodiment, the sand control screen assembly 100 is located
within an open hole portion of formation 102 having a surface 104. The sand control screen
assembly 100 includes one or more telescoping perforations 106 that are shown in an
unextended position.
[0049] The sand control screen assembly 100 includes a concentric layer of swellable material
112 that surrounds a base pipe 108 having an interior flow path 120. In one aspect, the
telescoping perforations 106 include a face plate 118 and a filter medium 110. The swellable
material 112 includes an outer surface 114. In the illustrated embodiment, face plates 118 are
embedded within swellable material 112 such that a substantially smooth outer surface is
established in the run in configuration. Located between the outer surface 114 and the surface
104 of the formation 102 is an annular region 116.
[0050] Referring additionally to figure 6, therein is depicted a cross sectional view of sand
control screen assembly 100 in its operating configuration. The swellable material 112 has
come in contact with an activating fluid, such as a hydrocarbon fluid, that has caused swellable
material 112 to radially expand into contact with the surface 104 of the formation 102.
Likewise, the radial expansion of swellable material 112 has caused telescoping perforations
106 to radially outwardly extend into contact with the surface 104 of the formation 102. In this
embodiment, filter medium 110 does not come into contact with the surface 104 of the
formation 102 due to a stand off region of face plate 118. Preferably, the outer surface 114 of
the swellable material 112 does contact the surface 104 of the formation 102.
[0051] Referring additionally to figure 7A, therein is depicted a distal end view of a portion of
swellable material 46, 112, a face plate 50, 118 and a filter media 52, 110 of a sand control
screen assembly 40, 100. As illustrated, face plate 50, 118 is positioned on the exterior surface
of swellable material 46, 112 (see also figures 3-6). As swellable material 46, 112 surrounds
the telescoping portions of telescoping perforations 48, 106 and as face plates 50, 118 have a
diameter that is larger than the diameter of the telescoping portions of telescoping perforations
48, 106, radial expansion of the swellable material 46,112 applies a radially outwardly directed
force on face plates 50, 118 which in turn causes telescoping perforations 48, 106 to radially
extend toward the surface 58, 104 of the formation 54,102.
[0052] Referring to figure 7B, telescoping perforation 48, 106 has an outer tubular element 74
and an inner tubular element 76. Preferably, outer tubular element 74 is connected to the base
pipe 44, 108 by threading or other suitable means. Inner tubular element 76 is connected to face
plate 50, 118. In this manner, when the radially outwardly directed force is applied to face plate
50, 118, inner tubular element 76 telescopes radially outwardly relative to outer tubular element
74. Together, inner and outer tubular elements 74, 76 of telescoping perforation 48, 106 defines
an internal flow path 72. Positioned within internal flow path 72 is the filter media 52, 110
which may be a mechanical screening element or other suitable filter member that is sized
according to the particular requirements of the production zone into which it will be installed.
Some exemplary sizes of the filter media 52 may be 20, 30, and 40 standard mesh sizes.
[0053] Even though figures 3-7B have depicted telescoping perforations 48, 106 as having inner
and outer tubular elements 74, 76, it should be understood by those skilled in the art that other
configurations of nested telescoping elements could alternatively be used in telescoping
perforations 48, 106 without departing from the principles of the present invention, In addition,
it should be noted that any number of telescoping perforations 48, 106 may be located on base
pipe 44, 108 and they may be positioned at any desirable location on the circumference of base
pipe 44, 108.
[00541 Preferably, when telescoping perforations 48, 106 are fully extended, a stand off distance
remains between the filter media 52, 110 and the surface 58, 104 of the formation 54, 102. For
example, if a filter cake has previously formed on the surface 58, 104 of the formation 54, 102,
then the stand off will prevent damage to the filter media 52, 110 and allow removal of the filter
cake using acid or other reactive fluid.
[0055] Referring to figure 8, therein is depicted a side view of a sand control screen assembly
150 in an unextended position. The sand control screen assembly 150 includes a concentric
layer of swellable material 154 that circumferentially surrounds a base pipe 152 having an
interior flow path 166. The base pipe 152 preferably includes a plurality of openings 168 that
are in fluid communication with the swellable material 154 for providing a fluid conduit
between the formation 162 and the interior flow path 166. In the illustrated embodiment, an
expandable control screen 158 was previously installed in the open hole completion such that
expandable control screen 158 is positioned against the surface 164 of the formation 162.
Expandable sand screen 158 is a fluid-porous, particulate restricting, metal material such as a
plurality of layers of a wire mesh that may be diffusion bonded or sintered together to form a
fluid porous wire mesh screen. Expandable sand screen 158, includes inner and outer tubulars
that protect the filter media. As shown, expandable sand screen 158 has an open section 160
where the screen has been worn through or damaged, which allows sand production into the
wellbore.
[0056] Referring additionally to figure 9, therein is depicted a side view of sand control screen
assembly 150 in an extended position. Specifically, the swellable material 154 has expanded
such that the outer surface 156 of swellable material 154 contacts the inner surface of sand
screen 158. This expansion has occurred in response to swellable material 154 contacting an
activation fluid such as a hydrocarbon fluid as described herein. As shown, the open section
160 of expandable sand screen 158 is now isolated such that sand production through open
section 160 is now prevented and the failed section of expandable sand screen 158 is repaired.
As such, in embodiments in which swellable material 154 is not permeable, sand control screen
assembly 150 may be placed down hole as a patch inside the damaged sand screen 158.
Alternatively, in embodiments in which swellable material 154 is fluid permeable but particulate
resistant, production fluid may pass through swellable material 154 and openings 168 of base
pipe 152 into interior flow path 166.
[0057] Referring to figures 10-11, therein is depicted a side view of a sand control screen
assembly 180 in an unextended and an extended position, respectively. In the illustrated
embodiment, sand control screen assembly 180 is positioned in a cased wellbore adjacent to
formation 190. Casing 192 has previously been perforated as indicated at 196 which created a
plurality of openings 194 through casing 192. Sand control screen assembly 180 includes a
concentric layer of swellable material 184 that circumferentially surrounds the base pipe 182.
Base pipe 182 includes a plurality of openings 198 and defines an interior flow path 200. As
seen in figure 11, the swellable material 184 has expanded such that the outer surface 186 of
swellable material 184 contact the inner surface of casing 192. This expansion has occurred in
response to swellable material 184 contacting an activation fluid such as a hydrocarbon fluid as
described herein. In the illustrated embodiment, the swellable material 184 may serve as a
packer to prevent fluid production and particulate production from the interval associated with
casing 192. Alternatively, swellable material 184 may be fluid permeable and particulate
resistant such that production fluid may pass through swellable material 184 and openings 198
of base pipe 182 into interior flow path 200.
[0058] The above described swellable materials such as swellable materials 46, 112, 154, 184
are materials that swells when contacted by an activation fluid, such as an inorganic or organic
fluid. In one embodiment, the swellable material is a material that swells upon contact with
and/or absorption of a hydrocarbon, such as oil. The hydrocarbon is absorbed into the swellable
material such that the volume of the swellable material increases creating a radial expansion of
the swellable material when positioned around a base pipe which creates a radially outward
directed force that may operate to radially extend telescoping perforations as described above.
Preferably, the swellable material will swell until its outer surface contacts the formation face in
an open hole completion or the casing wall in a cased wellbore. The swellable material
accordingly provides the energy to extend the telescoping perforations to the surface of the
formation.
[0059] Some exemplary swellable materials include elastic polymers, such as EPDM rubber,
styrene butadiene, natural rubber, ethylene propylene monomer rubber, ethylene propylene
diene monomer rubber, ethylene vinyl acetate rubber, hydrogenized acrylonitrile butadiene
rubber, acrylonitrile butadiene rubber, isoprene rubber, chloroprene rubber and polynorbomene.
These and other swellable materials swells in contact with and by absorption of hydrocarbons so
that the swellable materials expands. In one embodiment, the rubber of the swellable materials
may also have other materials dissolved in or in mechanical mixture therewith, such as fibers of
cellulose. Additional options may be rubber in mechanical mixture with polyvinyl chloride,
methyl methacrylate, acrylonitrile, ethylacetate or other polymers that expand in contact with
oil.
[0060] In some embodiments, the swellable materials may be permeable to certain fluids but
prevent particulate movement therethrough due to the porosity within the swellable materials.
For example, the swellable material may have a pore size that is sufficiently small to prevent the
passage of the sand therethrough but sufficiently large to allow hydrocarbon fluid production
therethrough. For example, the swellable material may have a pore size of less than 1 mm.
[0061] Referring to figure 12, therein is depicted a side view of a sand control screen assembly
220 in an expanded configuration. Sand control screen assembly 220 includes a base pipe 222
that has a plurality of openings 224 and defines an interior flow path 226. Positioned
concentrically around base pipe 222 is a filter medium 228. Filter medium 228 is depicted as a
fluid-porous, particulate restricting, metal material such as a plurality of layers of a wire mesh
that may be diffusion bonded or sintered together to form a fluid porous wire mesh screen.
Those skilled in the art will understand that other types of filter media could alternatively be
used in sand control screen assembly 220 such as a wire wrap screen, a sand packed screen or
the like. Sand control screen assembly 220 also includes a layer of swellable material 230 that
circumferentially surrounds filter medium 228. Collectively, filter medium 228 and swellable
material 230 may be referred to as a swellable filter media.
[0062] In a manner similar to that described above, sand control screen assembly 220 is run
downhole with swellable material 230 in its unexpanded configuration. As seen in figure 12, the
swellable material 230 has expanded such that the outer surface 232 of swellable material 230
contacts the surface of the open hole wellbore 234. This expansion has occurred due to
swellable material 230 contacting an activation fluid such as a hydrocarbon fluid as described
herein, hi the illustrated embodiment, the swellable material 230 is permeable to fluids and, in
some embodiments, permeable to certain particulate materials which are prevented from
entering the interior flow path 226 of base pipe 222 by filter media 228.
[0063] Referring to figure 13, therein is depicted a side view of a sand control screen assembly
240 in an expanded configuration. Sand control screen assembly 240 includes a base pipe 242
that has a plurality of openings 244 and defines an interior flow path 246. Positioned
concentrically around base pipe 242 is a layer of swellable material 248. Positioned
concentrically around swellable material 248 is a filter medium 250. Filter medium 2S0 is
depicted as a fluid-porous, particulate restricting, metal material such as a plurality of layers of a
wire mesh that may be diffusion bonded or sintered together to form a fluid porous wire mesh
screen. Those skilled in the art will understand mat other types of filter media could
alternatively be used in sand control screen assembly 220 such as a wire wrap screen, sand
packed screen or the like. Sand control screen assembly 240 also includes a layer of swellable
material 252 that circumferentially surrounds filter medium 250. Swellable material 248
includes a plurality of perforations 254 and swellable material 252 includes a plurality of
perforations 256. Collectively, filter medium 250 and swellable materials 248, 252 may be
referred to as a swellable filter media.
[0064] In a manner similar to that described above, sand control screen assembly 240 is run
downhole with swellable materials 248, 252 in their unexpanded configuration. As seen in
figure 13, swellable materials 248, 252 have expanded such that the outer surface 258 of
swellable material 252 contacts the surface of the open hole wellbore 260. This expansion has
occurred due to swellable materials 248, 252 contacting an activation fluid such as a
hydrocarbon fluid as described herein.
[0065] In addition to the aforementioned aspects and embodiments of the present sand control
screen assemblies, the present invention further includes methods for making a sand control
screen assembly. Figure 14 illustrates an embodiment 320 of an exemplary process for making
a sand control screen assembly. In step 322, a base pipe is provided of a desired length for use
in a desired application. In step 324, a coating of swellable material is disposed on the exterior
of the base pipe. This step may include any type of application process appropriate for the
swellable materials disclosed herein, including: dipping, spraying, wrapping, applying and the
like. Generally, the swellable material is applied in a desired length on the base pipe according
to the desired application in the wellbore. Also, the location of the swellable material on the
base pipe may be determined by where the base pipe will be in the wellbore in relation to the
production areas.
[0066] In step 326, openings are created in the swellable material. This step may be performed
by removing those portions of the swellable material by drilling, cutting and the like. In this
step, corresponding portions of the base pipe may also be removed to create holes in the base
pipe using the same or a different drilling or cutting process.
[0067] In step 328, the holes in the base pipe may be tapped or threaded for acceptance of the
telescoping perforations. In step 330, the telescoping perforations, including face plates, are
installed through the removed portions of the swellable material and threaded into the tapped
holes of the base pipe to complete the sand control screen assembly.
[0068] Figure IS illustrates an embodiment 340 of an exemplary process for controlling sand
and hydrocarbon production from a production interval. In step 342, a wellbore is drilled such
that is traverses a subterranean hydrocarbon bearing formation. This step may include placing
various casings or liners in the wellbore and performing various other well construction
activities prior to insertion of the work string including one or more sand control screen
assemblies of the present invention. In step 344, one or more sand control screen assemblies are
inserted into the wellbore and the sand control screen assemblies are positioned adjacent to their
respective production intervals. In this step, the sand control screen assemblies are preferably
run into a hole with a smooth inner bore and smooth outer bore to minimize the risk of getting
stuck.
[0069] In step 346, an activating fluid, such as a hydrocarbon, contacts the sand control screen
assemblies and they expand, extend and/or swell radially outwards to come in contact with the
surface of the formation of the wellbore. In those embodiments including telescoping
perforations, steps 348 and 350 involve radially expanding the swellable material of the sand
control screen assemblies which creates a outward radial force on the face plates such that
telescoping perforations radially extend.
[0070] At this point, the wellbore is highly suitable for post treatment stimulation as there are no
restrictions inside the wellbore. Further, it is not necessary to pump gravel or cement to achieve
effective zone isolation and sand control. As described above, this process may further include
incorporating blank packers, including swell packers, in the work string to further isolate desired
sections of the wellbore making it possible to complete long, heterogeneous intervals.
[0071] The available flow area can be regulated by the density and size of the telescoping
perforations used. In any of the steps above, packers may be set up to run control lines or fiber
optics. Thus, it may be further configured to include fiber optics for continuous temperature and
pressure monitoring as well as other control lines to perform smart well functions.
[0072] While this invention has been described with reference to illustrative embodiments, this
description is not intended to be construed in a limiting sense. Various modifications and
combinations of the illustrative embodiments as well as other embodiments of the invention,
will be apparent to persons skilled in the art upon reference to the description. It is, therefore,
intended that the appended claims encompass any such modifications or embodiments.
WE CLAIM:
1. A sand control screen assembly comprising:
a base pipe having at least one opening in a sidewall portion thereof;
a swellable material layer disposed exteriorly of the base pipe and having at least one
opening corresponding to the at least one opening of the base pipe;
a telescoping perforation operably associated with the at least one opening of the base pipe
and at least partially disposed within the at least one opening of the swellable material layer; and
a filter medium disposed within the telescoping perforation, the filter medium recessed
radially inwardly from a distal end of the telescoping perforation;
wherein, in response to contact with an activating fluid, radial expansion of the swellable
material layer causes the telescoping perforation to radially outwardly extend.
2. The sand control screen assembly as recited in claim 1 wherein the telescoping
perforation is a telescoping tubular perforation.
3. The sand control screen assembly as recited in claim 1 wherein the activating fluid is at
least one of a hydrocarbon fluid and water.
4. The sand control screen assembly as recited in claim 1 wherein the swellable material is
selected from the group consisting of elastic polymers, EPDM rubber, styrene butadiene, natural
rubber, ethylene propylene monomer rubber, ethylene propylene diene monomer rubber, ethylene
vinyl acetate rubber, hydrogenized acrylonitrile-butadiene rubber, acrylonitrile butadiene rubber,
isoprene rubber, chloroprene rubber and polynorbornene.
5. A sand control screen assembly comprising:
a base pipe having a plurality of circumferentially and longitudinally distributed openings in
a sidewall portion thereof and defining an internal flow path;
a swellable material layer disposed exteriorly of the base pipe and having a plurality of
openings that correspond to the openings of the base pipe;
a plurality of circumferentially and longitudinally distributed telescoping perforations, each
of the telescoping perforations operably associated with one of the openings of the base pipe and at
least partially disposed within the corresponding opening of the swellable material layer, the
telescoping perforations providing fluid flow paths between a fluid source disposed exteriorly of the
base pipe and the interior flow path; and
a filter medium disposed within each of the telescoping perforations;
wherein, in response to contact with an activating fluid, radial expansion of the swellable
material layer causes the telescoping perforations to radially outwardly extend.
6. The sand control screen assembly as recited in claim 5 wherein the activating fluid is at
least one of a hydrocarbon fluid and water.
7. The sand control screen assembly as recited in claim 5 wherein the filter medium is
recessed radially inwardly from the distal end of the telescoping perforation.
8. The sand control screen assembly as recited in claim 5 wherein the swellable material is
selected from the group consisting of elastic polymers, EPDM rubber, styrene butadiene, natural
rubber, ethylene propylene monomer rubber, ethylene propylene diene monomer rubber, ethylene
vinyl acetate rubber, hydrogenized acrylonitrile-butadiene rubber, acrylonitrile butadiene rubber,
isoprene rubber, chloroprene rubber and polynorbornene.
9. A method for making a sand control screen assembly comprising:
providing a base pipe having an interior flow path;
disposing a swellable material layer on the exterior of the base pipe;
forming corresponding openings in the base pipe and the swellable material layer; and
operably associating a plurality of circumferentially and longitudinally distributed
telescoping perforations having filter media with the openings of the base pipe and at least partially
disposing the telescoping perforations within the corresponding openings of the swellable material
layer such that upon radial expansion of the swellable material layer, the telescoping perforations
are radially outwardly extendable.
10. The method as recited in claim 9 wherein the step of forming corresponding openings in
the base pipe and the swellable material layer further comprises forming the openings after the
swellable material layer is disposed on the exterior of the base pipe.
11. A method of installing a sand control screen assembly in a subterranean well
comprising:
running the sand control screen assembly to a target location within the subterranean well;
contacting a swellable material layer disposed exteriorly on a base pipe with an activating
fluid, the swellable material layer and the base pipe having corresponding openings;
radially expanding the swellable material layer in response to contact with the activating
fluid; and
radially outwardly extending circumferentially and longitudinally distributed telescoping
perforations having filter media that are operably associated with the openings of the base pipe and
at least partially disposed within the corresponding openings of the swellable material layer, in
response to the radial expansion of the swellable material layer.
12. The method as recited in claim 11 wherein the step of contacting a swellable material
layer with an activating fluid further comprises contacting the swellable material layer with at least
one of a hydrocarbon fluid and water.

A sand control screen assembly (40) includes a base pipe (44) having a plurality of openings (45) in a sidewall
portion thereof and a swellable material layer (46) disposed exteriorly of the base pipe (44) and having a plurality of openings (47)
that correspond to the openings (45) of the base pipe (44). A plurality of telescoping perforations (48) are operably associated with
the openings (45) of the base pipe (44) and at least partially disposed within the corresponding openings (47) of the swellable material
layer (46). A filter medium (56) is disposed within each of the telescoping perforations (48). In operation, radial expansion of the
swellable material layer (46), in response to contact with an activating fluid, causes the telescoping perforations (48) to radially
outwardly extend.