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 subterranean formation and, in particular, to a sand control screen assembly having a
swellable material layer that is operable to radially expand downhole in response to contact
with an activating fluid.
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,
flow control devices and safety devices. 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 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, 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 extended or deviated wellbores including
wellbores having long, 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 dehydrate and 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 production interval.
[0007] In addition, it has been found that gravel packing is not feasible in certain open hole
completions. Attempts have been made to use expandable metal sand control screens in such
open hole completions. These expandable metal sand control screens are typically installed
in the wellbore then radially expanded using a hydraulic swage or cone that passes through
the interior of the screen or other metal forming techniques. In addition to filtering
particulate materials out of the formation fluids, one benefit of these expandable sand control
screens is the radial support they provide to the formation which helps prevent formation
collapse. It has been found, however, that conventional expandable sand control screens do
not contact 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,
which has resulted in incomplete contact between the expandable sand control screens and
the wellbore. In addition, with certain conventional expandable sand control screens, the
threaded connections are not expandable which creates a very complex profile, at least a
portion of which does not contact the wellbore. Further, when conventional expandable sand
control screens are expanded, the radial strength of the expanded screens is drastically
reduced resulting in little, if any, radial support to the borehole.
[0008] 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 interventionlessly 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 long,
horizontal, open hole completions.
SUMMARY OF THE INVENTION
[0009] 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 or operates as an injection well. 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 interventionlessly provides radial support to the formation without the need for
expanding metal tubulars. Further, the sand control screen assembly of the present invention
is suitable for operation in open hole completions in long, horizontal production intervals.
[0010] In one aspect, the present invention is directed to a sand control screen assembly that
is operable to be positioned within a wellbore. The sand control screen assembly includes a
base pipe having at least one opening in a sidewall portion thereof and an internal flow path.
A swellable material layer is disposed exteriorly of at least a portion of the base pipe. A fluid
collection subassembly is disposed exteriorly of the swellable material layer and is in fluid
communication with the internal flow path via the opening. A filter medium is operably
associated with the sand control screen assembly and is disposed in a fluid path between the
exterior of the sand control screen assembly and the internal flow path. In response to
contact with an activating fluid, such as a hydrocarbon fluid, water and gas, radial expansion
of the swellable material layer causes at least a portion of the fluid collection subassembly to
be displaced toward a surface of the wellbore and preferably in close proximity to or contact
with the wellbore.
[0011] In one embodiment, the swellable material layer is disposed exteriorly of a blank pipe
section of the base pipe. In another embodiment, the swellable material layer is disposed
exteriorly of a perforated section of the base pipe. In certain embodiments, the fluid
collection subassembly includes a plurality of circumferentially distributed perforated
tubulars. In such embodiment, fluid discharged from the perforated tubulars may be received
in a chamber prior to entering the internal flow path. In other embodiments, the fluid
collection subassembly may include a plurality of fluid inlets such as telescoping fluid inlets,
flexible fluid inlets and the like.
[0012] In one embodiment, the filter medium is disposed external to the fluid collection
subassembly. In another embodiment, the filter medium is disposed internal to the fluid
collection subassembly. In a further embodiment, the filter medium is disposed downstream
of the fluid collection subassembly. The filter medium may be a single layer mesh screen, a
multiple layer mesh screen, a wire wrapped screen, a prepack screen, a ceramic screen, a
fluid porous, particulate resistant sintered wire mesh screen, a fluid porous, particulate
resistant diffusion bonded wire mesh screen or the like. In certain embodiments, a screen
element may be disposed external to the fluid collection subassembly and the swellable
material layer.
[0013] In another aspect, the present invention is directed to a sand control screen assembly
that is operable to be positioned within a wellbore. The sand control screen assembly
includes a base pipe having a perforated section, a blank pipe section and an internal flow
path. A swellable material layer is disposed exteriorly of the blank pipe section of the base
pipe. A fluid collection subassembly is disposed exteriorly of the swellable material layer
and is in fluid communication with the internal flow path. A filter medium is disposed
exteriorly of the perforated section of the base pipe. In response to contact with an activating
fluid, radial expansion of the swellable material layer causes at least a portion of the fluid
collection subassembly to be displaced toward a surface of the wellbore.
[0014] In a further aspect, the present invention is directed to method of installing a sand
control screen assembly in a wellbore. The method includes running the sand control screen
assembly to a target location within the wellbore, the sand control screen assembly having a
fluid collection subassembly disposed exteriorly of a swellable material layer that is disposed
exteriorly of at least a portion of a base pipe, contacting the swellable material layer with an
activating fluid, radially expanding the swellable material layer in response to contact with
the activating fluid and displacing at least a portion of the fluid collection subassembly
toward a surface of the wellbore in response to the radial expansion of the swellable material
layer.
[0015] In yet another aspect, the present invention is directed to a downhole tool that is
operably positionable within a wellbore. The downhole tool includes a tubular member
having an internal flow path. A swellable material layer is disposed exteriorly of at least a
portion of the tubular member. A sensor is disposed exteriorly of the swellable material
layer. In response to contact with an activating fluid, radial expansion of the swellable
material layer causes the sensor to be displaced toward a surface of the wellbore and
preferably in close proximity to or contact with the wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] 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:
[0017] Figure 1A is a schematic illustration of a well system operating a plurality of sand
control screen assemblies in their running configuration according to an embodiment of the
present invention;
[0018] Figure 1B is a schematic illustration of a well system operating a plurality of sand
control screen assemblies in their operating configuration according to an embodiment of the
present invention;
[0019] Figure 2A is a cross sectional view taken along line 2A-2A of a sand control screen
assembly of figure 1A in a running configuration according to an embodiment of the present
invention;
[0020] Figure 2B is a cross sectional view taken along line 2B-2B of a sand control screen
assembly of figure 1B in an operating configuration according to an embodiment of the
present invention;
[0021] Figure 3 is a side view partially in quarter section of a sand control screen assembly
according to an embodiment of the present invention;
[0022] Figure 4A is a cross sectional view of a sand control screen assembly in a running
configuration according to an embodiment of the present invention;
[0023] Figure 4B is a cross sectional view of a sand control screen assembly in an operating
configuration according to an embodiment of the present invention;
[0024] Figure 5 is a side view partially in quarter section of a sand control screen assembly
according to an embodiment of the present invention;
[0025] Figure 6 is a side view partially in quarter section and partially in half section of a
sand control screen assembly according to an embodiment of the present invention;
[0026] Figure 7 is a side view partially in quarter section of a sand control screen assembly
according to an embodiment of the present invention;
[0027] Figure 8A is a cross sectional view of a sand control screen assembly in a running
configuration according to an embodiment of the present invention;
[0028] Figure 8B is a cross sectional view of a sand control screen assembly in an operating
configuration according to an embodiment of the present invention;
[0029] Figure 9A is a cross sectional view of a sand control screen assembly according to an
embodiment of the present invention;
[0030] Figure 9B is a cross sectional view of a sand control screen assembly according to an
embodiment of the present invention;
[0031] Figure 9C is a cross sectional view of a sand control screen assembly according to an
embodiment of the present invention;
[0032] Figure 10A is a cross sectional view of a sand control screen assembly in a running
configuration according to an embodiment of the present invention;
[0033] Figure 10B is a cross sectional view of a sand control screen assembly in an operating
configuration according to an embodiment of the present invention;
[0034] Figure 11 is a cross sectional view of a sand control screen assembly according to an
embodiment of the present invention;
[0035] Figure 12 is a cross sectional view of a sand control screen assembly according to an
embodiment of the present invention;
[0036] Figure 13A is a side view of a sand control screen assembly in a running
configuration according to an embodiment of the present invention;
[0037] Figure 13B is a side view of a sand control screen assembly in an operating
configuration according to an embodiment of the present invention;
[0038] Figure 14A is a cross sectional view taken along line 14A-14A of a sand control
screen assembly of figure 13 A in a running configuration according to an embodiment of the
present invention;
[0039] Figure 14B is a cross sectional view taken along line 14B-14B of a sand control
screen assembly of figure 13B in an operating configuration according to an embodiment of
the present invention;
[0040] Figure 15A is a quarter sectional view of a sand control screen assembly in a running
configuration according to an embodiment of the present invention;
[0041] Figure 15B is a quarter sectional view of a sand control screen assembly in an
operating configuration according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0042] 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.
[0043] 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 is
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 that is cemented
within wellbore 12. 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.
[0044] 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 running or unextended
configuration.
[0045] Referring also to figure 1B, therein is depicted the well system of figure 1A with sand
control screen assemblies 24 in their operating or radially expanded configuration. As
explained in greater detail below, each of the depicted sand control screen assemblies 24 has
a base pipe, a fluid collection subassembly, a filter medium and a swellable material layer. In
general, the swellable material layer is disposed exteriorly around the circumference of a
blank pipe section of the base pipe and the fluid collection subassembly is disposed exteriorly
of the swellable material layer. The filter medium may be disposed externally of the fluid
collection subassembly, internally of the fluid collection subassembly, downstream of the
fluid collection subassembly or any combination thereof. In this configuration, when sand
control screen assemblies 24 come in contact with an activating fluid, such as a hydrocarbon
fluid, water or a gas, the swellable material layer of each sand control screen assembly 24
radially expands which in turn causes the fluid collection subassembly of each sand control
screen assemblies 24 to contact the surface of wellbore 12.
[0046] Even though figures 1A-1B, depict tubing string 22 as including only sand control
screen assemblies 24, those skilled in the art will recognize that tubing string 22 may include
any number of other tools and systems such as fluid flow control devices, communication
systems, safety systems and the like. Also, tubing string 22 may be divided into a plurality of
intervals using zonal isolation devices such as packers. Similar to the swellable material in
sand control screen assemblies 24, these zonal isolation devices may be made from materials
that swell upon contact with a fluid, such as an inorganic or organic fluid. Some exemplary
fluids that may cause the zonal isolation devices to swell and isolate include water, gas and
hydrocarbons.
[0047] In addition, even though figures 1A-1B 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.
Likewise, even though figures 1A-1B depict the sand control screen assemblies of the
present invention in a wellbore having a single borehole, 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 multilateral wellbores having a main wellbore and a plurality of branch
wellbores.
[0048] Referring to figure 2A, therein is depicted a cross sectional view of a sand control
screen assembly in its running configuration that embodies principles of the present invention
and is generally designated 40. Sand control screen assembly 40 includes base pipe 42 that
defines an internal flow path 44. Base pipe 42 has a plurality of openings (not pictured in this
cross section) that allow fluid to pass between the exterior of base pipe 42 and internal flow
path 44. Positioned around base pipe 42 is a swellable material layer 46. Swellable material
layer 46 is attached to base pipe 42 by bonding or other suitable technique. Preferably, the
thickness of swellable material layer 46 is optimized based upon the diameter of sand control
screen assembly 40 and the diameter of wellbore 48 such that upon expansion, as explained
in greater detail below, substantially uniform contact between both swellable material layer
46 and a fluid collection subassembly 50 with the surface of wellbore 48 is achieved.
[0049] In the illustrated embodiment and as best seen in figure 3, fluid collection
subassembly 50 includes a plurality of perforated tubulars 52. Preferably, perforated tubulars
52 are circumferentially distributed about the portion of sand control screen assembly 40 that
includes swellable material layer 46. In operation, production fluids enter fluid collection
subassembly 50 via openings 54 of perforated tubulars 52 and are discharged into annular
region 56 between base pipe 42 and outer housing 58. Even though perforated tubulars 52
have been depicted as having a circular cross section, it should be understood by those skilled
in the art that perforated tubulars 52 could alternatively have cross sections of different
shapes including ovals, triangles, rectangles and the like as well as non symmetric cross
sections.
[0050] Base pipe 42 includes a plurality of openings 60 that allow production fluids to enter
internal flow path 44. Disposed around this portion of base pipe 42 and within annular region
56 is a filter medium 62. Filter medium 62 may comprise a mechanical screening element
such as a fluid-porous, particulate restricting, metal screen having one or more layers of
woven wire or fiber mesh that may be diffusion bonded or sintered together to form a screen
designed to allow fluid flow therethrough but prevent the flow of particulate materials of a
predetermined size from passing therethrough. In the illustrated embodiment, filter medium
62 includes outer and inner drainage layers 64, 66 that have a relatively course wire mesh
with a filtration layer 68 disposed therebetween having a relatively fine mesh. It should be
noted that other types of filter media may be used with the sand control screen assemblies of
the present invention, such as a wire wrapped screen, a prepack screen, a ceramic screen,
metallic beads such as stainless steel beads or sintered stainless steel beads and the like.
Filter medium 62 is sized according to the particular requirements of the production zone into
which it will be installed. Some exemplary sizes of the gaps in filter medium 62 may be in
the 20-250 standard mesh range.
[0051] Referring additionally now to figure 2B, therein is depicted a cross sectional view of
sand control screen assembly 40 in its operating configuration. In the illustrated
embodiment, swellable material layer 46 has come in contact with an activating fluid, such as
a hydrocarbon fluid, water or gas, which has caused swellable material layer 46 to radially
expand into contact with the surface of wellbore 48, which, in the illustrated embodiment, is
the formation face. In addition, the radial expansion of swellable material layer 46 has
caused perforated tubulars 52 of fluid collection subassembly 50 to come into contact with
the surface of wellbore 48. One benefit provided by the sand control screen assemblies of the
present invention is that in addition to providing a path for formation fluids to enter internal
flow path 44 and filtering particulate materials out of the formation fluids, the sand control
screen assemblies of the present invention also provide support to the formation to prevent
formation collapse. Compared with convention expandable metal sand control screens as
discussed above, the sand control screen assemblies of the present invention provide
improved contact with the formation as greater radial expansion is achievable and the
swellable material layer is more compliant such that it is better able to conform to a
nonuniform wellbore face. In a preferred implementation, the sand control screen assemblies
of the present invention provide between about 500 psi and 2000 psi of collapse support to
the wellbore. Those skilled in the art will recognize that the collapse support provided by the
present invention can be optimized for a particular implementation though specific design
features of the base pipe, the swellable material layer and the fluid collection subassembly.
[0052] Various techniques may be used for contacting swellable material layer 46 with an
appropriate activating fluid for causing swelling of swellable material layer 46. For example,
the activating fluid may already be present in the well when sand control screen assembly 40
is installed in the well, in which case swellable material layer 46 preferably includes a
mechanism for delaying the swelling of swellable material layer 46 such as an absorption
delaying or preventing coating or membrane, swelling delayed material compositions or the
like.
[0053] Alternatively, the activating fluid may be circulated through the well to swellable
material layer 46 after sand control screen assembly 40 is installed in the well. As another
alternative, the activating fluid may be produced into the wellbore from the formation
surrounding the wellbore. Thus, it will be appreciated that any method may be used for
causing swelling of swellable material layer 46 of sand control screen assembly 40 in keeping
with the principles of the invention.
[0054] Swellable material layer 46 is formed from one or more materials that swell when
contacted by an activation fluid, such as an inorganic or organic fluid. For example, the
material may be a polymer that swells multiple times its initial size upon activation by an
activation fluid that stimulates the material to expand. In one embodiment, the swellable
material is a material that swells upon contact with and/or absorption of a hydrocarbon, such
as an oil or a gas. The hydrocarbon is absorbed into the swellable material such that the
volume of the swellable material increases, creating radial expansion of the swellable
material. Preferably, the swellable material will swell until its outer surface and perforated
tubulars 52 of fluid collection subassembly 50 contact the formation face in an open hole
completion or the casing wall in a cased wellbore. The swellable material accordingly
provides the energy to position perforated tubulars 52 of fluid collection subassembly 50 in
contact with the formation.
[0055] 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
polynorbornene. These and other swellable materials swell in contact with and by absorption
of hydrocarbons so that the swellable materials expand. 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.
[0056] In another embodiment, the swellable material is a material that swells upon contact
with water. In this case, the swellable material may be a water-swellable polymer such as a
water-swellable elastomer or water-swellable rubber. More specifically, the swellable
material may be a water-swellable hydrophobic polymer or water-swellable hydrophobic
copolymer and preferably a water-swellable hydrophobic porous copolymer. Other polymers
useful in accordance with the present invention can be prepared from a variety of hydrophilic
monomers and hydrophobically modified hydrophilic monomers. Examples of particularly
suitable hydrophilic monomers which can be utilized include, but are not limited to,
acrylamide, 2-acrylamido-2-methyl propane sulfonic acid, N,N-dimethylacrylamide, vinyl
pyrrolidone, dimethylaminoethyl methacrylate, acrylic acid, trimethylammoniumethyl
methacrylate chloride, dimethylarninopropylmethacrylamide, methacrylamide and
hydroxyethyl acrylate.
[0057] A variety of hydrophobically modified hydrophilic monomers can also be utilized to
form the polymers useful in accordance with this invention. Particularly suitable
hydrophobically modified hydrophilic monomers include, but are not limited to, alkyl
acrylates, alkyl methacrylates, alkyl acrylamides and alkyl methacrylamides wherein the
alkyl radicals have from about 4 to about 22 carbon atoms, alkyl dimethylammoniumethyl
methacrylate bromide, alkyl dimethylammoniumethyl methacrylate chloride and alkyl
dimethylammoniumethyl methacrylate iodide wherein the alkyl radicals have from about 4 to
about 22 carbon atoms and alkyl dimethylammonium-propylmethacrylamide bromide, alkyl
dimethylammonium propylmethacrylamide chloride and alkyl dimethylammonium-
propylmethacrylamide iodide wherein the alkyl groups have from about 4 to about 22 carbon
atoms.
[0058] Polymers which are useful in accordance with the present invention can be prepared
by polymerizing any one or more of the described hydrophilic monomers with any one or
more of the described hydrophobically modified hydrophilic monomers. The polymerization
reaction can be performed in various ways that are known to those skilled in the art, such as
those described in United States Patent Number 6,476,169 which is hereby incorporated by
reference for all purposes.
[0059] Suitable polymers may have estimated molecular weights in the range of from about
100,000 to about 10,000,000 and preferably in the range of from about 250,000 to about
3,000,000 and may have mole ratios of the hydrophilic monomer(s) to the hydrophobically
modified hydrophilic monomer(s) in the range of from about 99.98:0.02 to about 90:10.
[0060] Other polymers useful in accordance with the present invention include
hydrophobically modified polymers, hydrophobically modified water-soluble polymers and
hydrophobically modified copolymers thereof. Particularly suitable hydrophobically
modified polymers include, but are not limited to, hydrophobically modified
polydimethylaminoethyl methacrylate, hydrophobically modified polyacrylamide and
hydrophobically modified copolymers of dimethylaminoethyl methacrylate and vinyl
pyrollidone.
[0061] As another example, the swellable material may be a salt polymer such as
polyacrylamide or modified crosslinked poly(meth)acrylate that has the tendency to attract
water from salt water through osmosis wherein water flows from an area of low salt
concentration, the formation water, to an area of high salt concentration, the salt polymer,
across a semi permeable membrane, the interface between the polymer and the production
fluids, that allows water molecules to pass therethrough but prevents the passage of dissolved
salts therethrough.
[0062] Referring to figure 4A, therein is depicted a cross sectional view of a sand control
screen assembly in its running configuration that embodies principles of the present invention
and is generally designated 70. Sand control screen assembly 70 is similar in design to sand
control screen 40 described above including a base pipe 72 that defines an internal flow path
74 and that includes a perforated longitudinal section and a blank pipe longitudinal section
which is depicted in the cross section of figure 4A. Positioned around base pipe 72 is a
swellable material layer 76. Swellable material layer 76 is attached to base pipe 72 by
bonding or other suitable technique. Positioned around swellable material layer 76 is a fluid
collection subassembly 78 that includes a plurality of perforated tubulars 80 that are
circumferentially distributed about swellable material layer 76 and operate substantially in
the manner described above with reference to fluid collection subassembly 50. Disposed
around both swellable material layer 76 and fluid collection subassembly 78 is a screen
element 82. Screen element 82 is attached to swellable material layer 76, base pipe 72 or
both by bonding or other suitable technique. Screen element 82 may be used in conjunction
with, in addition to or as an alternatively to other filter media such as filter medium 62
discussed above as well as the other types of filter media discussed herein including filter
media disposed external to, internal to or downstream of fluid collection subassembly 78. In
certain embodiments, screen element 82 may primarily serve as a drainage layer or a carrier
for a chemical treatment or other agent, as discussed in greater detail below.
[0063] In the illustrated embodiment, screen element 82 is formed from a plurality of
circumferential screen segments that overlap one another in the running configuration of sand
control screen assembly 70. Even though screen element 82 has been depicted as including
four segments, it should be understood by those skilled in the art that other numbers of
segments both greater than and less than four, including one segment, could alternatively be
used in keeping with the principles of the present invention.
[0064] Referring additionally now to figure 4B, therein is depicted a cross sectional view of
sand control screen assembly 70 in its operating configuration. In the illustrated
embodiment, swellable material layer 76 has come in contact with an activating fluid, such as
a hydrocarbon fluid, water or gas, which has caused swellable material layer 76 to radially
expand placing screen element 82 into contact with the surface of wellbore 84. In addition to
providing support to the formation to prevent formation collapse, in this embodiment, screen
element 82 provides a stand off region between perforated tubulars 80 and wellbore 84. The
use of this configuration is beneficial, for example, if a filter cake has previously formed on
the surface of the formation, then the stand off will prevent damage to perforated tubulars 80
and allow removal of the filter cake using acid or other reactive substance.
[0065] Preferably, screen element 82 has the reactive substance impregnated therein. For
example, the reactive substance may fill the voids in screen element 82 during installation.
Preferably, the reactive substance is degradable when exposed to a subterranean well
environment. More preferably, the reactive substance degrades when exposed to water at an
elevated temperature in a well. Most preferably, the reactive substance is provided as
described in United States Patent No. 7,036,587 which is hereby incorporated by reference
for all purposes.
[0066] In certain embodiments, the reactive substance includes a degradable polymer.
Suitable examples of degradable polymers that may be used in accordance with the present
invention include polysaccharides such as dextran or cellulose, chitins, chitosans, proteins,
aliphatic polyesters, poly(lactides), poly(glycolides), poly(e-caprolactones), poly(anhydrides),
poly(hydroxybutyrates), aliphatic polycarbonates, poly(orthoesters), poly(amino acids),
poly(ethylene oxides), and polyphosphazenes. Of these suitable polymers, aliphatic
polyesters such as poly(lactide) or poIy(lactic acid) and polyanhydrides are preferred.
[0067] The reactive substance may degrade in the presence of a hydrated organic or
inorganic compound solid, which may be included in sand control screen assembly 70, so that
a source of water is available in the well when the screens are installed. Alternatively,
another water source may be delivered to the reactive substance after sand control screen
assembly 70 is conveyed into the well, such as by circulating the water source down to the
well or formation water may be used as the water source.
[0068] Referring to figure 5, therein is depicted a sand control screen assembly in its running
configuration that embodies principles of the present invention and is generally designated
90. Sand control screen assembly 90 includes base pipe 92 that defines an internal flow path
94. Base pipe 92 has a plurality of openings 96 that allow fluid to pass to internal flow path
94 from an annular region 98 between base pipe 92 and outer housing 100. Positioned
around a blank pipe section of base pipe 92 is a swellable material layer 102. Swellable
material layer 102 is attached to base pipe 92 by bonding or other suitable technique.
Disposed around swellable material layer 102 a fluid collection subassembly 104 that
includes a plurality of perforated tubulars 106 that are circumferentially distributed about
swellable material layer 102 and operate substantially in the manner described above with
reference to fluid collection subassembly 104. In the illustrated embodiment, a filter medium
108 is positioned around each of the perforated tubulars 106. Filter medium 108 may include
a wire wrap or one or more layers of wire or fiber mesh having various drainage layers and
filtration layers as desired. This type of filter medium may be used in place of or in addition
to a filter medium such as filter medium 62 or screen element 82 discussed above.
Alternatively or additionally, filter materials could be placed inside of perforated tubulars
106. Such filter materials may include single or multiple layer sintered or unsintered mesh,
steel or ceramic balls or beads that may be sintered in perforated tubulars 106, prepacked or
resin coated sand, combinations of the above and the like.
[0069] In certain embodiments, it may be desirable to selectively allow and prevent flow
through a sand control screen assembly of the present invention such as sand control screen
assembly 90. In such embodiments, a valve or other flow control device may be placed in the
fluid flow path between the exterior of sand control screen assembly 90 and internal flow
path 94. For example, a sliding sleeve (not pictured) may be operably associated with base
pipe 92 and openings 96. The sliding sleeve may be disposed internally of base pipe 92
within internal flow path 94 or may preferably be disposed externally of base pipe 92 within
annular region 98. The sliding sleeve may have an open position wherein fluid flow through
openings 96 is allowed and a closed position wherein fluid flow though openings 96 is
prevented. In addition, the position of the sliding sleeve may be infinitely variable such that
the sliding sleeve may provide a choking function. The sliding sleeve may be operated
mechanically, electrically, hydraulically or by other suitable means.
[0070] Referring next to figure 6, therein is depicted a sand control screen assembly in its
running configuration that embodies principles of the present invention and is generally
designated 120. Sand control screen assembly 120 includes a fluid collection section 122,
sand control section 124, a fluid discriminator section 126, a flow restrictor section 128 and a
fluid inlet section 130. Sand control screen assembly 120 includes a base pipe 132 that
defines an internal flow path 134. In fluid collection section 122 of sand control screen
assembly 120 a swellable material layer 136 is disposed around a blank pipe section of base
pipe 132 and is attached thereto by bonding or other suitable technique. Disposed around
swellable material layer 136 a fluid collection subassembly 138 that includes a plurality of
perforated tubulars 140 that are circumferentially distributed about swellable material layer
136 and operate substantially in the manner described above with reference to fluid collection
subassembly 50. Sand control section 124 includes a filter medium 142 that is illustrated as a
multi-layer wire mesh filter medium including various drainage layers and filtration layers
disposed in series.
[0071] Fluid discriminator section 126 is configured in series with sand control section 124
such that fluid must pass through sand control section 124 prior to entering fluid
discriminator section 126. Fluid discriminator section 126 includes an outer housing 144 that
defines an annular chamber 146 with a nonperforated section of base pipe 132. Fluid
discriminator section 126 also includes retainer ring 148 that has a plurality of outlets 150
circumferentially spaced therein designed to provide a fluid passageway from chamber 146 to
flow restrictor section 128.
[0072] One or more flow blocking members 152, depicted as spherical members or balls are
disposed within chamber 146 between retainer ring 148 and filter medium 142, cooperate
with outlets 150 to restrict the flow of any undesired portion of the production fluids that
enter fluid discriminator section 126. For example, in the case of a production fluid
containing both oil and water, the density of members 152 is such that certain of the outlets
150 are blocked by certain of the members 152 to shut off or choke the flow of water
therethrough. Thus, when the production fluid is mainly oil, members 152 will be positioned
relatively distant from outlets 150, for example, at the bottom of chamber 146. When a
sufficient proportion of water is present in the production fluid, however, members 152 will
restrict flow of the water by shutting off or choking flow through certain ones of the outlets
150.
[0073] Flow restrictor section 128 is configured in series with fluid discriminator section 126
such that fluid must pass through fluid discriminator section 126 prior to entering flow
restrictor section 128. Flow restrictor section 128 includes an outer housing 154 that is
suitably coupled to or integral with outer housing 144 of fluid discriminator section 126.
Outer housing 154 defines an annular chamber 156 with a nonperforated section of base pipe
132. Disposed within chamber 156 is a flow rate controller 158. Flow rate controller 158
includes one or more tubular passageways 160 that provide a relative long, narrow and
tortuous pathway for the fluids to travel within flow restrictor section 128 and that provide a
more restrictive pathway than the unrestricted pathway through fluid discriminator section
126. As such, flow restrictor section 128 is operable to restrict the flow rate of the production
fluids through sand control screen assembly 120.
[0074] Once the production fluids pass through flow rate controller 158 of flow restrictor
section 128, they enter annular chamber 162 and eventually enter the interior flow path 134
of base pipe 132 via openings 164 which are depicted in the form of slots. Once inside base
pipe 132, the production fluids flow to the surface within the tubing string.
[0075] Fluid discriminator section 126 is operable in various flow regimes and with various
configurations of flow blocking members 152. For example, members 152 may have a single
density and be designed to block a single type of undesirable fluid such as water or gas in an
oil production operation, or may have two densities and be designed to block multiple types
of undesirable fluids such as water and gas in an oil production operation. Also, all of the
members intended to block a certain undesired fluid do not necessarily have the same density.
Instead, the members in each category could have a range of different densities so that the
members are neutrally buoyant in different densities of production fluids.
[0076] Even though figure 6 has described a particular embodiment of a fluid discriminator
section, other types of fluid discriminating mechanisms can be used in association with the
sand control screen assemblies of the present invention, such as those described in United
States Patent Number 7,185,706, and United States Application Publication Numbers US
2008-0041580 A1, US 2008-0041581 A1, US 2008-0041588 A1, and US 2008-0041582 A1,
each of which is hereby incorporated by reference for all purposes. Likewise, even though
figure 6 has described a particular embodiment of a flow restrictor section, other types of
flow restricting mechanisms can be used in association with the sand control screen
assemblies of the present invention, such as those described in United States Patent Numbers
5,803,179, 6,857,476, 6,886,634, 6,899,176, 7,055,598, 7,096,945, and 7,191,833, and United
States Application Publication Numbers US 2006-0042795 A1, US 2007-0039741 A1, US
2007-0246407 A1, US 2007-0246210 A1, and US 2007-0246213 Al, each of which is
hereby incorporated by reference for all purposes.
[0077] Referring to figure 7, therein is depicted a sand control screen assembly in its running
configuration that embodies principles of the present invention and is generally designated
170. Sand control screen assembly 170 includes base pipe 172 that defines an internal flow
path 174. Base pipe 172 has a plurality of openings 176 that allow fluid to enter internal flow
path 174 from an annular region 178 between base pipe 172 and outer housing 180.
Positioned around an imperforated portion of base pipe 172 is a swellable material layer 182.
Swellable material layer 182 is attached to base pipe 172 by bonding or other suitable
technique. Preferably, the thickness of swellable material layer 182 is optimized based upon
the diameter of sand control screen assembly 170 and the diameter of the wellbore such that
upon expansion, as described above, substantially uniform contact between both swellable
material layer 182 and a fluid collection subassembly 184 with the surface of the wellbore is
achieved.
[0078] Fluid collection subassembly 184 includes a plurality of perforated tubulars 186 that
operate substantially in a manner as described above with reference to fluid collection
subassembly 50. Preferably, perforated tubulars 186 are circumferentially distributed about
the portion of sand control screen assembly 170 that includes swellable material layer 182.
Disposed around the perforated portion of base pipe 172 and within annular region 178 is a
filter medium 188. Filter medium 188 may comprise any suitable mechanical screening
element or elements and is depicted as a multi-layer wire or fiber mesh screen designed to
allow fluid flow therethrough but prevent the flow of particulate materials of a predetermined
size from passing therethrough.
[0079] Fluid collection subassembly 184 of sand control screen assembly 170 also includes
instrumentation and communication systems that allow information relating to the adjacent
formation to be obtained and transmitted to the surface substantially in real time as desired.
As illustrated, one of the perforated tubular 186 has been replaced with an electronics
package 190 that includes one or more sensors. The sensors may be any one or more of the
following types of sensors, including pressure sensors, temperature sensors, piezoelectric
acoustic sensors, flow meters for determining flow rate, accelerometers, resistivity sensors for
determining water content, velocity sensors, weight sensors or any other sensor that measures
a fluid property or physical parameter downhole. As used herein, the term sensor shall
include any of these sensors as well as any other types of sensors that are used in downhole
environments and the equivalents to these sensors. For example, a fiber optic distributed
temperature sensor 192 is depicted as being wrapped around one of the perforated tubular
186. The sensors may include or be associated with a microprocessor to allow manipulation
and interpretation of the sensor data and for processing instructions. Likewise, the sensors
may be coupled to a memory which provides for storing information for later batch
processing or batch transmission, if desired. Importantly, this combination of components
provides for localized control and operation of other downhole components such as an
actuator which may be associated with a flow control device, a safety device or other
actuatable downhole device. Alternatively or additionally, the sensor data may be digitally
encoded and sent to the surface using electrical, optical, acoustic, electromagnetic or other
telemetry techniques.
[0080] Even though the sand control screen assemblies of the present have been described as
having a fluid collection assembly that channels fluids into a fluid collecting annular chamber
or manifold prior to entry into the internal flow path of the base pipe, those skilled in the art
will recognize that other types of fluid collection techniques could alternatively be used. For
example, as best seen in figure 8A, a sand control screen assembly in its running
configuration that embodies principles of the present invention and is generally designated
200 is depicted. Sand control screen assembly 200 includes base pipe 202 that defines an
internal flow path 204. Base pipe 202 has a plurality of openings 206. Positioned around
base pipe 202 is a swellable material layer 208. Swellable material layer 208 is attached to
base pipe 202 by bonding or other suitable technique. Sand control screen assembly 200
includes a fluid collection subassembly that is circumferentially distributed around swellable
material layer 208 at one or more longitudinal locations and is depicted as a plurality of
telescoping piston type fluid inlets 210. In the illustrated embodiment, each of the fluid inlets
210 including a tubular member 212 having a plurality of perforations 214. Proximate a
center point of tubular member 212 is a discharge tube 216 that extends radially inwardly
from tubular member 212 through an opening in swellable material layer 208 and opening
206 of base pipe 202. Fluid inlets 210 include a filter medium that is disposed within tubular
member 212, discharge tube 216 or both. The filter medium may be single or multiple layer
sintered or unsintered mesh, steel or ceramic balls or beads that may be sintered, prepacked
or resin coated sand, combinations of the above and the like.
[0081] In a manner similar to that described above, sand control screen assembly 200 is run
downhole with swellable material layer 208 in its unexpanded configuration. Upon contact
with the activation fluid, such as a hydrocarbon fluid, water or gas as described herein,
swellable material layer 208 is radially expanded, as best seen in figure 8B, such that the
outer surface of swellable material layer 208 and tubular members 212 of fluid inlets 210
contact the surface of the open hole wellbore 218. As shown, when swellable material layer
208 is radially expanded, fluid inlets 210 are radially outwardly shifted in a piston-like
manner. In addition to providing support to the formation to prevent formation collapse and
placing the entry points for formations fluids in contact with the formation, in this
embodiment, fluid inlets 210 provide a plurality of substantially direct paths for formation
fluids to enter internal flow path 204 of base pipe 202.
[0082] Even though the sand control screen assembly 200 has been described as having fluid
inlets 210 formed in the shape of a "T", those skilled in the art will recognize that other fluid
inlets having other shapes could alternatively be used and would be considered within the
scope of the present invention. For example, as best seen in figure 9 A, a sand control screen
assembly 220 that includes base pipe 222 and swellable material layer 224 has a plurality of
telescoping piston type fluid inlets 226 formed in the shape of an "L". Specifically, fluid
inlets 226 include a tubular member 228 having a plurality of perforations that are covered by
a suitable filter medium 230 and a discharge tube 232 that extends radially inwardly from
tubular member 228 through an opening in swellable material layer 224 and opening 234 of
base pipe 222. Likewise, as best seen in figure 9B, a sand control screen assembly 240 that
includes base pipe 242 and swellable material layer 244 has a plurality of telescoping piston
type fluid inlets 246 formed in the shape of a "U". Specifically, fluid inlets 246 include a
tubular member 248 having a plurality of perforations that are covered by a suitable filter
medium 250 and a pair of discharge tubes 252 that extend radially inwardly from tubular
member 248 through openings in swellable material layer 244 and a pair of opening 254 of
base pipe 242. Further, as best seen in figure 9C, a sand control screen assembly 260 that
includes base pipe 262 and swellable material layer 264 has a plurality of telescoping piston
type fluid inlets 266 formed in the shape of an "M". Specifically, fluid inlets 266 include a
tubular member 268 having a plurality of perforations that are covered by a pair of suitable
filter media 270 and three discharge tubes 272 that extends radially inwardly from tubular
member 268 through openings in swellable material layer 264 and openings 274 of base pipe
262. Accordingly, it can be seen that fluid inlets that provide one or more direct paths for
formation fluids to enter an internal flow path of a base pipe can take many shapes or
configurations, each of which are considered to be within the scope of the present invention.
[0083] Even though the sand control screen assemblies 200, 220, 240, 260 have been
described as having fluid inlets that radially outward shift in a piston-like manner, those
skilled in the art will recognize that other techniques may be used to radially extend fluid
inlets which would be considered within the scope of the present invention. For example, as
best seen in figure 10A, a sand control screen assembly 280 that includes base pipe 282 and
swellable material layer 284 has a plurality of flexible fluid inlets 286 formed in the shape of
an "L" in the running configuration. Fluid inlets 286 include a tubular member 288 having a
plurality of perforations 290 and a discharge tube 292 that extends radially inwardly from
tubular member 288 through an opening in swellable material layer 284 and opening 294 of
base pipe 282. A filter medium of a type discussed above may be disposed within tubular
member 288, discharge tube 292 or both. Fluid inlets 286 also include a pair flexible joints
296, 298 which enhance the ability of tubular member 288 to contact the wellbore 300 when
swellable material layer 284 is activated, as best seen in figure 10B.
[0084] Referring next to figure 11, therein is depicted a sand control screen assembly in its
running configuration that embodies principles of the present invention and is generally
designated 310. Sand control screen assembly 310 includes base pipe 312 that defines an
internal flow path 314. Base pipe 312 has a plurality of openings 316. Positioned around
base pipe 312 is a swellable material layer 318. Swellable material layer 318 is attached to
base pipe 312 by bonding or other suitable technique. Sand control screen assembly 310
includes a fluid collection subassembly that is circumferentially distributed around swellable
material layer 318 at one or more longitudinal locations and is depicted as a plurality of
telescoping piston type fluid inlets 320. In the illustrated embodiment, each of the fluid inlets
320 including a tubular member 322 having a plurality of perforations 324. Proximate a
center point of each tubular member 322 is a discharge tube 326 that extends radially
inwardly from tubular member 322 through an opening in swellable material layer 318 and
one of the openings 316 of base pipe 312. Fluid inlets 320 include a filter medium that is
disposed within tubular member 322, discharge tube 326 or both. The filter medium may be
any of the filter media discussed herein including a single or multiple layer sintered or
unsintered mesh, steel or ceramic balls or beads that may be sintered, prepacked or resin
coated sand, combinations of the above and the like.
[0085] Each fluid inlet 320 also includes a fluid flow control device 328 that is disposed
within discharge tube 326. Depending upon the desired operation, fluid flow control device
328 may take a variety of forms. For example, it may be desirable to temporarily prevent
fluid flow through fluid inlets 320. In this case, fluid flow control device 328 may be a
dissolvable, removable or shearable plug formed from sand, salt, wax, aluminum, zinc or the
like or may be a pressure activated device such as burst disk. As another example, it may be
desirable to prevent fluid loss into the formation during high pressure operations internal to
sand control screen assembly 310 in which case, fluid flow control device 328 may be a one-
way valve or a check valve. In a further example, it may be desirable to control the rate of
production into sand control screen assembly 310 in which case, fluid flow control device
328 may be an inflow control device such as a nozzle, a flow tube, an orifice or other flow
restrictor. As yet another example, it may be desirable to control the type of fluid entering
sand control screen assembly 310 in which case, fluid flow control device 328 may be a
production control device such as a valve that closes responsive to contact with an undesired
fluid, such as water. Such valves may be actuated by a swellable material including those
discussed above, organic fibers, an osmotic cell or the like.
[0086] Referring next to figure 12, therein is depicted a sand control screen assembly in its
running configuration that embodies principles of the present invention and is generally
designated 330. Sand control screen assembly 330 includes base pipe 332 and an inner
sleeve 334 that defines an internal flow path 336. Base pipe 332 has a plurality of openings
338. Positioned around base pipe 332 is a swellable material layer 340. Swellable material
layer 340 is attached to base pipe 332 by bonding or other suitable technique. Sand control
screen assembly 330 includes a fluid collection subassembly that is circumferentially
distributed around swellable material layer 340 at one or more longitudinal locations and is
depicted as a plurality of telescoping piston type fluid inlets 342. In the illustrated
embodiment, each of the fluid inlets 342 including a tubular member 344 having a plurality
of perforations 346. Proximate a center point of each tubular member 344 is a discharge tube
348 that extends radially inwardly from tubular member 344 through an opening in swellable
material layer 340 and one of the openings 338 of base pipe 332. Fluid inlets 342 include a
filter medium that is disposed within tubular member 344, discharge tube 348 or both. The
filter medium may be any of the filter media discussed herein including a single or multiple
layer sintered or unsintered mesh, steel or ceramic balls or beads that may be sintered,
prepacked or resin coated sand, combinations of the above and the like.
[0087] Disposed between base pipe 332 and sleeve 334 is a pair of fluid flow control devices
350, 352. As described above, depending upon the desired operation, fluid flow control
devices 350, 352 may take a variety of forms including in any combination of dissolvable,
removable or shearable plugs, a burst disk, a one-way valve, a check valve, a nozzle, a flow
tube, an orifice or other flow restrictor, a valve that closes responsive to contact with an
undesired fluid and the like. In certain embodiments, sleeve 334 is removable by mechanical
or chemical means such that the operation of fluid flow control devices 350, 352 can be
disabled if desired.
[0088] Referring to figure 13 A, therein is depicted a sand control screen assembly in its
running configuration that embodies principles of the present invention and is generally
designated 360. Sand control screen assembly 360 includes base pipe 362, as best seen in
figure 14A, that defines an internal flow path 364. Base pipe 362 has a plurality of openings
366 that allow fluid to pass between the exterior of base pipe 362 and internal flow path 364.
Positioned around base pipe 362 is a swellable material layer 368. Swellable material layer
368 is attached to base pipe 362 by bonding or other suitable technique. Swellable material
layer 368 has a plurality of openings 370 that allows fluid produced through screen sections
372 to enter internal flow path 364. Screen sections 372 may be formed from a variety of
filter media as discussed herein and are illustrated as having a plurality of layers of wire or
fiber mesh including drainage layers and filtration layers as well as a perforated outer shroud.
Preferably, the thickness of swellable material layer 368 is optimized based upon the
diameter of sand control screen assembly 360 and the diameter of wellbore 374 such that
upon expansion, as explained above, substantially uniform contact between both swellable
material layer 368 and screen sections 372 with the surface of wellbore 374 is achieved, as
best seen in figures 13B and 14B.
[0089] In addition to providing a path for formation fluids to enter internal flow path, sand
control screen assembly 360 provides support to formation to prevent formation collapse.
Specifically, the shape and configuration of screen sections 372 makes the outer surface of
sand control screen assembly 360 particularly compliant which improves the contact between
sand control screen assembly 360 and the formation upon radial expansion of swellable
material layer 368.
[0090] Referring to figure 15A, therein is depicted a sand control screen assembly in its
running configuration that embodies principles of the present invention and is generally
designated 380. Sand control screen assembly 380 includes a base pipe 382 that defines an
internal flow path 384 and a plurality of openings 386 that allow fluid to pass between the
exterior of base pipe 382 and internal flow path 384. Disposed around base pipe 382 is a
filter medium 388. As illustrated, filter medium 388 includes an outer perforated shroud,
outer and inner drainage layers that have a relative course wire mesh with a filtration layer
disposed therebetween having a relatively fine mesh. Positioned around base pipe 382 is a
swellable material layer 390. Swellable material layer 390 is attached to filter medium 388
by bonding or other suitable technique. As illustrated, swellable material layer 390 includes a
plurality of bands 392 that extend circumferentially around 360 degrees of base pipe 382. In
this configuration, swellable material layer 390 provides isolation completely around multiple
sections of filter medium 388 upon activation of swellable material layer 390, as best seen in
figure 15B, which places swellable material layer 390 in contact with the formation. In this
configuration, the use of packers or other sealing devices in conjunction with one or more
sand control screen assemblies 380 may be reduced or eliminated.
[0091] 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.
What is claimed is:
1. A sand control screen assembly operably positionable within a wellbore, the
sand control screen assembly comprising:
a base pipe having at least one opening in a sidewall portion thereof, a blank pipe
section and an internal flow path;
a swellable material layer disposed exteriorly of the blank pipe section of the base
pipe;
a fluid collection subassembly disposed exteriorly of the swellable material layer and
in fluid communication with the internal flow path via the opening; and
a filter medium operably associated with the sand control screen assembly and
disposed in a fluid path between the exterior of the sand control screen assembly and the
internal flow path;
wherein, in response to contact with an activating fluid, radial expansion of the
swellable material layer causes at least a portion of the fluid collection subassembly to be
displaced toward a surface of the wellbore.
2. The sand control screen assembly as recited in claim 1 wherein the fluid collection
subassembly further comprises a plurality of circumferentially distributed perforated tubulars.
3. The sand control screen assembly as recited in claim 2 wherein fluid discharged
from the perforated tubulars of the fluid collection subassembly is received in a chamber
prior to entering the internal flow path.
4. The sand control screen assembly as recited in claim 1 wherein the filter medium is
disposed external to the fluid collection subassembly.
5. The sand control screen assembly as recited in claim 1 wherein the filter medium is
disposed internal to the fluid collection subassembly.
6. The sand control screen assembly as recited in claim 1 wherein the filter medium is
disposed downstream of the fluid collection subassembly.
7. The sand control screen assembly as recited in claim 1 wherein the filter medium
further comprises at least one of a single layer mesh screen, a multiple layer mesh screen, a
wire wrapped screen, a prepack screen, a ceramic screen, a fluid porous, particulate resistant
sintered wire mesh screen and a fluid porous, particulate resistant diffusion bonded wire mesh
screen.
8. The sand control screen assembly as recited in claim 1 further comprising a screen
element disposed external to the fluid collection subassembly and the swellable material
layer.
9. The sand control screen assembly as recited in claim 1 wherein the activating fluid
is at least one of a hydrocarbon fluid, water and gas.
10. The sand control screen assembly as recited in claim 1 wherein, in response to
contact with the activating fluid, radial expansion of the swellable material layer causes at
least a portion of the fluid collection subassembly to contact the wellbore.
11. The sand control screen assembly as recited in claim 1 further comprising at least
one fluid flow control device disposed in the fluid path between the exterior of the sand
control screen assembly and the internal flow path.
12. The sand control screen assembly as recited in claim 11 wherein the at least one
fluid flow control device is at least one of a plug, a one-way valve, an inflow control device
and a production control device.
13. The sand control screen assembly as recited in claim 11 wherein the fluid flow
control capability of the at least one fluid flow control device is operable to be disabled.
14. A sand control screen assembly operably positionable within a wellbore, the
sand control screen assembly comprising:
a base pipe having a perforated section, a blank pipe section and an internal flow path;
a swellable material layer disposed exteriorly of the blank pipe section of the base
pipe;
a fluid collection subassembly disposed exteriorly of the swellable material layer and
in fluid communication with the internal flow path; and
a filter medium disposed exteriorly of the perforated section of the base pipe;
wherein, in response to contact with an activating fluid, radial expansion of the
swellable material layer causes at least a portion of the fluid collection subassembly to be
displaced toward a surface of the wellbore.
15. The sand control screen assembly as recited in claim 14 wherein the fluid
collection subassembly further comprises a plurality of circumferentially distributed
perforated tubulars.
16. The sand control screen assembly as recited in claim 14 wherein fluid discharged
from the fluid collection subassembly is received in a chamber prior to passing through the
filter medium.
17. The sand control screen assembly as recited in claim 14 wherein the filter medium
further comprises at least one of a single layer mesh screen, a multiple layer mesh screen, a
wire wrapped screen, a prepack screen, a ceramic screen, a fluid porous, particulate resistant
sintered wire mesh screen and a fluid porous, particulate resistant diffusion bonded wire mesh
screen.
18. The sand control screen assembly as recited in claim 14 wherein the activating
fluid is at least one of a hydrocarbon fluid, water and gas.
19. The sand control screen assembly as recited in claim 14 wherein, in response to
contact with the activating fluid, radial expansion of the swellable material layer causes at
least a portion of the fluid collection subassembly to contact the wellbore.
20. A method of installing a sand control screen assembly in a wellbore, the
method comprising:
running the sand control screen assembly to a target location within the wellbore, the
sand control screen assembly having a fluid collection subassembly disposed exteriorly of a
swellable material layer that is disposed exteriorly of a blank pipe section of a base pipe;
contacting the swellable material layer with an activating fluid;
radially expanding the swellable material layer in response to contact with the
activating fluid; and
displacing at least a portion of the fluid collection subassembly toward a surface of
the wellbore in response to the radial expansion of the swellable material layer.
21. The method as recited in claim 20 wherein the step of radially expanding the
swellable material layer in response to contact with the activating fluid further comprises
contacting the swellable material layer with at least one of a hydrocarbon fluid, water and
gas.
22. The method as recited in claim 20 wherein the step of displacing at least a
portion of the fluid collection subassembly toward a surface of the wellbore in response to the
radial expansion of the swellable material layer further comprises placing at least a portion of
the fluid collection subassembly in contact with the wellbore in response to the radial
expansion of the swellable material layer.
23. A downhole tool operably positionable within a wellbore, the downhole tool
comprising:
a tubular member having an internal flow path;
a swellable material layer disposed exteriorly of at least a portion of the tubular
member; and
a sensor disposed exteriorly of the swellable material layer;
wherein, in response to contact with an activating fluid, radial expansion of the
swellable material layer causes the sensor to be displaced toward a surface of the wellbore.
24. The downhole tool as recited in claim 23 wherein the swellable material layer
is disposed exteriorly of a blank pipe section of the base pipe.
25. The downhole tool as recited in claim 23 wherein the swellable material layer
is disposed exteriorly of a perforated section of the base pipe.
26. The downhole tool as recited in claim 23 wherein the activating fluid is at least
one of a hydrocarbon fluid, water and gas.
27. The downhole tool as recited in claim 23 wherein, in response to contact with
the activating fluid, radial expansion of the swellable material layer causes the sensor to
contact the wellbore.
28. The downhole tool as recited in claim 23 wherein the sensor is selected from
at least one of a pressure sensor, a temperature sensor, a piezoelectric acoustic sensor, a flow
meter, an accelerometers, a resistivity sensor, a velocity sensors and a weight sensor
29. The downhole tool as recited in claim 23 wherein the sensor further comprises
a fiber optic sensor.
30. The downhole tool as recited in claim 23 wherein the downhole tool is a sand
control screen assembly.
31. A sand control screen assembly operably positionable within a wellbore, the
sand control screen assembly comprising:
a base pipe having at least one opening in a sidewall portion thereof and an internal
flow path;
a swellable material layer disposed exteriorly of at least a portion of the base pipe;
a fluid collection subassembly disposed exteriorly of the swellable material layer and
in fluid communication with the internal flow path via the opening;
a filter medium operably associated with the sand control screen assembly and
disposed in a fluid path between the exterior of the sand control screen assembly and the
internal flow path; and
a drainage layer disposed exteriorly of the fluid collection subassembly and the
swellable material layer;
wherein, in response to contact with an activating fluid, radial expansion of the
swellable material layer causes at least a portion of the fluid collection subassembly and the
drainage layer to be displaced toward a surface of the wellbore.
32. The sand control screen assembly as recited in claim 31 wherein the swellable
material layer is disposed exteriorly of a blank pipe section of the base pipe.
33. The sand control screen assembly as recited in claim 31 wherein the fluid
collection subassembly further comprises a plurality of circumferentially distributed
perforated tubulars.
34. The sand control screen assembly as recited in claim 31 wherein the filter
medium is disposed internal to the fluid collection subassembly.
35. The sand control screen assembly as recited in claim 31 wherein the filter
medium is disposed downstream of the fluid collection subassembly.
36. The sand control screen assembly as recited in claim 31 wherein the activating
fluid is at least one of a hydrocarbon fluid, water and gas.
37. The sand control screen assembly as recited in claim 31 wherein, in response
to contact with the activating fluid, radial expansion of the swellable material layer causes at
least a portion of the drainage layer to contact the wellbore.
38. The sand control screen assembly as recited in claim 37 wherein the drainage
layer provides a stand off region between the fluid collection subassembly and the wellbore.
39. The sand control screen assembly as recited in claim 31 wherein the drainage
layer further comprises a plurality of circumferential drainage layer segments.
40. The sand control screen assembly as recited in claim 31 wherein an additive is
carried within the drainage layer.
41. The sand control screen assembly as recited in claim 40 wherein the additive
further comprises a reactive substance.
42. The sand control screen assembly as recited in claim 40 wherein the additive
further comprises a degradable polymer selected from the group consisting of
polysaccharides, dextran, cellulose, chitins, chitosans, proteins, aliphatic polyesters,
poly(lactides), poly(glycolides), poly(?-caprolactones), poly(anhydrides),
poly(hydroxybutyrates), aliphatic polycarbonates, poly(orthoesters), poly(amino acids),
poly(ethylene oxides) and polyphosphazenes.
43. The sand control screen assembly as recited in claim 40 wherein the additive
is selected from the group consisting of aliphatic polyesters, poly(lactides), poly(lactic acids)
and poly(anhydrides).

A sand control screen assembly (40) is operably positionable within a wellbore (48). The sand control screen assembly
(40) includes a base pipe (42) having at least one opening (60) and an internal flow path (44). A swellable material layer
(46) is disposed exteriorly of the base pipe (42). A fluid collection subassembly (50) is disposed exteriorly of the swellable material
layer (46). The fluid collection subassembly (50) is in fluid communication with the internal flow path (44). A filter medium
(62) is operably associated with the sand control screen assembly (40) and is disposed in a fluid path between the exterior of the
sand control screen assembly (40) and the internal flow path (44). In response to contact with an activating fluid, radial expansion
of the swellable material layer (46) causes at least a portion of the fluid collection subassembly (50) to contact the wellbore (48).