US20250314156A1

US20250314156A1 - Sealing of an annular space proximate to a sand screen

Info

Publication number: US20250314156A1
Application number: US18/629,237
Authority: US
Inventors: Jalpan Piyush Dave; Scott Wallace; Nithin Kumar Gupta Dachepally; Mohan Gunasekaran; Ganga Venkata Jayaram Kantipudi
Original assignee: Halliburton Energy Services Inc
Current assignee: Halliburton Energy Services Inc
Priority date: 2024-04-08
Filing date: 2024-04-08
Publication date: 2025-10-09
Also published as: WO2025216745A1

Abstract

An apparatus for sealing an annular space proximate to an end of a sand screen on a downhole tubular may include a flexible seal configured to encircle the tubular. The flexible seal may include a first state in which an outer diameter of the flexible seal is less than a diameter of a wellbore, and a second state in which the outer diameter of the flexible seal is the same as the diameter of the wellbore. The apparatus may further include a deployment mechanism configured to cause the flexible seal to transition from the first state to the second state.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

None.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

FIELD

The present disclosure relates generally to sealing of an annular space proximate to a sand screen. More particularly, the present disclosure relates to deploying a flexible seal, for example, a flexible seal, to seal the annular space.

BACKGROUND

Sand screens may be, for example, filtration devices used in well production which are designed to prevent sand and/or other fine particles from entering and damaging production equipment. They may be helpful for extraction of hydrocarbons from sandstone or other reservoirs where sand production may be a problem. Sand screens may also help maintain the structural integrity of the well by filtering out sand and sediments while allowing fluids like oil, gas, and water to flow through, and/or by providing some level of support for the wellbore.
In some scenarios, it may be beneficial to seal tail ends of a sand screen joint, seal off other parts of the sand screen, or otherwise tailor flow in, around, or near the sand screen. However, conventional methods of sealing may require multiple trips, specialized chemicals, and/or specialized tools.
Thus, there may be a need for an apparatus for tailoring flow in, around, or near a sand screen that can be run in a single trip and/or without the need for special chemicals or specialized tools.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

FIG. 1A is a schematic diagram of a well with sand screens in an unactivated configuration according to an embodiment of the present disclosure;

FIG. 1B is a schematic diagram of the well of FIG. 1A with sand screens in an activated configuration;

FIG. 2 is a cut-away perspective view of an exemplary sand screen, according to an embodiment of the present disclosure;

FIG. 3 is a cross-sectional perspective view of the sand screen of FIG. 2 in an unactivated state;

FIG. 4 is a cross-sectional perspective view of the sand screen of FIG. 2 in an activated state;

FIG. 5 is an exploded view of the sand screen of FIG. 2 in the activated state;

FIG. 6 is a cross-sectional perspective view of the sand screen of FIG. 2 in the contracted state;

FIG. 7 is a cut-away perspective view of the sand screen of FIG. 2 in the activated state;

FIG. 8 is a perspective view of the sand screen of FIG. 2 in the activated state;

FIG. 9 is a cross sectional view of the sand screen of FIG. 3 configured for production;

FIG. 10A is a schematic diagram of an exemplary apparatus for sealing an annular space proximate to a sand screen in a first state according to an embodiment of the present disclosure;

FIG. 10B is a schematic diagram of the apparatus of FIG. 10A in a second state;

FIG. 11A is a schematic diagram of an exemplary apparatus for sealing an annular space proximate a sand screen in a first state according to another embodiment of the present disclosure;

FIG. 11B is a schematic diagram of the apparatus of FIG. 11A in a second state;

FIG. 12A is a schematic diagram of an exemplary apparatus for sealing an annular space proximate a sand screen in a first state according to yet another embodiment of the present disclosure;

FIG. 12B is a schematic diagram of the apparatus of FIG. 12B in a second state;

FIG. 13A is a schematic diagram of an exemplary apparatus for sealing an annular space proximate a sand screen in a first state according to yet another embodiment of the present disclosure;

FIG. 13B is a schematic diagram of the apparatus of FIG. 13A in a second state;

FIG. 14A is a schematic diagram of an exemplary apparatus for sealing an annular space proximate a sand screen in a first state according to yet another embodiment of the present disclosure;

FIG. 14B is a schematic diagram of FIG. 14A in a second state;

FIG. 14C is a cross sectional side view of an exemplary embodiments of the fracturable sleeve of FIG. 14A; and

FIG. 15 is a flow diagram of an exemplary method for installing a sand screen in a well, according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The description that follows includes example systems, methods, techniques, and program flows that embody aspects of the disclosure. However, it is understood that this disclosure may be practiced without these specific details. For brevity, well-known steps, protocols, structures, and techniques have not been shown in detail in order not to obfuscate the description. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.
As used herein the terms “uphole”, “upwell”, “above”, “top”, and the like refer directionally in a wellbore towards the surface, while the terms “downhole”, “downwell”, “below”, “bottom”, and the like refer directionally in a wellbore towards the toe of the wellbore (e.g. the end of the wellbore distally away from the surface), as persons of skill will understand. Orientation terms “upstream” and “downstream” are defined relative to the direction of flow of fluid, for example relative to flow of well fluid in the well. As used herein, orientation terms “upstream,” “downstream,” are defined relative to the direction of flow of well fluid in the well casing. “Upstream” is directed counter to the direction of flow of well fluid, towards the source of well fluid (e.g., towards perforations in well casing through which hydrocarbons flow out of a subterranean formation and into the casing). “Downstream” is directed in the direction of flow of well fluid, away from the source of well fluid.
As used herein, the term “seal” does not necessarily mean a perfect seal. In some embodiments, there may be leakage past the seal but the flow can be significantly reduced by the seal.
According to an embodiment, an apparatus according to the present disclosure may be configured to seal an annular space (e.g. between a tubular and a wellbore into which the tubular is disposed) in proximity to a sand screen, for example in proximity to the tail ends of a sand screen. For example, the apparatus may include a flexible seal configured to encircle a tubular, and a deployment mechanism configured to cause the flexible seal to transition from a first state to a second state. In the first state, the flexible seal may have an outer diameter less than a diameter of the wellbore (e.g. a radial gap may exist between the flexible seal and the interior surface of the wellbore), and in the second state, the outer diameter of the flexible seal may be the same as the diameter of the wellbore (e.g. the flexible seal may span from the tubular to the interior surface of the wellbore, with no gap therebetween). For example, in the second state, the flexible seal may be configured to seal the annular space about the tubular, for example substantially preventing axial fluid flow therepast. In embodiments, the apparatus may include a settable seal style element configured to seal the end of a sand screen, for example, in order to control/tailor fluid flow. It should be understood that in this context providing a seal may not require a complete seal with no leakage, but may for example provide significant and/or substantial sealing (e.g. significantly reducing axial fluid flow therepast and/or blocking substantially all axial fluid flow therepast). Embodiments of the apparatus may be configured for use with an expandable sand screen.
In embodiments, the deployment mechanism may be configured to be activated responsive to expansion of the sand screen. In some embodiments, activating the expansion screen comprises inflating the expansion screen so that it plastically deforms and is not easily deflated. In embodiments, transitioning the flexible seal from the first state to the second state may comprise placing a portion of the flexible seal into contact with and/or overlapping the sand screen, so that expansion of the sand screen can transition the flexible seal to the second state. For example, upon activation, the seal element may move axially to slide over a corresponding end of the sand screen. In embodiments, expansion of the sand screen (e.g. by activation of the activation chambers of the sand screen) may push the seal (e.g., a rubber cup) radially outward and enable sealing against the wellbore. In some embodiments, the seal outer diameter in the first state may fit within the existing tool max outer diameter.
In some embodiments, a cup style metal bonded rubber element (e.g. seal) may be disposed in proximity to one or more end of the sand screen, and may sit below the max outer diameter of the tool. The flexible seal (e.g. rubber element) may be biased towards the sand screen, for example by a spring. Upon activation, the seal may slide axially until the rubber element of the flexible seal overlaps a length of the sand screen. This way, when the activation chamber of the sand screen pushes the screen out, it may also push the rubber of the flexible seal out until the rubber seals against the wellbore.
In some embodiments, the deployment mechanism may have a metal coupling that connects it to a screen clamp ring, for example with a shear pin. The activation of the activation chambers of the sand screen may cause the screen clamp ring to rotate as it sets/expands the screen. This may cause the shear pin connecting the seal to the clamp ring to shear, and allow the compressed spring (e.g. biasing the flexible seal towards the sand screen) to release its energy and push the seal axially.
When deployed, the spring may press against the seal (e.g. driving the seal towards the sand screen), and the seal may ride up and radially outward at an angle. For example, the rubber element of the flexible seal and/or the end (e.g. screen clamp ring or separate wedge element) of the sand screen may include an angled portion. The seal may then come into contact with the open hole inner diameter of the wellbore and create a seal. An internal slip (e.g., a collar with teeth or other axial fixing element on the inside of it to prevent axial movement) may be used to anchor an end of the spring in place. The rubber seal may releasably pinned to a body portion of the sand screen so that when the screen is activated, there may a component that rotates radially, which may shear the pin (e.g. overlapping layers of the sand screen may slide over each other to shear the pin). When the pin shears, the spring may be free to extend. The spring may push the seal over the screen component. As the screen is activated, the seal may extend over it.
In some embodiments, the seal may be activated hydrostatically. For example, the flexible seal may transition from the first state to the second state based on activation by hydrostatic pressure (e.g. in the annular space between the tubular and the wellbore), placing a portion of the flexible seal into contact with and/or overlapping the sand screen, so that expansion of the sand screen can transition the flexible seal to the second state. In an embodiment, a difference in piston areas at the metal end of the seal and a vacuum inside the metal end may cause the downhole hydrostatic pressure to have a net force to drive the seal axially towards the sand screen. The seal may pinned to a value equal to the force applied when the seal reaches depth. The hydrostatic force may then push the seal over the screen. In another embodiment, the seal may be pinned (e.g. using a shear pin) to a value slightly greater than the hydrostatic at depth. The formation may be pressured up to a small applied value (e.g., 200-300 psi) to cause the shear pins to shear. There may be a vacuum inside the apparatus, and hydrostatic pressure outside. A vacuum port (e.g., a hole) may be used to pull the vacuum, and then the vacuum port may be plugged.
In some embodiments, the seal may be filled with an oil instead of vacuum and/or may include a flow restrictor to cause a time delay. When the seal is run to depth, the shear pins may shear due to hydrostatic pressure alone, but the flow restrictor may cause a delay so that the sand screen can be run to position before the seal slides over the screen thereby ensuring that the seal always stays below the max outer diameter of the sand screen.
In some embodiments, the flexible seal may be biased radially outward (e.g. towards the wellbore), but initially retained in its first state. The biasing may be configured so that, when unrestrained, the flexible seal transitions to its second state. In some embodiments, a positively biased seal may be packed under a dissolvable sleeve to cause a time delay for deployment of the seal. For example, the seal may be run to depth in an inert fluid. Upon swapping the inert fluid with another fluid, the sleeve may start to dissolve. Alternatively, the seal may be run in fluid that causes it to start dissolving immediately but is designed such that it will only dissolve enough to enable the positively biased seal to deploy long after the tool has been run to depth. At a desired time (e.g. based on exposure to the fluid), the sleeve may dissolve completely (or dissolve sufficiently to break), at which time the positively biased seal may be deployed to create a seal with the open hole inner diameter. In some embodiments, the seal may not need to hold a pressure differential, but may be designed to create a choke in the flow of the production fluid. When the dissolvable sleeve loses structural integrity, the rubber seal may come out and make contact with the sand screen.
In some embodiments, a positively biased seal may be packed under a sleeve of a material that is brittle. For example, the sleeve may include fracture lines. In embodiments, the sleeve may not create a seal and/or may prevent the seal from deploying. In embodiments, the sleeve may have holes. In embodiments, the sleeve may rest on an end of the sand screen (e.g., on the transition zone). When the sand screen is deployed, the expansion of the sand screen may cause the brittle sleeve to shatter and deploy the positively biased rubber seal to create a seal with the open hole outer diameter. In embodiments, the seal may not need to hold a pressure differential but may be designed to create a choke in the flow of the production fluid.
Referring to FIG. 1A, a well 10 with components for filtering sand from formation fluid in a well is depicted. A wellbore 12 may extend through the various earth strata. In some embodiments, the wellbore 12 may have a vertical section 14, the upper portion of which is have installed therein a casing string 16 that may be cemented within wellbore 12. In embodiments, the wellbore 12 may also have a horizontal section 18 that may extend through a hydrocarbon bearing subterranean formation 20. The horizontal section 18 of wellbore 12 may be open hole in some embodiments. It should be understood that in some embodiments, the well may be substantially vertical, substantially horizontal, angled, or some combination thereof, and that orientation of the well may not impact implementation of the disclosed apparatus, system, or method embodiments.
Positioned within the wellbore 12 and extending from the surface may be a tubular 22 (e.g., tubing string). The tubular 22 may provide a conduit for formation fluids to travel from the formation 20 to the surface. For example, one or more pump, for example positioned at the surface and/or in the wellbore, may be configured to pump formation fluids uphole (e.g. through the tubular 22). Positioned within the tubular 22 may be one or more sand screens 24. In embodiments, the sand screens 24 may be configured to be expandable. The sand screens 24 are shown in FIG. 1A in a running or unactivated configuration. In FIG. 1B, the sand screens 24 are shown in an activated configuration.
Those skilled in the art will recognize that the tubular 22 may include any number of other tools and systems such as fluid flow control devices, communication systems, safety systems and the like. Also, the tubular 22 may be divided into a plurality of intervals using zonal isolation devices such as packers. Similar to the swellable material in sand screens 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.
In the exemplary embodiment of FIG. 2 , the sand screens 24 have been run to setting depth. The sand screens 24 may be run below hanger or packer systems. The sand screens 24 may be disposed in production zones (e.g., zones that have been fractured). The well 10 may be balanced to well hydrostatic when running inhole. As can be seen in FIG. 6 , screen valve modules 29 in each screen joint when closed may provide a high-pressure window, and circulation may be achieved without premature screen activation. Upon reaching the desired depth, the hanger may be set. In some embodiments, circulation may occur before screen activation. Placement of filter cake breaker systems can be achieved. After hanger running tool release, and the completion circulation flowpath may be closed, and internal tubing pressure can be applied.
Referring to FIGS. 3-5 , the screen may include a tubular 22 (or a body configured to be made up in a tool string) and activation chambers 243 surrounding the tubular 22. A drainage/support layer 245 may surround the activation chambers 243. One or more production flow channels 242 may be bounded by the tubular 22, the activation chambers 243, and the support layer 245. A sand filtration media 246 may surround the support layer 245. A protective outer shroud 247 may surround the sand filtration media 246. That is, the support layer 245 may be disposed between the activation chambers 243 and the sand filtration media 246, and the sand filtration media 246 may be disposed between the support layer 245 and the protective outer shroud 247.
Referring to FIGS. 10-14 , an apparatus 1,1′,1″,1′″ respectively may be provided for sealing an annular space S proximate to an end 24E of a sand screen 24 on a downhole tubular 22. Hereinafter, reference numbers may also refer to primed element numbers where applicable. For example, reference number 1 may refer in the alternative to 1, 1″, or 1′″ where applicable. A flexible seal 2 (e.g. cup) may be configured to encircle the tubular 22. The flexible seal 2 may have a first (e.g. run-in) state in which an outer diameter of the flexible seal 2 is less than a diameter of the wellbore 12 (e.g. there is a gap G between the flexible seal 2 and the interior surface of the wellbore 12), and a second (e.g. deployed) state in which the outer diameter of the flexible seal 2 is the same as the diameter of the wellbore 12 (e.g. the flexible seal 2 extends radially outward from the tubular 22 to contact an interior surface of the wellbore 12) and/or in which the flexible seal 2 seals the annular space between the tubular 22 and the wellbore 12. A deployment mechanism 3 may be configured to cause the flexible seal 2 to transition from the first state to the second state. The apparatus 1 may be configured to seal an area adjacent to the sand screen 24 (e.g. adjacent an end of the sand screen 24). The wellbore 12 may be a wellbore of a hydrocarbon (e.g. oil and/or gas) well 10. The wellbore 12 may be either cased or uncased. The sealing of the annular space S may substantially prevent axial flow of fluid in the annular space S beyond the end 24E of the sand screen 24 (e.g. above or below the sand screen).
In some embodiments, the tubular 22 may be casing or tubing. The sand screen 24 may be configured to expand radially outwardly from the tubular 22 (e.g. into contact and/or proximity with the interior surface of the wellbore 12). The sand screen 24 may expand in response to the activation chambers 243 of the sand screen 24 being pressurized. The activation chamber 243 being pressurized may occur as a result of the tubular 22 being pressurized in some embodiments. The sand screen 24 may be configured to filter out sand particles between the interior surface of the wellbore 12 and the tubular 22 (e.g. filtering formation fluid before it enters inside the tubular). In embodiments, the flexible seal 2 may be made of rubber or some other elastomeric material. The flexible seal 2 may include a hole 2H extending therethrough. The hole 2H may be an axial hole. The hole 2H may be configured to have the tubular 22 extending therethrough.
The flexible seal 2 may be impermeable. The flexible seal 2 may include a flexible wall 21 encircling the tubular 22. A proximal end of the flexible wall 21 may be mounted/fixed to the tubular 22, and a distal end of the flexible wall may be free (in some embodiments, the proximal end of the flexible wall 21 may be (radially) fixedly attached to the tubular 22, while the remainder of the flexible wall 21 may be free). In some embodiments, the distal end of the flexible wall 21 extends towards the sand screen 24 (e.g. the free end may be disposed towards the sand screen 24, with the distal end disposed between the sand screen 24 and the proximal end). In the first state, the flexible seal 2 may be axially spaced from the sand screen 24, and in the second state, the flexible seal 2 may extend over an end of the sand screen 24 (e.g. axially overlap and/or be sandwiched between the sand screen 24 and the wellbore 12, thereby being held in the second state).
Referring to FIGS. 10-11 , the deployment mechanism 3 may include a coupling 4 (e.g., rod) configured to fix the axial position of the flexible seal 2 with respect to the sand screen 24 (or any other means of mechanically coupling the seal 2 to the sand screen 24 so that the activation of the sand screen 24 releases the mechanical coupling and allows the biasing member 5 to push the seal 2 over the sand screen 24). A biasing member 5 may be configured to bias the (e.g. distal end of the) flexible seal 2 towards the sand screen 24. The coupling 4 may be configured to release the flexible seal 2 in response to expansion of the sand screen 24. The deployment mechanism 3 may include a base 31, The flexible seal 2 may be mounted (e.g. radially affixed) to the tubular 22 by the base 3. The coupling 4 may extend from the base or the flexible seal 4 and/or may be configured to be affixed to the sand screen 24. A slip 6 (e.g., locking device) may be configured to be affixed to the tubular, and the biasing member 5 may extend from the slip 6 to the base 31. Any other locking device that forces to biasing member 5 to move the seal 2 upon activation of the sand screen 24 may be used. In some embodiments, the slip 6 or other locking device fixes the end of the biasing member 5 (e.g., spring) in place so that when released the biasing member 5 forces the seal 2 over the expanding sand screen 24.
The base 31 may be a metal base configured to encircle the tubular 22. The flexible seal 2 may be bonded to the metal base 3. The coupling 4 may be made of metal. The coupling 4 may include a shear pin. The coupling 4 may be shearably attached to the sand screen 24 (e.g. with a shear pin).
The deployment mechanism 3 may be configured to cause the flexible seal 2 to transition to the second state, in response to the coupling 4 (or its attachment) breaking/shearing. The coupling 4 may be configured to break/shear, in response to the sand screen 24 expanding. The sand screen 24 expanding may cause a clamp ring of the sand screen 24 to rotate. The coupling 4 may be affixed to the clamp ring. The coupling 4 may be configured to break/shear, in response to the rotation of the clamp ring.
The biasing member 5 may include a spring. The spring may include a coil spring configured to encircle the tubular 22. In response to the coupling 4 breaking/shearing, the biasing member 5 may expand to push the base 31 axially along the tubular 22 (e.g. the base 31 may be mounted to the tubular in such a way as to allow axial movement from the first position to the second position, once the coupling 4 is no longer fixing its axial position). In some embodiments, the biasing member 5 may drive the flexible seal 2 towards the sand screen, and radial expansion of the sand screen may radially expand the flexible seal 2 to the second state. In some embodiments, the activated sand screen may push the distal end of the flexible seal 2 radially outward into contact with the wellbore. In some embodiments, the distal end of the flexible seal 2 may be sandwiched between the sand screen and the wellbore in the second state, while in other embodiments the distal end of the flexible seal 2 may not be wedged between the sand screen and the wellbore.
Referring to FIG. 11 , the flexible seal 2 may include an inclined plane 26 (e.g. at its distal end, for example with the thickness of the flexible wall 21 reducing as the flexible wall 21 extends away from the base 31 and/or with the inclined plane 26 disposed in proximity to/facing the tubular). In embodiments, the inclined plane 26 can be configured to guide the flexible seal 2 over a wedge 7 (e.g., a clamp ring) when the flexible seal 2 transitions from the first state to the second state. Sliding of the flexible seal 2 over the wedge 7 (as the sand screen 24 expands) may cause the flexible seal 2 to transition from the first state to the second state (e.g. the expansion of the sand screen 24 and/or the axial movement of the flexible seal 2 with respect to the wedge 7 can induce radial movement of the flexible seal 2 outward). In the second state, the distal end of the flexible seal 2 may be disposed/wedged between the interior of the wellbore 12 and the sand screen 24.
Referring to FIGS. 10-11 , the slip 6 may include a set screw configured to fasten the slip 6 to the tubular. The slip 6 may be annular. The slip 6 may be configured to encircle the tubular 22. The spring 5 may extend from an end of the metal base 31 to an end of the slip 6.
Referring to FIGS. 12A-B, in some embodiments, the deployment mechanism 3′ may include a base 31′. The flexible seal 2 may extend from the base 31′ towards the sand screen 24 (e.g. with a proximal end attached to base 31′ and a distal end free and disposed towards and/or in proximity to the sand screen 24). The base 31′ may be configured for activation based on hydrostatic pressure in the well. For example, the base 31′ may include a first portion 32 having a first inner diameter corresponding to a first outer diameter of the tubular 22; and a second portion 33 having a second inner diameter corresponding to a second outer diameter of the tubular 22.
In embodiments, a port 8 may extend radially inward from an outer surface. A volume/chamber C may be formed between the tubular 22 and the base 31′. A shearable retaining element 4′ (e.g. shear pin) may axially fix the base 31′ to the tubular 22. The port 8 may include a vacuum port configured to facilitate drawing a vacuum in the volume/chamber C, with the port 8 then being closed/plugged to seal the chamber C. Alternatively, the port 8 may be configured for introduction of oil, and chamber C may contain oil. In some embodiments, a flow restrictor may be configured to cause a time delay. In some embodiments, for the seal 2 to be able to move, it must first displace the oil (or other fluid) contained inside chamber C. In one embodiment, this fluid may be displaced into another chamber in the tubular 22. A check valve or other fluid control devices may be used to prevent the fluid from being vented into the other chamber prematurely. Upon reaching depth where the hydrostatic pressure is sufficient to shear the retaining element 4′, the seal 2 may start to move axially due to the hydrostatic pressure. However, due to the flow restrictor, there may be a time delay in the movement and there may be a time lag between when the retaining member 4′ shears and the seal 2 has moved axially at a distance sufficient for the inclined plane 26 to ramp over wedge 7. As a result, the seal 2 may continue to sit below the tool diameter even after the retaining member 4′ has been sheared. This may be useful operationally because a ramping of the seal 2 over the wedge 7 can cause the rubber to be proud of the tool outer diameter and can cause the tool to get stuck before the tool has reached its intended depth. The time delay can be configured by adjusting the fluid volume in chamber C, size/design of restriction of the restrictor, the length of gap between base 31′ to where it bottoms out on the third surface 22S3 or a combination thereof. In some embodiments, the time lag is configured to be 4 hours. In some embodiments, the time lag can be from 1 hour to several days. The first inner diameter of the base 31′ may be greater than the second inner diameter of the base 31′. The first outer diameter of the tubular may be greater than the second outer diameter of the tubular. The first inner diameter may be sized to create a slip fit with the first outer diameter. The second inner diameter may be sized to create a slip fit with the second outer diameter. The first outer diameter may be configured to act as a stop for axial movement of the base 31′ (e.g. due to interference interaction between the first inner diameter of the base 31′ and the second outer diameter of the tubular 22). The base 31′ may include a first axial end 31E1 and a second axial end 31E2. The shearable retaining element 4′ (e.g., shear pin) may be configured to break/shear in response to a difference between a first hydrostatic force on the first axial end 31E1 and a second hydrostatic force on the second axial end 31E2 exceeding a threshold (thereby moving the flexible seal 2 from the first position to the second position).
The first hydrostatic force may be based on a first projected surface area of the first axial end 31E1 in a plane approximately perpendicular to a longitudinal central axis of the tubular 22. The second hydrostatic force may be based on a second projected surface area of the second axial end 31E2 in another plane approximately perpendicular to a longitudinal central axis of the tubular 22 (e.g. the two planes are approximately parallel to each other). The first hydrostatic force may be further based on pressure in the well/annular space at a first axial location at which the first projected surface area is disposed, and/or the second hydrostatic force may be further based on pressure in the well/annular space at a second axial location at which the first projected surface area is disposed. The force at the second axial end 31E2 may be greater than the pressure at the first axial end 31E1 due to the area difference between the second axial end 31E2 and the first axial end 31E1. The first projected surface area may be greater than the second projected surface area. Due to the configuration of the base 31′, hydrostatic pressure may be used to activate the deployment mechanism, transitioning the flexible seal 2 from the first state to the second state. The base 31′ may comprises a stepped (e.g. inner) profile (e.g. forming the vacuum chamber/volume between the base and the tubular).
Upon release of the shearable retaining element 4′ (e.g. due to application of sufficient hydrostatic pressure), a first surface 31S1 of the base 31′ may slide along a first surface 22S1 of the tubular, and a second surface 31S2 of the base may slide along a second surface 22S2 of the tubular (e.g. from the first position to the second position). The first inner diameter may be an inner diameter of the first surface 22S1 of the base 31′ and the second inner diameter may be the inner diameter of the second surface 31S2 of the base 31′. A third surface 31S3 of the base 31′ may be configured to stop against a third surface 22S3 of the tubular 22 (upon axial movement of the base, e.g. to the second position, for example towards the sand screen 24 and/or downward). The third surface 31S3 of the base 31′ may be disposed between the first surface 31S1 of the base 31′ and the second surface 31S2 of the base 31′, and the third surface 22S3 of the tubular 22 may be disposed between the first surface 22S1 of the tubular 22 and the second surface 22S2 of the tubular 22. The first surface 31S1 of the base 31′ may be approximately parallel with the second surface 22S2 of the base 31′. The first surface 22S1 of the tubular 22 may be approximately parallel with the second surface 22S2 of the tubular 22. The third surface 31S3 of the base 31′ may be approximately parallel with the third surface 22S3 of the tubular 22. The third surface 31S3 of the base 31′ may extend radially outward, for example at an oblique angle, with the first surface 31S1 of the base 31′. The third surface 22S3 of the tubular 22 may extend radially outward as well (e.g. at an oblique angle with the first surface 22S1 of the tubular 22). The third surface 22S3 of the tubular 22 may limit axial translation of the base 31′ (e.g. act as a stop on axial movement).
The threshold at which the deployment mechanism 3 is configured to actuate via hydrostatic pressure may be based on the desired depth of deployment (e.g. a shearable retaining element has a threshold based on the force applied when the flexible seal 2 reaches desired depth, e.g. automatically deploying at the desired depth). The threshold at which the deployment mechanism 3 is configured to actuate may be greater than the hydrostatic pressure based on the desired depth of deployment (e.g. the shearable retaining element has a threshold based on the force applied when the flexible seal 2 reaches desired depth plus some additional applied pressure (e.g. from the surface), e.g. being deployed in response to being properly located and then having sufficient pressure applied downhole in the annular space).
In the first state, the third surface 31S3 of the base 31′ may be spaced apart from the third surface 22S3 of the tubular 22 (e.g. forming the vacuum chamber). In the second state, the third surface 31S3 of the base 31′ may abut or be in proximity to the third surface 22S3 of the tubular 22 (e.g. there may be substantially no vacuum chamber remaining). A first seal 321 can be disposed between the first portion 32′ of the base and the tubular 22 and a second seal 331 can be disposed between the second portion 33′ of the base 31′ and the tubular 22. The first portion 32′ may have a first groove 322 formed therein, the second portion 33′ may have a second groove 332 formed therein. The first seal 321 may be disposed within the first groove 322, and the second seal 331 may be disposed within the second groove 332. The first seal 321 may make a seal on the first surface 22S1 of the tubular 22, and the second seal 331 may make a seal on the second surface 22S2 of the tubular 22. The first seal 321 and the second seal 331 may maintain the vacuum (e.g. inside the vacuum chamber C between the base 31′ and the tubular 22, at least in the first state). The first seal 321 may be a first O-ring, and/or the second seal 331 may be a second O-ring.
The vacuum port 8 may include a bore 81 extending (e.g. substantially radially) from an outer surface 31S4 of the base 31′ to an inner surface of the base 31′ (e.g. the third surface 31S3 of the base 31′). A plug 82 may plug/seal the bore (e.g. after the vacuum is drawn). The vacuum port 8 may facilitate the pulling of the vacuum (thereby creating the vacuum in the vacuum chamber C disposed between the base 31′ and the tubular 22).
The base 31′ may be made of metal, such as steel. The flexible seal 2 may be made of rubber or another elastomeric material. The flexible seal 2 may be bonded to the base 31′. For example, the flexible seal 2 may be bonded to the first axial end 31E1 of the base 31′. The base 31′ may be integrally formed in some embodiments.
Referring to FIG. 13 , the deployment mechanism 3″ may include a dissolvable sleeve 91 configured to constrain the flexible seal 2″ in the first state. The flexible seal 2″ may be biased outward (e.g. configured so that, if unrestrained, the distal end would expand radially outward to the second state (e.g. to make (e.g. substantially sealing) contact with the wellbore 12). The dissolvable sleeve 91 may be configured to restrain the flexible seal 2″ (e.g. the distal end of the flexible seal) at a diameter less than that of the wellbore 12 (e.g. at a diameter no more than the run-in outer diameter of the tubular 22 and/or sand screen 24). The dissolvable sleeve 91 may be mounted on the tubular 22. In the first state, the flexible seal 2″ may be disposed between the dissolvable sleeve 91 and the tubular 22. The dissolvable sleeve 91 may be approximately concentrically located about the flexible seal 2 and/or the tubular 22 in some embodiments. The dissolvable sleeve 91 may be cup-shaped. The dissolvable sleeve 91 may have a bore 91B in a first end 91E1 thereof. The bore 91B may have the tubular 22 extending therethrough. The bore 91B may be concentric with a hole/bore 2B″ in the flexible seal 2″. The bores 91B,2B″ of the dissolvable sleeve 91 and the flexible seal 2″ may be concentric with the tubular 22 (e.g. the longitudinal bore of the tubular 22).
The dissolvable sleeve 91 may be fastened to the tubular 22. The dissolvable sleeve 91 may be configured to be fastened to the tubular 22 by a set screw. In some embodiments, the dissolvable sleeve 91 may be configured to extend to an end of the sand screen 24 (although in other embodiments, the dissolvable sleeve may be configured to retain the flexible seal in its first state without contacting the sand screen). The dissolvable sleeve 91 may be configured to extend over the end of the sand screen 24 in some embodiments. The dissolvable sleeve 91 may be configured to dissolve when in contact with fluid in the well 10. The fluid may include hydrocarbons. The fluid may include a chemical pumped into the well. The sleeve material may be selected based on the fluids in the wellbore 12, or in other cases where the wellbore 12 fluid may not be able to dissolve the sleeve, a fluid that can dissolve the sleeve may be swapped with the fluid in the wellbore 12 for a designated amount of time to dissolve the sleeve 91. The dissolving fluid may be hydrocarbons, water, brine or any other suitable chemical substance. The dissolvable sleeve 91 may be configured to dissolve within an hour, a day, or a week of continuous exposure to the fluid.
In embodiments, the dissolvable sleeve 91 can comprise one or more degradable (e.g. including dissolvable) material that will undergo degradation and/or dissolution and cause the dissolvable sleeve 91 to lose structural integrity in situ under ambient conditions within the wellbore. The degradation and/or dissolution may be the result of contact of the degradable material with an ambient wellbore fluid, contact of the degradable material with an activator/catalytic fluid or compound placed into the wellbore, the effect of ambient conditions (e.g., heat or corrosion) in the wellbore, or combinations thereof. Examples of suitable degradable materials include metals and alloys, polymers, composite materials, or combinations thereof. Suitable metals and alloys may include corrosive metals, such as magnesium and aluminum alloys. Suitable polymers include hydrophilic polymeric materials such as polylactic acid (PLA), polyglycolic acid (PGA), polycaprolactone (PCL), or combinations thereof. Composite materials include fiber reinforced composites having synthetic or natural fibers (e.g., cellulose) and a binder resin/matrix (e.g., a polymer such as PLA, PGA, or PCL). In embodiments, the dissolvable sleeve 91 may comprise one or more degradable material, such as a polymeric or metal alloy based degradable material. In some embodiments, the degradable material may comprise polymeric-based material, polymeric material that uses reinforcement particles or materials, and/or degradable metal alloys (such as Magnesium or Aluminum based alloys). In some embodiments, the degradable material may comprise a coating, for example providing a delay in degradation. In some embodiments, the degradable materials may comprise lactic acid, polylactic acid (PLA), PGA, and/or highly corrosive materials. In some embodiments, the reactive fluid for degrading the degradable material may comprise wellbore fluid, activator/catalytic fluid or compound, water, and/or mud. In some embodiments, the temperature of the reactive fluid may be controlled to cause or accelerate degradation. In some embodiments, the reactive fluid may have a high chlorine content. In some embodiments, the dissolvable sleeve 91 may be configured to degrade (e.g. when exposed to reactive fluid and/or conditions) in more than 12 hours and/or in less than 5 days. In some embodiments, the dissolvable sleeve 91 may be configured to degrade (e.g. when exposed to reactive fluid and/or conditions) in more than 5 days (e.g. approximately 5-10 days, approximately 5-7 days, or approximately 7-10 days).
In some embodiments, the dissolvable sleeve 91 may include holes/apertures configured to allow the fluid to pass from an exterior of the sleeve 91 to an interior of the sleeve 91 (e.g. radially extending). The holes may be pores. In the first state, the flexible seal 2″ may be configured to exert outward pressure on an interior surface of the dissolvable sleeve 91. In the first state, the flexible seal 2″ may be fastened to the dissolvable sleeve 91. In the second state, the flexible seal 2″ may be configured to contact and/or exert outward pressure on the wellbore 12 (e.g. substantially sealing contact). In the second state, the flexible seal 2″ may be configured to seal the annular space S in proximity to the end of the sand screen 24 (but typically not overlapping)
Referring to FIG. 14 , the deployment mechanism 3′″ may include a fracturable sleeve 92 configured to constrain the flexible seal 2′″ in the first state. The flexible seal 2′″ may be biased outward (e.g. configured so that, unrestrained, the distal end would expand radially outward to the second state (e.g. to make (e.g. substantially sealing) contact with the wellbore). The fracturable sleeve 92 may be configured to restrain the flexible seal 2′″ (e.g. the distal end of the flexible seal 2′″) at a diameter less than that of the wellbore 12 (e.g. at a diameter no more than the run-in outer diameter of the tubular 22 and/or sand screen 24). The fracturable sleeve 92 may be mounted on the tubular 22. In the first state, the flexible seal 2′″ may be disposed between the fracturable sleeve 92 and the tubular 22. The fracturable sleeve 92 may be approximately concentrically located about the flexible seal 2′″ and/or the tubular 22. The fracturable sleeve 92 may be cup-shaped in some embodiments. The fracturable sleeve 92 may include a bore 92B in a first end thereof. The bore 92B may have the tubular 22 extending therethrough. The bore 92B may be concentric with a hole/bore 2B′″ in the flexible seal 2′″ and/or a longitudinal bore of the tubular 22 and/or sand screen 24. The fracturable sleeve 92 may be configured to be fastened to the tubular 22. The fracturable sleeve 92 may be configured to be fastened to the tubular by set screws. In the first state, the fracturable sleeve 92 may extend over the end of the sand screen 24. The fracturable sleeve 92 may be configured to extend over at least a portion of the sand screen 24 (e.g. over at least a portion of the filter element).
The fracturable sleeve 92 may be configured to fracture in response to the sand screen 24 being deployed (e.g. expanding, for example to contact the wellbore). For example, the force of the expansion of the sand screen 24 radially outward may be sufficient to break/fragment/shatter the fracturable sleeve 92, for example when the activation chambers 243 of the sand screen 24 are pressurized. The fracturable sleeve 92 may include one or more fracture lines 921. The fracture lines 921 may extend axially along the fracturable sleeve 92 in some embodiments. For example, the fracture lines 921 may define rectangular detachable/fragmentable segments 922. The detachable segments 922 may be arranged in a cylinder. Alternatively, the detachable segments 922 may be arranged in a polygon. The fracturable sleeve 92 may be cup-shaped. The fracturable sleeve 92 may be made of a brittle material.
The flexible seal 2′″ may transition from the first state to the second state, in response to the fracturable sleeve 92 fracturing. The fracturable sleeve 92 fracturing may involve the detachable/fragmentable segments 922 detaching/fragmenting. In the second state, the flexible seal 2′″ may contact and/or exert outward pressure on the wellbore 12 (e.g. substantially sealing contact). In the second state, the flexible seal 2′″ may seal the annular space in proximity to the end of the sand screen 24 (but typically not overlapping). In some embodiments, the spacing from the flexible seal 2′″ to the end of the sand screen 24 is approximately the same as the radial distance between the tubular 22 and the inner diameter of the wellbore 12. In some embodiments, the spacing from the flexible seal 2′″ to the end of the sand screen 24 may be from 2 inches to 1 foot.
Referring to FIG. 15 , an exemplary method 150 of installing a sand screen in a well may include the step 152 of expanding the sand screen radially outward (e.g. so that the sand screen conforms to an interior surface of a wellbore of the well). The sand screen may be disposed between the interior surface of the wellbore and a tubular of the well. The method 150 may further include the step 154 of activating an apparatus to cause a flexible seal to transition from a first state to a second state. In the first state, there may be a gap between the flexible seal and the interior surface of the wellbore. In the second state, the flexible seal may span from the tubular to the interior surface of the wellbore to seal an area proximate to the sand screen and between the interior surface of the wellbore and the tubular (e.g. in proximity to an end of the sand screen). Activating the apparatus may include activating the apparatus by activating a deployment mechanism. Expanding the sand screen may include activating an activation chamber. Activating the activation chamber may include applying pressure to the activation chamber and/or contracting fluid with swellable material in the activation chamber. The transition from the first state to the second state may include closing the gap/sealing the annular space between the wellbore and the tubular.
In some embodiments, activating the apparatus may occur in response to expanding the sand screen. The activating of the deployment mechanism may be responsive to the activating of the activation chamber. The method 150 may further include positioning the sand screen axially at a position in the wellbore for production. The method 150 may further include prior to positioning, perforating and/or fracturing at the position (e.g. using a perforating gun or other tool string, which may then be removed to allow insertion of the tubular with sand screen(s)). The method 15 may further include activating the sealing sleeve, and producing fluid from the formation to the surface. A pump may be used to draw fluid from the formation, through the sand screen, into the tubular bore, up the bore to the surface.
In some embodiments, expanding the sand screen may shear a shearable retaining element. Activating the apparatus may occur in response to shearing the shearable retaining element. Activating the apparatus may include axially shifting the flexible seal towards the sand screen (e.g. until the distal end of the flexible seal overlaps or contacts the end of the sand screen). The distal end of the apparatus may expand radially due to radial expansion of the sand screen (e.g. when overlapped). In the second state the distal end of the flexible seal may be wedged/sandwiched/held between the sand screen and the wellbore. The activating of the deployment mechanism may be responsive to the activating of the activation chamber shearing a pin of the deployment mechanism. The flexible seal may be biased towards the sand screen. The axial position of the flexible seal may be fixed by a shear pin, and the deployment mechanism may axially translate the flexible seal along the tubular and/or towards the sand screen, in response to the shearing of the pin. The axial translation may be caused by expansion of a spring between a metal base of the expansion mechanism and a slip of the expansion mechanism. The slip of the expansion mechanism may be affixed to the tubular. In an alternate embodiment, axial position of the flexible seal may be fixed by a J-slot mechanism whereby rotation of a component of the sand screen during activation may cause the J-slot mechanism to disengage thereby allowing axial translation of the flexible seal.
In some embodiments, the apparatus may be activated based on hydrostatic pressure. Activating the apparatus may include disposing the apparatus at a depth at which hydrostatic pressure will activate (e.g. shear the shearable retaining mechanism and move the flexible seal axially towards the sand screen). Activating the apparatus may include disposing the apparatus at a depth and applying pressure in the wellbore above hydrostatic pressure to activate (e.g. shear the shearable retaining mechanism and move the flexible seal axially towards the sand screen). Activating the deployment mechanism may be responsive to pressuring up fluid between the interior surface of the wellbore and the tubular. Activating the deployment mechanism may include translating the deployment mechanism along the tubular. Translating the deployment mechanism may occur in response to the pressuring up of the fluid causing a pin of the deployment mechanism to break. Breaking the pin may be caused by hydrostatic pressure, resulting from the pressuring up, exerting a net force on the deployment mechanism. The net force may occur by virtue of a vacuum between the deployment mechanism and the tubular and/or a surface area difference between ends of the apparatus/deployment mechanism.
In some embodiments, activating the apparatus may include dissolving a sleeve (e.g. which is configured to retain the flexible seal in its first state). Dissolving the sleeve may include applying a fluid for sufficient duration. The fluid may include hydrocarbons, mud, or a chemical. Dissolving the sleeve may include dissolving from an inner and an outer surface of the sleeve. Activating the deployment mechanism may include dissolving a sleeve. Dissolving the sleeve may enable the flexible seal to expand to transition from the first state to the second state.
In some embodiments, activating the apparatus may include fracturing a sleeve (e.g. a sleeve configured to retain the flexible seal in its first state and to fracture to release the flexible sleeve and allow it to expand to its second state). Fracturing the sleeve may include radially expanding a sand screen (e.g. with the sleeve disposed to overlap the sand screen, such that fracturing the sleeve is responsive to expansion of the sand screen applying radial forces via the expanding sand screen). Activating the deployment mechanism may include fracturing a sleeve. Fracturing the sleeve may be caused by the sand screen exerting a radially outward force on the sleeve as the sand screen expands during the activating of the activation chamber. Fracturing the fracturing sleeve may include detaching of segments from the deployment mechanism. Detaching the segments may include fracturing of the segments along fracture lines. The segments may move away from the deployment mechanism after the detaching of the segments.
Referring to FIGS. 10-14 , a system for filtering sand from formation fluid in a well 10 may include a tubular 22 disposed inside a wellbore 12 of the well 10 and a sand screen 24 fixed to the tubular 22. The sand screen 24 may be configured to radially expand upon actuation. The system may further include the apparatus 1, which may include the flexible seal 2 configured to encircle the tubular 22. The flexible seal 2 may have a first (e.g. run-in) state in which an outer diameter of the flexible seal 2 is less than a diameter of a wellbore 12 (e.g. there is a gap between the flexible seal 2 and the interior surface of the wellbore 12), and a second (e.g. deployed) state in which the outer diameter of the flexible seal 2 is the same as the diameter of the wellbore 12 (e.g. the flexible seal 2 extends radially outward from the tubular 22 to contact an interior surface of the wellbore 12) and/or in which the flexible seal 2 seals the annular space between the tubular 22 and the wellbore 12. The apparatus 1 may further include a deployment mechanism 3 configured to cause the flexible seal 2 to transition from the first state to the second state. In some embodiments, an apparatus 1 may be disposed in proximity to each end of the sand screen 24 (e.g. the sand screen 24 may be disposed on the tubular between two apparatus 1.
Referring to FIG. 6 , an initial pressure cycle may shear internal sleeves of each screen valve module 29 (which may each be disposed between sand screens 24). After releasing initial pressure, valves 291 of the screen valve module may be in a position ready for screen activation. As shown in FIGS. 7-8 , surface applied pressure may activate all of the sand screens 24 by adding fluid volume into the screen activation chambers 243. Activation pressure may be locked inside the screen activation chambers 243. Referring FIG. 9 , after the activation pressure is let off, ports 292 in the screen valve module 29 may be aligned for production or injection. That is, fluid may be allowed to flow through the production flow channel 242.
Referring to FIGS. 10-14 , the apparatus 1 may be disposed in proximity to one end of the sand screen 24. There may be two or more sand screens 24 disposed on the tubular. The apparatus 1 may be disposed in proximity to one or more end of each sand screen 24. The sand screen 24 may extend axially in a section of the wellbore 12. Between adjacent sand screens 24, a portion of the tubular 22 may not have an associated sand screen (e.g. no sand screen encircling it, for example exposed to the wellbore). An axial location of the wellbore 12 may be configured for fluid production, and wherein the sand screen 24 is disposed at that axial location.
The apparatus 1 may be configured to prevent axial fluid flow. The sand screen 24 may include activation chambers 243 arranged around a circumferential surface of the tubular 22. The activation chambers 243 may be configured to activate to cause the sand screen 24 to conform to the interior surface of the wellbore 12. The sand screen 24 may further include a support layer 245 surrounding the activation chambers 243. The support layer 245 may be configured for drainage into the production flow channel 242. The support layer 245 may include holes and/or plates. Holes may be formed in the plates. Flow channels 244 may be formed between the activation chambers 243 and the support layer 245. The sand screen 24 may further include a sand filtration media 246 surrounding the support layer 245. The sand filtration media 246 may be configured to filter sand particles above a threshold size. The sand screen 24 may further include a protective shroud 247 surrounding the sand filtration media 246. The protective shroud 247 may include a mesh.
A method of making a sand screening system includes disposing a sand screen on a tubular, wherein the sand screen is configured to expand radially outward upon activation. The method may further include disposing an apparatus on the tubular in proximity to an end of the sand screen. The apparatus may include a flexible seal configured to encircle the tubular, wherein the flexible seal includes a first (e.g. run-in) state in which an outer diameter of the flexible seal is less than a diameter of a wellbore (e.g. there is a gap between the flexible seal and the interior surface of the wellbore), and a second (e.g. deployed) state in which the outer diameter of the flexible seal is the same as the diameter of the wellbore (e.g. the flexible seal extends radially outward from the tubular to contact an interior surface of the wellbore) and/or in which the flexible seal seals the annular space between the tubular and the wellbore. The apparatus further includes a deployment mechanism configured to cause the flexible seal to transition from the first state to the second state. In some embodiments, the method may further include axially biasing the flexible seal using a spring, and affixing an axial position of the flexible seal with respect to sand screen using a shearable retaining element. In some embodiments, the method may further include configuring the apparatus so that hydrostatic pressure provides an axial force to move the flexible seal towards the sand screen (e.g. with the apparatus having two surface areas of different size and/or a vacuum therebetween), and affixing an axial position of the flexible seal with respect to the sand screen using a shearable retaining element. In some embodiments, the method may further include compressing the flexible seal with a dissolvable sleeve (e.g. retaining the flexible seal in its first state using a dissolvable/degradable sleeve). The method may further include compressing the flexible seal with a fracturable sleeve (e.g. retaining the flexible sleeve in its first state using a fracturable sleeve).
It will be appreciated by those skilled in the art that the apparatus 1 of the present disclosure may be used to seal other parts of the sand screen 24 (i.e., not only the ends). For example, in some screen embodiments, flow ports or an inflow control device may be positioned in the middle of the joint. That section may be sealed off from the screen directly above it and/or below it in some embodiments. Those skilled in the art will also appreciate that the apparatus 1 may be used in injector-type applications. In some embodiments, an entire screen section may be blocked off. In some embodiments, a seal may be created on at least a portion of a sand screen in order to tailor where flow can and cannot occur. In some embodiments, the seal can be on both ends, covering part of the screen.
In some embodiments, the apparatus according to the present disclosure may be able to seal tail ends of a sand screen joint. In some embodiments, the apparatus may be used or adapted to seal off other parts of the sands screen, or otherwise tailor flow in, around, or near the sand screen. In some embodiments, the apparatus, system, and method of the present disclosure may improve the reliability and production rates of the sand screen, potentially leading to greater recovery of oil and gas. In some embodiments, the apparatus, system, and method can accomplish the seal by being run and set in a single trip and/or without any chemicals and/or without any specialized tools.

Additional Disclosure

The following are non-limiting, specific embodiments in accordance with the present disclosure:
In a first embodiment, an apparatus for sealing an annular space proximate to an end of a sand screen on a downhole tubular, comprises: a flexible seal configured to encircle the tubular, wherein the flexible seal comprises a first (e.g. run-in) state in which an outer diameter of the flexible seal is less than a diameter of a wellbore (e.g. there is a gap between the flexible seal and the interior surface of the wellbore), and a second (e.g. deployed) state in which the outer diameter of the flexible seal is the same as the diameter of the wellbore (e.g. the flexible seal extends radially outward from the tubular to contact an interior surface of the wellbore) and/or in which the flexible seal seals the annular space between the tubular and the wellbore; and a deployment mechanism configured to cause the flexible seal to transition from the first state to the second state.
A second embodiment can include the apparatus of the first embodiment, wherein the apparatus seals an area adjacent to a sand screen.
A third embodiment can include the apparatus of the first or second embodiments, wherein the wellbore is a wellbore of a hydrocarbon (e.g. oil and/or gas) well. For injection wells, a medium such as sea water or CCUS may be used.
A fourth embodiment can include the apparatus of any one of the first through third embodiments, wherein the wellbore is either cased or uncased.
A fifth embodiment can include the apparatus of any one of the first through fourth embodiments, wherein the sealing of the annular space substantially prevents axial flow of fluid in the annular space beyond the end of the sand screen (e.g. above or below the sand screen).
A sixth embodiment can include the apparatus of any one of the first through fifth embodiments, wherein the tubular comprises casing.
A seventh embodiment can include the apparatus of any one of the first through fifth embodiments, wherein the tubular comprises tubing.
An eighth embodiment can include the apparatus of any one of the first through seventh embodiments, wherein the sand screen is configured to expand radially outwardly from the tubular (e.g. into contact and/or proximity with the interior surface of the wellbore).
A ninth embodiment can include the apparatus of any one of the first through eighth embodiments, wherein the sand screen is configured to expand in response to activation chambers of the sand screen being pressurized/activated.
A tenth embodiment can include the apparatus of any one of the first through ninth embodiments, wherein the activation chamber being pressurized occurs as a result of the tubular being pressurized.
An eleventh embodiment can include the apparatus of any one of the first through tenth embodiments, wherein the sand screen is configured to filter out sand particles between the interior surface of the wellbore and the tubing.
A twelfth embodiment can include the apparatus of any one of the first through eleventh embodiments, wherein the flexible seal is made of rubber or some other deployable flexible sealing member such as a thermoplastic or composite material.
A thirteenth embodiment can include the apparatus of any one of the first through twelfth embodiments, wherein the flexible seal comprises a hole extending therethrough.
A fourteenth embodiment can include the apparatus of any one of the first through thirteenth embodiments, wherein the hole is an axial hole.
A fifteenth embodiment can include the apparatus of any one of the first through fourteenth embodiments, wherein the hole is configured to have the tubular extending therethrough.
A sixteenth embodiment can include the apparatus of any one of the first through fifteenth embodiments, wherein the flexible seal is (e.g. fluid) impermeable.
A seventeenth embodiment can include the apparatus of any one of the first through sixteenth embodiments, wherein the flexible seal comprises a flexible wall encircling the tubular.
An eighteenth embodiment can include the apparatus of any one of the first through seventeenth embodiments, wherein a proximal end of the flexible wall is mounted/fixed to the tubular, and a distal end of the flexible wall is free (in some embodiments, the proximal end of the flexible wall may be fixedly attached to the tubular, while the remainder of the flexible wall may be free).
A nineteenth embodiment can include the apparatus of any one of the first through eighteenth embodiments, wherein the distal end of the flexible wall/seal extends towards the sand screen (e.g. the free end is disposed towards the sand screen, with distal end disposed between sand screen and proximal end).
A twentieth embodiment can include the apparatus of any one of the first through nineteenth embodiments, wherein in the first state, the flexible seal is axially spaced from the sand screen (e.g. in transitioning from the first to second state, the flexible seal moves linearly towards the sand screen), and/or in the second state, the flexible seal extends over an end of the sand screen (e.g. axially overlapping and/or sandwiched between the sand screen and the wellbore—thereby being held in the second state).
A twenty-first embodiment can include the apparatus of any one of the first through twentieth embodiments, wherein the deployment mechanism is configured to be activated in response to hydrostatic pressure in the wellbore exceeding a threshold, and wherein the threshold at which the deployment mechanism is configured to actuate via hydrostatic pressure is based on the desired depth of deployment (e.g. the shearable retaining element has a threshold based on the force applied when the flexible seal reaches desired depth—e.g. automatically deploying at the desired depth).
A twenty-second embodiment can include the apparatus of any one of the first through twenty-first embodiments, wherein the threshold at which the deployment mechanism is configured to actuate is greater than the hydrostatic pressure based on the desired depth of deployment (e.g. the shearable retaining element has a threshold based on the hydrostatic force applied when the flexible seal reaches desired depth plus some additional applied pressure (e.g. from the surface)—e.g. being deployed in response to being properly located and then having sufficient pressure applied downhole in the annular space).
A twenty-third embodiment can include the apparatus of any one of the first through twenty-second embodiments, wherein the deployment mechanism comprises: a coupling configured to fix the axial position of the flexible seal with respect to the sand screen; and a biasing member configured to bias the (e.g. distal end of the) flexible seal towards the sand screen, wherein the coupling is configured to release the flexible seal in response to expansion of the sand screen.
A twenty-fourth embodiment can include the apparatus of any one of the first through twenty-third embodiments, wherein the deployment mechanism comprises: a base, wherein the flexible seal is mounted to the tubular by the base; a coupling extending from the base or the flexible seal and configured to be affixed to the sand screen; a slip configured to be affixed to the tubular; and a biasing member extending from the slip to the base.
A twenty-fifth embodiment can include the apparatus of any one of the first through twenty-fourth embodiments, wherein the base comprises a metal base configured to encircle the tubular.
A twenty-sixth embodiment can include the apparatus of any one of the first through twenty-fifth embodiments, wherein the flexible seal is bonded to the metal base.
A twenty-seventh embodiment can include the apparatus of any one of the first through twenty-sixth embodiments, wherein the metal base comprises a lip, the flexible seal comprises a groove, and the lip is disposed inside the groove.
A twenty-eighth embodiment can include the apparatus of any one of the first through twenty-seventh embodiments, wherein the coupling is made of metal.
A twenty-ninth embodiment can include the apparatus of any one of the first through twenty-eighth embodiments, wherein the coupling comprises a shear pin.
A thirtieth embodiment can include the apparatus of any one of the first through twenty-ninth embodiments, wherein the coupling is shearingly attached to the sand screen (e.g. with a shear pin).
A thirty-first embodiment can include the apparatus of any one of the first through thirtieth embodiments, wherein the deployment mechanism is configured to cause the flexible seal to transition to the second state, in response to the coupling (or its attachment) breaking/shearing.
A thirty-second embodiment can include the apparatus of any one of the first through thirty-first embodiments, wherein the coupling is configured to break/shear, in response to the sand screen expanding.
A thirty-third embodiment can include the apparatus of any one of the first through thirty-second embodiments, wherein the sand screen expanding causes a clamp ring of the sand screen to rotate.
A thirty-fourth embodiment can include the apparatus of any one of the first through thirty-third embodiments, wherein the coupling is affixed to the clamp ring.
A thirty-fifth embodiment can include the apparatus of any one of the first through thirty-fourth embodiments, wherein the coupling is configured to break/shear, in response to the rotation of the clamp ring.
A thirty-sixth embodiment can include the apparatus of any one of the first through thirty-fifth embodiments, wherein the biasing member comprises a spring.
A thirty-seventh embodiment can include the apparatus of any one of the first through thirty-sixth embodiments, wherein the spring comprises a compression (e.g., coil) spring configured to encircle the tubular.
A thirty-eighth embodiment can include the apparatus of any one of the first through thirty-seventh embodiments, wherein in response to the coupling breaking/shearing, the spring is configured to expand to push the base axially along the tubular (e.g. base mounted to the tubular in such a way as to allow axial movement from the first position to the second position, once the coupling is no longer fixing its axial position).
A thirty-ninth embodiment can include the apparatus of any one of the first through thirty-eighth embodiments, wherein the flexible seal comprises an inclined plane (e.g. at its distal end, for example with the thickness of the flexible wall reducing as the flexible wall extends away from the base and/or with the inclined plane disposed in proximity to/facing the tubular (e.g. inward)).
A fortieth embodiment can include the apparatus of any one of the first through thirty-ninth embodiments, wherein the inclined plane is configured to guide the flexible seal over the clamp ring when the flexible seal transitions from the first state to the second state.
A forty-first embodiment can include the apparatus of any one of the first through fortieth embodiments, wherein sliding of the flexible seal over the clamp ring (as the sand screen expands) causes the flexible seal to transition from the first state to the second state (e.g. the expansion of the sand screen induces radial movement of the flexible seal outward).
A forty-second embodiment can include the apparatus of any one of the first through forty-first embodiments, wherein in the second state, the distal end of the flexible seal is disposed/wedged between the interior of the wellbore and the sand screen).
A forty-third embodiment can include the apparatus of any one of the first through forty-second embodiments, wherein the slip comprises a set screw configured to fasten the slip to the tubular.
A forty-fourth embodiment can include the apparatus of any one of the first through forty-third embodiments, wherein the slip is annular.
A forty-fifth embodiment can include the apparatus of any one of the first through forty-fourth embodiments, wherein the slip is configured to encircle the tubular.
A forty-sixth embodiment can include the apparatus of any one of the first through forty-seventh embodiments, wherein the spring extends from an end of the metal base to an end of the slip.
A forty-seventh embodiment can include the apparatus of any one of the first through twenty-second embodiments, wherein the deployment mechanism comprises a base, wherein the flexible seal extends from the base towards the sand screen (e.g. proximal end attached to base and distal end free and disposed towards and/or in proximity to the sand screen), and wherein the base is configured for activation based on hydrostatic pressure in the well.
A forty-eighth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh embodiments, wherein the base comprises: a first portion having a first inner diameter corresponding to a first outer diameter of the tubular; a second portion having a second inner diameter corresponding to a second outer diameter of the tubular; a port extending radially inward from an outer surface and a volume/chamber formed between the tubular and the base; and a shearable retaining element (e.g. shear pin) configured to axially fix the base to the tubular.
A forty-ninth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through forty-eighth embodiments, wherein the port comprises a vacuum port configured to facilitate drawing of a vacuum in the volume/chamber,
A fiftieth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through forty-ninth embodiments, wherein the port is configured for introduction of fluid (e.g., oil).
A fifty-first embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through fiftieth embodiments, wherein the chamber comprises fluid (e.g., oil) and a flow restrictor configured to cause a time delay.
A fifty-second embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through fifty-first embodiments, wherein the first inner diameter is greater than the second inner diameter.
A fifty-third embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through fifty-second embodiments, wherein the first outer diameter of the tubular is greater than the second outer diameter of the tubular.
A fifty-fourth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through fifty-third embodiments, wherein the first inner diameter is sized to create a slip fit with the first outer diameter.
A fifty-fifth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through fifty-fourth embodiments, wherein the second inner diameter is sized to create a slip fit with the second outer diameter.
A fifty-sixth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through fifty-fifth embodiments, wherein the first outer diameter is configured to act as a stop for axial movement of the base (e.g. due to interference interaction between the first inner diameter of the base and the second outer diameter of the tubular).
A fifty-seventh embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through fifty-sixth embodiments, wherein the base comprises a first axial end and a second axial end, and wherein the shear pin is configured to break/shear in response to a difference between a first hydrostatic force on the first axial end and a second hydrostatic force on the second axial end exceeding a threshold (thereby moving the flexible seal from the first position to the second position).
A fifty-eighth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through fifty-seventh embodiments, wherein the first hydrostatic force is based on a first projected surface area of the first axial end in a plane approximately perpendicular to a longitudinal central axis of the tubular, and the second hydrostatic force is based on a second projected surface area of the second axial end in another plane approximately perpendicular to a longitudinal central axis of the tubular (e.g. the two planes are approximately parallel to each other).
A fifty-ninth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through fifty-eighth embodiments, wherein the first hydrostatic force is further based on pressure in the well/annular space at a first axial location at which the first projected surface area is disposed, and the second hydrostatic force is further based on pressure in the well/annular space at a second axial location at which the first projected surface area is disposed.
A sixtieth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through fifty-ninth embodiments, wherein the pressure at the second axial location is greater than the pressure at the first axial location, for example due to greater depth.
A sixty-first embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through sixtieth embodiments, wherein the first projected surface area is greater than the second projected surface area.
A sixty-second embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through sixty-first embodiments, wherein the base comprises a stepped (e.g. inner) profile (e.g. forming the vacuum chamber/volume between the base and the tubular).
A sixty-third embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through sixty-second embodiments, wherein upon release of the shearable retaining element, a first surface of the base is configured to slide along a first surface of the tubular, and a second surface of the base is configured to slide along a second surface of the tubular (e.g. from the first position to the second position).
A sixty-fourth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through sixty-third embodiments, wherein the first inner diameter is an inner diameter of the first surface of the base and the second inner diameter is the inner diameter of the second surface of the base.
A sixty-fifth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through sixty-fourth embodiments, wherein a third surface of the base is configured to stop against a third surface of the tubular (upon axial movement of the base, e.g. to the second position, for example towards the sand screen and/or downward), wherein the third surface of the base is disposed between the first surface of the base and the second surface of the base, and wherein the third surface of the tubular is disposed between the first surface of the tubular and the second surface of the tubular.
A sixty-sixth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through sixty-fifth embodiments, wherein the first surface of the base is approximately parallel with the first surface of the base.
A sixty-seventh embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through sixty-sixth embodiments, wherein the first surface of the tubular is approximately parallel with the second surface of the tubular.
A sixty-eighth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through sixty-seventh embodiments, wherein the third surface of the base is approximately parallel with the third surface of the tubular.
A sixty-ninth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through sixty-eighth embodiments, wherein the third surface of the base extends radially outward at an oblique angle with the first surface of the base.
A seventieth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through sixty-ninth embodiments, wherein the third surface of the tubular extends radially outward at an oblique angle with the first surface of the tubular.
A seventy-first embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through seventieth embodiments, wherein third surface of the tubular is configured to limit axial translation of the base (e.g. act as a stop on axial movement).
A seventy-second embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through seventy-first embodiments, wherein in the first state, the third surface of the base is spaced apart from the third surface of the tubular (e.g. forming the vacuum chamber).
A seventy-third embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through seventy-second embodiments, wherein in the second state, the third surface of the base abuts or is in proximity to the third surface of the tubular (e.g. there is substantially no vacuum chamber remaining).
A seventy-fourth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through seventy-third embodiments, wherein a first seal is disposed between the first portion of the base and the tubular and a second seal is disposed between the second portion of the base and the tubular.
A seventy-fifth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through seventy-fourth embodiments, wherein the first portion has a first groove formed therein, the second portion has a second groove formed therein, a first seal is disposed within the first groove, and a second seal is disposed within the second groove.
A seventy-sixth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through seventy-fifth embodiments, wherein the first seal is configured to make a seal on the first surface of the tubular, and the second seal is configured to make a seal on the second surface of the tubular.
A seventy-seventh embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through seventy-sixth embodiments, wherein first seal and the second seal are configured to maintain the vacuum (e.g. defining the vacuum chamber between the base and the tubular, at least in the first state).
A seventy-eighth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through seventy-seventh embodiments, wherein the first seal is a first O-ring, and the second seal is a second O-ring.
A seventy-ninth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through seventy-eighth embodiments, wherein the vacuum port comprises a bore extending (e.g. substantially radially) from an outer surface of the base to an inner surface of the base (e.g. the third surface of the base), and a plug configured to plug/seal the bore (e.g. after the vacuum is drawn).
An eightieth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through seventy-ninth embodiments, wherein the vacuum port is configured to facilitate the pulling of the vacuum (thereby creating the vacuum in the vacuum chamber disposed between the base and the tubular).
An eighty-first embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through eightieth embodiments, wherein the base is made of metal, such as steel.
An eighty-second embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through eighty-first embodiments, wherein the flexible seal is made of rubber or thermoplastic, composite or other materials that can seal or at least substantially block flow.
An eighty-third embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through eighty-second embodiments, wherein the flexible seal is bonded to the base.
An eighty-fourth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through eighty-third embodiments, wherein the flexible seal is bonded to the first axial end of the base.
An eighty-fifth embodiment can include the apparatus of any one of the first through twenty-second and forty-seventh through eighty-fourth embodiments, wherein the base is integrally formed.
An eighty-sixth embodiment can include the apparatus of any one of the first through twenty-second embodiments, wherein the deployment mechanism comprises a dissolvable sleeve configured to constrain the flexible seal in the first state (e.g., prevent the flexible seal from transitioning from the first state to the second state).
An eighty-seventh embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth embodiments, wherein the flexible seal is biased outward (e.g. configured so that, if unrestrained, the distal end would expand radially outward to the second state (e.g. to (e.g. substantially sealing) contact with the wellbore).
An eighty-eighth embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through eighty-seventh embodiments, wherein the dissolvable sleeve is configured to restrain the flexible seal (e.g. the distal end of the flexible seal) at a diameter less than that of the wellbore (e.g. at a diameter no more than the run-in outer diameter of the tubular and/or the sand screen).
An eighty-ninth embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through eighty-eighth embodiments, wherein the dissolvable sleeve is mounted on the tubular.
A ninetieth embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through eighty-ninth embodiments, wherein in the first state, the flexible seal is disposed between the dissolvable sleeve and the tubular.
A ninety-first embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through ninetieth embodiments, wherein the dissolvable sleeve is approximately concentrically located about the flexible seal and/or the tubular.
A ninety-second embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through ninety-first embodiments, wherein the dissolvable sleeve is seal-shaped or any geometry that can restrict the rubber seal from deploying.
A ninety-third embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through ninety-second embodiments, wherein the dissolvable sleeve has a bore in a first end thereof.
A ninety-fourth embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through ninety-third embodiments, wherein the bore is configured to have the tubular extending therethrough.
A ninety-fifth embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through ninety-fourth embodiments, wherein the bore is concentric with a hole/bore in the flexible seal.
A ninety-sixth embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through ninety-fifth embodiments, wherein the bores of the dissolvable sleeve and the flexible seal are concentric with the tubular (e.g. the longitudinal bore of the tubular).
A ninety-seventh embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through ninety-sixth embodiments, wherein the dissolvable sleeve is configured to be fastened to the tubular.
A ninety-eighth embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through ninety-seventh embodiments, wherein the dissolvable sleeve is configured to be fastened to the tubular by a set screw.
A ninety-ninth embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through ninety-eighth embodiments, wherein the dissolvable sleeve is configured to extend to an end of the sand screen.
A one hundredth embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through ninety-ninth embodiments, wherein the dissolvable sleeve is configured to extend over the end of the sand screen.
A one-hundred-first embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through one hundredth embodiments, wherein the dissolvable sleeve is configured to dissolve when in contact with fluid in the well.
A one-hundred-second embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through one-hundred-first embodiments, wherein the fluid comprises hydrocarbons.
A one-hundred-third embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through one-hundred-second embodiments, wherein the fluid comprises a chemical pumped into the well.
A one-hundred-fourth embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through one-hundred-third embodiments, wherein the dissolvable sleeve is configured to dissolve within an hour of continuous exposure to the fluid.
A one-hundred-fifth embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through one-hundred-fourth embodiments, wherein the dissolvable sleeve is configured to dissolve within a day of continuous exposure to the fluid.
A one-hundred-sixth embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through one-hundred-fifth embodiments, wherein the dissolvable sleeve is configured to dissolve within a week of continuous exposure to the fluid.
A one-hundred-seventh embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through one-hundred-sixth embodiments, wherein the dissolvable sleeve comprises holes/apertures configured to allow the fluid to pass from an exterior of the sleeve to an interior of the sleeve (e.g. radially extending).
A one-hundred-eighth embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through one-hundred-seventh embodiments, wherein the holes are pores.
A one-hundred-ninth embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through one-hundred-eighth embodiments, wherein in the first state, the flexible seal is configured to exert outward pressure on an interior surface of the dissolvable sleeve.
A one-hundred-tenth embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through one-hundred-ninth embodiments, wherein in the first state, the flexible seal is fastened to the dissolvable sleeve.
A one-hundred-eleventh embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through one-hundred-tenth embodiments, wherein in the second state, the flexible seal is configured to contact and/or exert outward pressure on the wellbore (e.g. substantially sealing contact).
A one-hundred-twelfth embodiment can include the apparatus of any one of the first through twenty-second and eighty-sixth through one-hundred-eleventh embodiments, wherein in the second state, the flexible seal is configured to seal the annular space in proximity to the end of the sand screen (but typically not overlapping).
A one-hundred-thirteenth embodiment can include the apparatus of any one of the first through twenty-second embodiments, wherein the deployment mechanism comprises a fracturable sleeve configured to constrain the flexible seal in the first state (e.g., prevent the flexible seal from transitioning to the second state).
A one-hundred-fourteenth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth embodiments, wherein the flexible seal is biased outward (e.g. configured so that, unrestrained, the distal end would expand radially outward to the second state (e.g. to (e.g. substantially sealing) contact with the wellbore).
A one-hundred-fifteenth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth through one-hundred-fourteenth embodiments, wherein the fracturable sleeve is configured to restrain the flexible seal (e.g. the distal end of the flexible seal) at a diameter less than that of the wellbore (e.g. at a diameter no more than the run-in outer diameter of the tubular and/or sand screen).
A one-hundred-sixteenth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth through one-hundred-fifteenth embodiments, wherein the fracturable sleeve is mounted on the tubular.
A one-hundred-seventh embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth through one-hundred-sixteenth embodiments, wherein in the first state, the flexible seal is disposed between the fracturable sleeve and the tubular.
A one-hundred-eighteenth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth through one-hundred-seventeenth embodiments, wherein the fracturable sleeve is approximately concentrically located about the flexible seal and/or the tubular.
A one-hundred-nineteenth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth through one-hundred-seventeenth embodiments, wherein the fracturable sleeve is cup-shaped.
A one-hundred-twentieth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth through one-hundred-nineteenth embodiments, wherein the fracturable sleeve comprises a bore in a first end thereof.
A one-hundred-twenty-first embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth through one-hundred-twentieth embodiments, wherein the bore is configured to have the tubular extending therethrough.
A one-hundred-twenty-second embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth through one-hundred-twenty-first embodiments, wherein the bore is concentric with a hole/bore in the flexible seal and/or a longitudinal bore of the tubular and/or sand screen.
A one-hundred-twenty-third embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth through one-hundred-twenty-second embodiments, wherein the fracturable sleeve is configured to be fastened to the tubular.
A one-hundred-twenty-fourth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth through one-hundred-twenty-third embodiments, wherein the fracturable sleeve is configured to be fastened to the tubular by set screws.
A one-hundred-twenty-fifth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth through one-hundred-twenty-fourth embodiments, wherein in the first state the fracturable sleeve is configured to extend over the end of the sand screen.
A one-hundred-twenty-sixth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth through one-hundred-twenty-fifth embodiments, wherein the fracturable sleeve is configured to extend over at least a portion of the sand screen (e.g. over at least a portion of the filter element).
A one-hundred-twenty-seventh embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth though one-hundred-twenty-sixth embodiments, wherein the fracturable sleeve is configured to fracture in response to the sand screen being deployed (e.g. expanding, for example to contact the wellbore) (e.g. the force of the expansion of the sand screen radially outward is sufficient to break/fragment/shatter the fracturable sleeve).
A one-hundred-twenty-eighth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth through one-hundred-twenty-seventh embodiments, wherein the sand screen being deployed comprises activation chambers of the sand screen being pressurized.
A one-hundred-twenty-ninth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth through one-hundred-twenty-eighth embodiments, wherein the fracturable sleeve comprises fracture lines.
A one-hundred-thirtieth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth through one-hundred-twenty-ninth embodiments, wherein the fracture lines extend axially along the fracturable sleeve.
A one-hundred-thirty-first embodiment can include the apparatus of any one of the first through twenty-second and one-hundred-thirteenth through one-hundred-thirtieth embodiments, wherein the fracture lines define rectangular detachable/fragmentable segments.
A one-hundred-thirty-second embodiment can include the apparatus of any one of the first through twenty-second and one-hundred thirteenth through one-hundred-thirty-first embodiments, wherein the detachable segments are arranged in a cylinder.
A one-hundred-thirty-third embodiment can include the apparatus of any one of the first through twenty-second and one-hundred thirteenth through one-hundred-thirty-second embodiments, wherein the detachable segments are arranged in a polygon.
A one-hundred-thirty-fourth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred thirteenth through one-hundred-thirty-third embodiments, wherein the fracturable sleeve is cup-shaped.
A one-hundred-thirty-fifth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred thirteenth through one-hundred-thirty-fourth embodiments, wherein the fracturable sleeve comprises a brittle material.
A one-hundred-thirty-sixth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred thirteenth through one-hundred-thirty-fifth embodiments, wherein the flexible seal is configured to transition from the first state to the second state, in response to the fracturable sleeve fracturing.
A one-hundred-thirty-seventh embodiment can include the apparatus of any one of the first through twenty-second and one-hundred thirteenth through one-hundred-thirty-sixth embodiments, wherein the fracturable sleeve fracturing comprises the detatchable/fragmentable segments detaching/fragmenting.
A one-hundred-thirty-eighth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred thirteenth through one-hundred-thirty-seventh embodiments, wherein in the second state, the flexible seal is configured to contact and/or exert outward pressure on the wellbore (e.g. substantially sealing contact).
A one-hundred-thirty-ninth embodiment can include the apparatus of any one of the first through twenty-second and one-hundred thirteenth through one-hundred-thirty-eighth embodiments, wherein in the second state, the flexible seal is configured to seal the annular space in proximity to the end of the sand screen (but typically not overlapping).
In a one-hundred-fortieth embodiment, a method of installing a sand screen in a well, the method comprising: expanding the sand screen radially outward (e.g. so that the sand screen conforms to an interior surface of a wellbore of the well), wherein the sand screen is disposed between the interior surface of the wellbore and a tubular of the well; and activating an apparatus to cause a flexible seal to transition from a first state to a second state, wherein in the first state, there is a gap between the flexible seal and the interior surface of the wellbore, and wherein in the second state, the flexible seal spans from the tubular to the interior surface of the wellbore to seal an area proximate to the sand screen and between the interior surface of the wellbore and the tubular (e.g. in proximity to an end of the sand screen). E.g., an outer diameter of the flexible seal is greater in the second state than in the first state. E.g., in the first state, the outer diameter of the flexible seal is less than a diameter of the wellbore; and in the second state, the outer diameter of the flexible seal is the same as the diameter of the wellbore.
A one-hundred-forty-first embodiment can include the method of the one-hundred-fortieth embodiment, wherein the apparatus is the apparatus of any of the first through one-hundred-thirty-ninth embodiments.
A one-hundred-forty-second embodiment can include the method of the one-hundred-fortieth or one-hundred-forty-first embodiments, wherein activating the apparatus comprises activating a deployment mechanism.
A one-hundred-forty-third embodiment can include the method of any of the one-hundred-fortieth through one-hundred-forty-second embodiments, wherein expanding the sand screen comprises activating an activation chamber.
A one-hundred-forty-fourth embodiment can include the method of any one of the one-hundred-fortieth through one-hundred-forty-third embodiments, wherein activating the activation chamber comprises applying pressure to the activation chamber and/or contracting fluid with swellable material in the activation chamber.
A one-hundred-forty-fifth embodiment can include the method of any one of the one-hundred-fortieth through one-hundred-forty-fourth embodiments, wherein the transition from the first state to the second state comprises closing the gap and/or sealing the annular space between the wellbore and the tubular.
A one-hundred-forty-sixth embodiment can include the method of any one of the one-hundred-fortieth through one-hundred-forty-fifth embodiments, wherein activating the apparatus occurs in response to expanding the sand screen.
A one-hundred-forty-seventh embodiment can include the method of any one of the one-hundred-fortieth through one-hundred-forty-sixth embodiments, wherein the activating of the deployment mechanism is responsive to the activating of the activation chamber.
A one-hundred-forty-eighth embodiment can include the method of any one of the one-hundred-fortieth through one-hundred-forty-seventh embodiments, further comprising positioning the sand screen axially at a position in the wellbore for production.
A one-hundred-forty-ninth embodiment can include the method of any one of the one-hundred-fortieth through one-hundred-forty-eighth embodiments, further comprising positioning, perforating and/or fracturing at the position (e.g. using a perforating gun or other tool string, which is then removed to allow insertion of the tubular with sand screen(s)).
A one-hundred-fiftieth embodiment can include the method of any one of the one-hundred-fortieth through one-hundred-forty-ninth embodiments, further comprising activating the sealing sleeve, and producing fluid from the formation to the surface.
A one-hundred-fifty-first embodiment can include the method of any one of the one-hundred-fortieth through one-hundred-fiftieth embodiments, wherein producing fluid comprises using a pump to draw fluid from the formation, through the sand screen, into the tubular bore, and up the bore to the surface.
A one-hundred-fifty-second embodiment can include the method of the one-hundred-forty-second through one-hundred-fifty-first embodiments, wherein expanding the sand screen shears a shearable retaining element, and wherein activating the apparatus occurs in response to shearing the shearable retaining element.
A one-hundred-fifty-third embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-second embodiments, wherein activating the apparatus comprises axially shifting the flexible seal towards the sand screen (e.g. until the distal end of the flexible seal overlaps the end of the sand screen).
A one-hundred-fifty-fourth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-third embodiments, wherein the distal end of the apparatus expands radially due to radial expansion of the sand screen (e.g. when overlapped), and/or wherein in the second state the distal end of the flexible seal is wedged/sandwiched/held between the sand screen and the wellbore.
A one-hundred-fifty-fifth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-fourth embodiments, wherein the activating of the deployment mechanism is responsive to the activating of the activation chamber shearing a pin of the deployment mechanism.
A one-hundred-fifty-sixth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-fifth embodiments, wherein the flexible seal is biased towards the sand screen, the axial position of the flexible seal is fixed by a shear pin, and the deployment mechanism axially translates the flexible seal.
A one-hundred-fifty-seventh embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-sixth embodiments, wherein the deployment mechanism axially translates the flexible seal along the tubular and/or towards the sand screen, in response to the shearing of the pin.
A one-hundred-fifth-eighth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-seventh embodiments, wherein the axial translation is caused by expansion of a spring between a metal base of the deployment mechanism and a slip of the deployment mechanism.
A one-hundred-fifty-ninth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-eighth embodiments, wherein the slip of the deployment mechanism is affixed to the tubular.
A one-hundred-sixtieth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first embodiments, wherein activating the apparatus comprises disposing the apparatus at a depth.
A one-hundred-sixty-first embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-sixtieth embodiments, wherein the depth is a depth at which hydrostatic pressure will activate (e.g. shear the shearable retaining mechanism and move the flexible seal axially towards the sand screen).
A one-hundred-sixty-second embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-sixtieth through one-hundred-sixty-first embodiments, wherein activating the apparatus comprises disposing the apparatus at a depth and applying pressure in the wellbore above hydrostatic pressure to activate (e.g. shear the shearable retaining mechanism and move the flexible seal axially towards the sand screen).
A one-hundred-sixty-third embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-sixtieth through one-hundred-sixty-second embodiments, wherein the activating of the deployment mechanism is responsive to pressuring up fluid between the interior surface of the wellbore and the tubular.
A one-hundred-sixty-fourth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-sixtieth through one-hundred-sixty-third embodiments, wherein the activation of the deployment mechanism comprises translating the deployment mechanism (e.g. axially) along the tubular.
A one-hundred-sixty-fifth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-sixtieth through one-hundred-sixty-fourth embodiments, wherein the translating of the deployment mechanism occurs in response to the pressuring up the fluid causing a pin of the deployment mechanism to break/shear.
A one-hundred-sixty-sixth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-sixtieth through one-hundred-sixty-fifth embodiments, wherein the breaking of the pin is caused by hydrostatic pressure, resulting from the pressuring up, exerting a net force on the deployment mechanism.
A one-hundred-sixty-seventh embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-sixtieth through one-hundred-sixty-sixth embodiments, wherein the net force occurs by virtue of a vacuum between the deployment mechanism and the tubular and/or an area difference between ends of the apparatus/deployment mechanism.
A one-hundred-sixty-eighth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first embodiments, wherein the deployment mechanism comprises a dissolvable sleeve, and activating the apparatus comprises dissolving the sleeve.
A one-hundred-sixty-ninth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-sixty-eighth embodiments, wherein dissolving the sleeve comprises applying a fluid for a sufficient duration.
A one-hundred-seventieth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-sixty-eighth through one-hundred-sixty-ninth embodiments, wherein the fluid comprises hydrocarbons, mud, or a chemical.
A one-hundred-seventy-first embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-sixty-eighth through one-hundred-seventieth embodiments, wherein dissolving the sleeve comprises dissolving from an inner and an outer surface of the sleeve.
A one-hundred-seventy-second embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-sixty-eighth through one-hundred-seventy-first embodiments, wherein the activation of the deployment mechanism comprises dissolving a sleeve.
A one-hundred-seventy-third embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-sixty-eighth through one-hundred-seventy-second embodiments, wherein the dissolving of the sleeve enables the flexible seal to expand to transition from the first state to the second state.
A one-hundred-seventy-fourth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first embodiments, wherein the deployment mechanism comprises a fracturable sleeve, and activating the apparatus comprises fracturing the sleeve.
A one-hundred-seventy-fifth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-seventy-fourth embodiments, wherein fracturing the sleeve comprises expanding the sand screen (e.g. the fracturable sleeve is disposed to overlap the sand screen, such that fracturing the sleeve is responsive to expansion of the sand screen-applying radial forces via the expanding the sand screen).
A one-hundred-seventy-sixth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-seventy-fourth through one-hundred-seventy-fifth embodiments, wherein the activation of the deployment mechanism comprises fracturing a sleeve, and wherein the fracturing of the sleeve is caused by the sand screen exerting a radially outward force on the sleeve as the sand screen expands during the activating of the activation chamber.
A one-hundred-seventy-seventh embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-seventy-fourth through one-hundred-seventy-sixth embodiments, wherein the fracturing of the fracturing sleeve comprises detaching of segments from the deployment mechanism.
A one-hundred-seventy-eighth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-seventy-fourth through one-hundred-seventy-seventh embodiments, wherein the detaching of the segments comprises fracturing the segments along fracture lines.
A one-hundred-seventy-ninth embodiment can include the method of any one of the one-hundred-forty-second through one-hundred-fifty-first and one-hundred-seventy-fourth through one-hundred-seventy-eighth embodiments, wherein the segments move away from the deployment mechanism after the detaching of the segments.
In a one-hundred-eightieth embodiment a system for filtering sand from formation fluid in a well, the system comprising: a tubular disposed inside a wellbore of the well; a sand screen fixed to the tubular, the sand screen being configured to radially expand (e.g. about the tubular) upon actuation; and an apparatus, comprising: a flexible seal configured to encircle the tubular, wherein the flexible seal comprises a first (e.g. run-in) state in which an outer diameter of the flexible seal is less than a diameter of a wellbore (e.g. there is a gap between the flexible seal and the interior surface of the wellbore), and a second (e.g. deployed) state in which the outer diameter of the flexible seal is the same as the diameter of the wellbore (e.g. the flexible seal extends radially outward from the tubular to contact an interior surface of the wellbore) and/or in which the flexible seal seals the annular space between the tubular and the wellbore; and a deployment mechanism configured to cause the flexible seal to transition from the first state to the second state.
A one-hundred-eighty-first embodiment can include the system of the one-hundred-eightieth embodiment wherein the apparatus is the apparatus according to any of the first through one-hundred-thirty-ninth embodiments.
A one-hundred-eighty-second embodiment can include the system of the one-hundred-eightieth or one-hundred-eighty-first embodiments, wherein an initial pressure cycle shears internal sleeves of each screen valve module.
A one-hundred-eighty-third embodiment can include the system of any of the one-hundred-eightieth through one-hundred-eighty-second embodiments, wherein after releasing initial pressure, valves will be positioned ready for screen activation.
A one-hundred-eighty-fourth embodiment can include the system of any of the one-hundred-eightieth through one-hundred-eighty-third embodiments, wherein surface applied pressure activates all screens by adding fluid volume into the screen activation chambers
A one-hundred-eighty-fifth embodiment can include the system of any of the one-hundred-eightieth through one-hundred-eighty-fourth embodiments, wherein activation pressure is locked inside the chambers.
A one-hundred-eighty-sixth embodiment can include the system of any of the one-hundred-eightieth through one-hundred-eighty-fifth embodiments, wherein activation pressure is let off, aligning ports for production or injection.
A one-hundred-eighty-seventh embodiment can include the system of any of the one-hundred-eightieth through one-hundred-eighty-sixth embodiments, wherein the apparatus is disposed in proximity to one end of the sand screen.
A one-hundred-eighty-eighth embodiment can include the system of any of the one-hundred-eightieth through one-hundred-eighty-seventh embodiments, further comprising another apparatus, wherein one of the two apparatus is disposed in proximity to each end of the sand screen.
A one-hundred-eighty-ninth embodiment can include the system of any of the one-hundred-eightieth through one-hundred-eighty-eighth embodiments, further comprising a plurality of sand screens, wherein an apparatus is disposed in proximity to one or more end of each sand screen.
A one-hundred-ninetieth embodiment can include the system of any of the one-hundred-eightieth through one-hundred-eighty-ninth embodiments, wherein the sand screen extends axially in a section of the wellbore.
A one-hundred-ninety-first embodiment can include the system of any of the one-hundred-eightieth through one-hundred-ninetieth embodiments, wherein between adjacent sand screens, a portion of the tubular does not have associated sand screen (e.g. no sand screen encircling it, for example exposed to the wellbore).
A one-hundred-ninety-second embodiment can include the system of any of the one-hundred-eightieth through one-hundred-ninety-first embodiments.
A one-hundred-ninety-third embodiment can include the system of any of the one-hundred-eightieth through one-hundred-ninety-second embodiments, wherein an axial location of the wellbore is configured for fluid production, and wherein the sand screen is disposed at that axial location.
A one-hundred-ninety-fourth embodiment can include the system of any of the one-hundred-eightieth through one-hundred-ninety-third embodiments, wherein the apparatus is configured to prevent axial fluid flow.
A one-hundred-ninety-fifth embodiment can include the system of any of the one-hundred-eightieth through one-hundred-ninety-fourth embodiments, wherein the sand screen comprises activation chambers arranged around a circumferential surface of the tubular.
A one-hundred-ninety-sixth embodiment can include the system of any of the first through one-hundred-ninety-fifth embodiments, wherein the activation chambers are configured to activate to cause the sand screen to conform to the interior surface of the wellbore.
A one-hundred-ninety-seventh embodiment can include the system of any of the one-hundred-eightieth through one-hundred-ninety-sixth embodiments, wherein the sand screen further comprises a support layer surrounding the activation chambers.
A one-hundred-ninety-eighth embodiment can include the system of any of the one-hundred-eightieth through one-hundred-ninety-seventh embodiments, wherein the support layer is configured for drainage into the production flow channel.
A one-hundred-ninety-ninth embodiment can include the system of any of the one-hundred-eightieth through one-hundred-ninety-ninth embodiments, wherein the support layer comprises holes.
A two-hundredth embodiment can include the system of any of the one-hundred-eightieth
through one-hundred-ninety-ninth embodiments, wherein the support layer comprises plates.
A two-hundred-first embodiment can include the system of any of the one-hundred-eightieth through two-hundredth embodiments, wherein holes are formed in the plates.
A two-hundred-second embodiment can include the system of any of the one-hundred-eightieth through two-hundred-first embodiments, wherein flow channels are formed between the activation chambers and the support layer.
A two-hundred-third embodiment can include the system of any of the one-hundred-eightieth through two-hundred-second embodiments, wherein the sand screen further comprises a sand filtration media surrounding the support layer.
A two-hundred-fourth embodiment can include the system of any of the one-hundred-eightieth through two-hundred-third embodiments, wherein the sand filtration media is configured to filter sand particles above a threshold size.
A two-hundred-fifth embodiment can include the system of any of the one-hundred-eightieth through two-hundred-fourth embodiments, wherein the sand screen further comprises a protective shroud surrounding the sand filtration media.
A two-hundred-sixth embodiment can include the system of any of the one-hundred-eightieth through two-hundred-fifth embodiments, wherein the protective shroud comprises a mesh.
In a two-hundred-seventh embodiment, a method of making comprises: disposing a sand screen on a tubular, wherein the sand screen is configured to expand radially outward; disposing an apparatus on the tubular in proximity to an end of the sand screen, the apparatus comprising: a flexible seal configured to encircle the tubular, wherein the flexible seal comprises a first (e.g. run-in) state in which an outer diameter of the flexible seal is less than a diameter of a wellbore (e.g. there is a gap between the flexible seal and the interior surface of the wellbore), and a second (e.g. deployed) state in which the outer diameter of the flexible seal is the same as the diameter of the wellbore (e.g. the flexible seal extends radially outward from the tubular to contact an interior surface of the wellbore) and/or in which the flexible seal seals the annular space between the tubular and the wellbore; and a deployment mechanism configured to cause the flexible seal to transition from the first state to the second state.
A two-hundred-eighth embodiment can include the method of the two-hundred-seventh embodiment, wherein the apparatus is the apparatus of any one of the first through one-hundred-thirty-ninth embodiments.
A two-hundred-ninth embodiment can include the method of the two-hundred-seventh or two-hundred-eighth embodiments, further comprising axially biasing the flexible seal using a spring, and affixing an axial position of the flexible seal with respect to sand screen using a shearable retaining element.
A two-hundred-tenth embodiment can include the method of any one of the two-hundred-seventh through two-hundred-ninth embodiments, further comprising configuring the apparatus for actuation based on hydrostatic pressure, and affixing an axial position of the flexible seal with respect to the sand screen using a shearable retaining element.
A two-hundred-eleventh embodiment can include the method of any of the two-hundred-seventh through two-hundred-tenth embodiments, further comprising compressing the flexible seal (e.g. retaining the flexible seal in its first state) with a dissolvable sleeve.
A two-hundred-twelfth embodiment can include the method of any one of the two-hundred-seventh through two-hundred-eleventh embodiments, further comprising compressing the flexible seal (e.g. retaining the flexible seal in its first state) with a fracturable sleeve.
While embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of this disclosure. The embodiments described herein are exemplary only and are not intended to be limiting. Many variations and modifications of the embodiments disclosed herein are possible and are within the scope of this disclosure. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented. Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other techniques, systems, subsystems, or methods without departing from the scope of this disclosure. Other items shown or discussed as directly coupled or connected or communicating with each other may be indirectly coupled, connected, or communicated with. Method or process steps set forth may be performed in a different order. The use of terms, such as “first,” “second,” “third” or “fourth” to describe various processes or structures is only used as a shorthand reference to such steps/structures and does not necessarily imply that such steps/structures are performed/formed in that ordered sequence (unless such requirement is clearly stated explicitly in the specification).
Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, Rl, and an upper limit, Ru, is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=Rl+k*(Ru−Rl), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . 50 percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Language of degree used herein, such as “approximately,” “about,” “generally,” and “substantially,” represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the language of degree may mean a range of values as understood by a person of skill or, otherwise, an amount that is +/−10%.
Disclosure of a singular element should be understood to provide support for a plurality of the element. It is contemplated that elements of the present disclosure may be duplicated in any suitable quantity.
Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, etc. When a feature is described as “optional,” both embodiments with this feature and embodiments without this feature are disclosed. Similarly, the present disclosure contemplates embodiments where this “optional” feature is required and embodiments where this feature is specifically excluded. The use of the terms such as “high-pressure” and “low-pressure” is intended to only be descriptive of the component and their position within the systems disclosed herein. That is, the use of such terms should not be understood to imply that there is a specific operating pressure or pressure rating for such components. For example, the term “high-pressure” describing a manifold should be understood to refer to a manifold that receives pressurized fluid that has been discharged from a pump irrespective of the actual pressure of the fluid as it leaves the pump or enters the manifold. Similarly, the term “low-pressure” describing a manifold should be understood to refer to a manifold that receives fluid and supplies that fluid to the suction side of the pump irrespective of the actual pressure of the fluid within the low-pressure manifold.
Accordingly, the scope of protection is not limited by the description set out above but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as embodiments of the present disclosure. Thus, the claims are a further description and are an addition to the embodiments of the present disclosure. The discussion of a reference herein is not an admission that it is prior art, especially any reference that can have a publication date after the priority date of this application. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated by reference, to the extent that they provide exemplary, procedural, or other details supplementary to those set forth herein.
Use of the phrase “at least one of” preceding a list with the conjunction “and” should not be treated as an exclusive list and should not be construed as a list of categories with one item from each category, unless specifically stated otherwise. A clause that recites “at least one of A, B, and C” can be infringed with only one of the listed items, multiple of the listed items, and one or more of the items in the list and another item not listed.
As used herein, the term “or” does not require selection of only one element. Thus, the phrase “A or B” is satisfied by either element from the set {A, B}, including multiples of any either element; and the phrase “A, B, or C” is satisfied by any element from the set {A, B, C} or any combination thereof, including multiples of any element. A clause that recites “A, B, or C” can be infringed with only one of the listed items, multiple of the listed items, and one or more of the items in the list and another item not listed.
As used herein, the terms “a” and “an” mean “one or more.” As used herein, the term “the” means “the one or more.” Thus, the phrase “an element” means “one or more elements;” and the phrase “the element” means “the one or more elements.”
As used herein, the term “and/or” includes any combination of the elements associated with the “and/or” term. Thus, the phrase “A, B, and/or C” includes any of A alone, B alone, C alone, A and B together, B and C together, A and C together, or A, B, and C together.

Claims

1. An apparatus for sealing an annular space proximate to an end of a sand screen on a tubular in a wellbore, the apparatus comprising:

a flexible seal configured to encircle the tubular, wherein the flexible seal comprises a first state in which an outer diameter of the flexible seal is less than a diameter of the wellbore, and a second state in which the outer diameter of the flexible seal is the same as the diameter of the wellbore; and

a spring configured to cause the flexible seal to transition from the first state to the second state.

2. The apparatus of claim 1, wherein the spring comprises a coil spring configured to encircle the tubular, wherein the coil spring is part of a deployment mechanism comprising a coupling configured to releasably fix the flexible seal to the sand screen, wherein the coil spring is configured to bias the flexible seal towards the sand screen, and wherein the coupling is configured to release the flexible seal in response to expansion of the sand screen.

3. The apparatus of claim 2, wherein

the deployment mechanism further comprises a base configured to encircle the tubular and a slip configured to be affixed to the tubular,

the flexible seal is mounted to the base,

the coupling extends from the base or the flexible seal, and

the coil spring extends from the slip to the base.

4. The apparatus of claim 1, wherein further comprising a deployment mechanism comprising a base, wherein the flexible seal extends from the base towards the sand screen, and wherein the base is configured to be activated in response to hydrostatic pressure in the wellbore exceeding a threshold.

5. The apparatus of claim 4, wherein the base comprises:

a first portion having a first inner diameter corresponding to a first outer diameter of the tubular;

a second portion having a second inner diameter corresponding to a second outer diameter of the tubular; and

a port extending radially inward from an outer surface of the base into a chamber formed between the base and the tubular,

wherein the deployment mechanism comprises a shearable retaining element configured to releasably fix the base to the tubular.

6. The apparatus of claim 1, further comprising a deployment mechanism comprising a dissolvable sleeve configured to constrain the flexible seal in the first state.

7. The apparatus of claim 6, wherein in the first state, the flexible seal is disposed between the dissolvable sleeve and the tubular.

8. The apparatus of claim 1, further comprising a deployment mechanism comprising a fracturable sleeve configured to constrain the flexible seal in the first state.

9. The apparatus of claim 8, wherein in the first state, the flexible seal is disposed between the fracturable sleeve and the tubular.

10. A method of installing a sand screen in a well, the method comprising:

expanding the sand screen radially outward, wherein the sand screen is disposed between a tubular of the well and an interior surface of a wellbore; and

activating an apparatus, by a spring, to cause a flexible seal to transition from a first state to a second state,

wherein in the first state, there is a gap between the flexible seal and the interior surface of the wellbore, and

wherein in the second state, the flexible seal spans from the tubular to the interior surface of the wellbore to seal an area proximate to the sand screen and between the tubular and the interior surface of the wellbore.

11. The method of claim 10, wherein the spring is part of a deployment mechanism of the apparatus.

12. The method of claim 10, wherein the expanding of the sand screen comprises activating an activation chamber of the sand screen.

13. The method of claim 11, wherein the activating of the deployment mechanism occurs in response to the expanding of the sand screen.

14. The method of claim 10, wherein the transitioning to the second state comprises extending the flexible seal over the sand screen.

15. The method of claim 10, wherein the flexible seal is releasably constrained in the first position by a sleeve.

16. A system for filtering sand from formation fluid in a well, the system comprising:

a tubular disposed inside a wellbore;

one or more sand screens fixed to the tubular and configured to radially expand upon activation; and

one or more apparatuses each disposed proximate to at least one of the one or more sand screens, each of the one or more apparatuses comprising:

17. The system of claim 16, wherein the spring is part of a deployment mechanism comprising a coupling configured to releasably fix the flexible seal to the sand screen, and a biasing member configured to bias the flexible seal towards the sand screen, wherein the coupling is configured to release the flexible seal in response to expansion of the sand screen.

18. The system of claim 16, wherein further comprising a deployment mechanism comprising a base, wherein the flexible seal extends from the base towards the sand screen, wherein the base is configured to be activated in response to hydrostatic pressure in the wellbore exceeding a threshold, wherein the base comprises a first portion having a first inner diameter corresponding to a first outer diameter of the tubular, a second portion having a second inner diameter corresponding to a second outer diameter of the tubular, and a port extending radially inward from an outer surface of the base into a chamber formed between the base and the tubular, and wherein the deployment mechanism comprises a shearable retaining element configured to releasably fix the base to the tubular.

19. The system of claim 16, wherein further comprising a deployment mechanism comprising a dissolvable sleeve configured to constrain the flexible seal in the first state, and wherein in the first state, the flexible seal is disposed between the dissolvable sleeve and the tubular.

20. The system of claim 16, wherein further comprising a deployment mechanism comprising a fracturable sleeve configured to constrain the flexible seal in the first state, and wherein in the first state, the flexible seal is disposed between the fracturable sleeve and the tubular.