Self-conforming screen

• US 20050173130A1
• Filed: 04/08/2005
• Published: 08/11/2005
• Est. Priority Date: 08/23/2002
• Status: Active Grant

• Current Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Original Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Inventors: Richard, Bennett M.
• Granted Patent: US 7,013,979 B2
• Time in Patent Office: Days
• US Class Current: 166/384
• CPC Class Codes: E21B 43/086 Screens with preformed openings, e.g. slotted liners comprising porous materials E21B43/082
• CPC Class Codes: E21B 43/103 of expandable casings, screens, liners, or the like
• CPC Class Codes: E21B 43/108 Expandable screens or perforated liners

Abstract

A screen that conforms to the borehole shape after expansion is disclosed. The screen comprises a compliant outer layer that takes the borehole shape on expansion. The outer layer is formed having holes to permit production flow. The material that is selected preferably swells with prolonged contact to well fluids to further close off annular gaps after expansion. In an alternative embodiment, the screen is not expanded and the swelling of the material alone closes off annular gaps. The outer sleeve is placed over the screen and the screen is placed on a base pipe and initially expanded from within the base pipe to secure the components of the screen assembly for running downhole, while minimizing or eliminating any welding among the layers. A variety of expansion tools can be used to expand the screen or screens downhole.

Claims

1. A well completion method, comprising:

covering a tubular having at least one opening with an unrestrained conforming material;

running said tubular to a desired location in the wellbore;

allowing said unrestrained conforming material to expand.

2. The method of claim 1, comprising:

allowing said conforming material to expand to the shape of the surrounding wellbore.

3. The method of claim 1, comprising:

securing said conforming material to said tubular by outward expansion of said tubular prior to said running said tubular into the wellbore.

4. The method of claim 1, comprising:

securing said conforming material to said tubular as a result of bonding.

5. The method of claim 2, comprising:

expanding said tubular and conforming material;

forcing said conforming material to flow along the wellbore by said expanding of said tubular.

6. The method of claim 1, comprising:

allowing the conforming material to swell.

7. The method of claim 6, comprising:

using well fluids to initiate said swelling.

8. The method of claim 1, comprising:

using a polymeric material as said conforming material.

9. The method of claim 1, comprising:

taking flow through said conforming material and said tubular after said expansion.

10. A well completion method, comprising:

covering a tubular having at least one opening with a conforming material, said conforming material having a relaxed outer dimension in an unrestrained condition;

running said tubular to a desired location in the wellbore;

allowing said conforming material to expand beyond said relaxed outer dimension.

11. The method of claim 10, comprising:

taking flow through said conforming material and said tubular after said expansion.

12. The method of claim 10, comprising:

using a polymeric material as said conforming material.

13. The method of claim 10, comprising:

allowing the conforming material to swell.

14. The method of claim 13, comprising:

using well fluids to initiate said swelling.

15. The method of claim 10, comprising:

expanding said tubular and conforming material;

forcing said conforming material to flow along the wellbore by said expanding of said tubular.

16. The method of claim 10, comprising:

allowing said conforming material to expand to the shape of the surrounding wellbore.

17. The method of claim 10, comprising:

securing said conforming material to said tubular by outward expansion of said tubular prior to said running said tubular into the wellbore.