Downhole radial expansion tool

Abstract

Apparatus and associated methods relate to a self-expanding downhole radial expansion tool. In an illustrative example, the downhole radial expansion tool may include an energized spring. The energized spring may, for example, be disposed around a pipe. For example, the energized spring may be attached at opposing ends to collars. When the collars are released, for example, the energized spring may rotate about the pipe. The collars may, for example, constrain the axial contraction and / or expansion of the spring. The downhole radial expansion tool may, for example, advantageously displace subterranean particles after the spring expands in an exemplary wellbore. Various embodiments may, for example, advantageously a mechanical pre-energized downhole expansion module independent of surface energy sources.

Description

DOWNHOLE RADIAL EXPANSION TOOLTECHNICAL FIELD

[0001] Various embodiments relate generally to oil and gas well drilling both on and offshore.BACKGROUND

[0002] Oil and gas drilling begins with geological surveys to identify reserves, followed by exploratory drilling to confirm hydrocarbon presence. Upon finding a viable reservoir, the development phase starts, focusing on drilling production wells and setting up infrastructure like pipelines for efficient extraction. This critical process demands sophisticated technology, substantial investment, and strategic planning to optimize recovery, manage costs, and mitigate environmental impact, ensuring sustainable global energy supply.

[0003] Offshore drilling refers to the process of extracting petroleum and natural gas from beneath the ocean floor. This operation is carried out using drilling platforms, which can be floating or fixed structures, positioned in both shallow and deep waters. The technique involves drilling wells to access underwater reserves, tapping into resources that are crucial for meeting global energy demands. Offshore drilling enables the exploration and production of oil and gas resources that are otherwise inaccessible, playing a vital role in enhancing energy security. The process requires advanced technology and engineering to efficiently and safely extract these resources from beneath the seabed.

[0004] Gravel packs are a sand control method used to prevent sand ingress in oil and gas wells by surrounding the well screen with gravel, acting as a filter. This technique ensures hydrocarbon flow while blocking sand, selected based on reservoir sand size. It's crucial for maintaining well integrity and prolonging productivity, especially in loose sand formations or high-rate wells.SUMMARY

[0005] Apparatus and associated methods relate to a self-expanding downhole radial expansion tool. In an illustrative example, the downhole radial expansion tool may include an energized spring. The energized spring may, for example, be disposed around a pipe. For example, the energized spring may be attached at opposing ends to collars. When the collars are released, for example, the energized spring may rotate about the pipe. The collars may, for example, constrain the axial contraction and / or expansion of the spring. The downhole radial expansion tool may, for example, advantageously displace subterranean particles after the spring expands in an exemplary wellbore. Various embodiments may, for example, advantageously a mechanical pre-energized downhole expansion module independent of surface energy sources.

[0006] The downhole radial expansion tool may, for example, be used in a system. The downhole radial expansion tool may be used in a sand control system. The downhole radial expansion tool may be used in a method. The radial expansion tool may be used in a sand control method.

[0007] In an illustrative example, a sand control system may include a perforated base pipe. The system may, for example, include a coiled spring that has an inner diameter which is larger than a outer diameter of the perforated base pipe. The coiled spring is placed outside the perforated base pipe. The coiled spring is wound around the perforated base pipe. The system includes a screen jacket. The screen jacket is placed outside the wound coiled spring and a gravel layer. The gravel layer is placed between a permeable membrane. The sand control system further includes a permeable membrane. The permeable membrane may, for example, include gravel. The permeable membrane may, for example, include be metal or composite spheres, foam closed or open cell, natural gravel, man-made ceramic spheres or simply left with only the permeable membrane and no particles.

[0008] In an illustrative example, some embodiments may, for example, include a sand control system. The exemplary sand control system includes a perforated base pipe and a coiled spring. The coiled spring has an inner diameter which is larger than an outer diameter of the perforated base pipe, is placed outside the perforated base pipe and is wound around the perforated base pipe. The exemplary sand control system includes a spring lock ring. The spring lock ring holds the first end of the wound coiled spring relative to the perforated base pipe and a rotating ring. The rotating rings hold a second end of the wound coiled spring relative to the perforated base pipe. The exemplary sand control system further includes a screen jacket. The screen jacket is placed outside the wound coiled spring and a gravel layer. The exemplary sand control system includes a permeable membrane around the gravel layer and one or more end caps. The one or more end caps are attached to the perforated base pipe. The one or more caps may advantageously hold the wound coiled spring, the screen jacket, the gravel layer and the permeable membrane in place relative to the perforated base pipe. The exemplary sand control system includes a spring release mechanism on each end of the perforated base pipe. The spring release mechanism releases the rotating ring, allowing the both ends of the wound coiled spring to move relative to the perforated base pipe.

[0009] In an illustrative aspect, some embodiments may, for example, include a method of deploying a sand control system in which a user of the method may use the method. The exemplary method includes the user of the method securing a coiled spring to a perforated base pipe. The method includes the user of the method using a spring lock ring and winding the spring. The method includes the user of the method securing the second end of the wound coiled spring to the perforated base pipe via a rotating ring. The exemplary method includes the user of the method placing a pin in the rotating ring. The pin may advantageously prevent motion of the rotating ringrelative to the perforated base pipe. The exemplary method includes the user of the method placing a screen jacket over the coiled spring. The exemplary method includes the user of the method placing a permeable membrane above and below a gravel layer under the screen jacket. The method includes the user of the method placing a permeable membrane above and below the gravel layer and mounting endcaps on the perforated base pipe. The method includes the user of the method installing the sand control system in a wellbore. The method includes the user of the method triggering a spring release mechanism. The spring release mechanism may, for example, release the rotating ring.

[0010] Various embodiments may achieve one or more advantages. For example, the downhole radial expansion tool may, for example, be used in a sand control system. For example, the downhole expansion tool may, for example, be used in a sand control method. The downhole radial expansion tool may advantageously include an easy to deploy trigger and actuator. The downhole radial expansion tool may advantageously quickly expand.

[0011] The radial expansion tool may, for example, be used in a sand control system to be tuned based on external parameters such as the formation of the targeted area. The radial expansion tool may, for example, be used in a sand control method. The radial expansion tool may advantageously be tuned based on the external parameter of depth to the targeted area. The targeted area may, for example, include the drilling site. The targeted area may, for example, include the wellbore. The targeted area may, for example, be underneath a body of water. The targeted area may, for example, be on land.

[0012] Some downhole radial expansion tool embodiments may advantageously allow a sand control system to have a high rate of sand retention and coverage. The downhole radial expansion tool may, for example, may advantageously be used in an exemplary sand control method to have a high rate of sand retention and coverage. The embodiments may advantageously allow an exemplary system to expand quickly. The exemplary system, method, and apparatus may advantageously be validated with logging tools.

[0013] The details of various embodiments are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1A depicts an exemplary downhole expansion tool and exemplary gravel pack employed in an illustrative use-case scenario.

[0015] FIG. IB depicts an exemplary downhole expansion tool and a sand control system in an undeployed configuration and / or ready to place configuration.

[0016] FIG. 1C depicts the downhole expansion tool and the sand control system in an deployed configuration.

[0017] FIG. 2 A depicts an exemplary block diagram of a downhole radial expansion tool in connection with a downhole expandable payload.

[0018] FIG. 2B depicts an exemplary block diagram of a downhole radial expansion tool in connection with a porous material pack (e.g., a gravel pack).

[0019] FIG. 2C depicts an exemplary spring release mechanism in a ready to deploy mode.

[0020] FIG. 2D depicts the exemplary spring control mechanism extending along the exterior of a perforated base pipe.

[0021] FIG. 2E depicts a closeup view of the spring release mechanism embodiment with a pinned coiled spring.

[0022] FIG. 3A depicts an exemplary shifter in a preconfigured ready to deploy mode in connection with the sand control system.

[0023] FIG. 3B depicts a cutaway view of FIG. 3 A.

[0024] FIG. 3C depicts an exemplary shifter in a deactivated mode.

[0025] FIG. 4 depicts a flow chart illustrating a method of deployment of an exemplary downhole expansion tool.

[0026] FIG. 5 depicts an exemplary method flowchart illustrating the process of assembly and manufacture, pre-configuration to a ready to deploy mode; and a deployment mode.

[0027] FIG. 6 depicts an exemplary method flowchart illustrating method of determining wellbore parameters and deploying an exemplary downhole expansion tool.

[0028] FIG. 7 depicts an exemplary method flowchart of operating a downhole radial expansion tool in a system.

[0029] FIG. 8 depicts an exemplary diagram of an exemplary method of operation, using a drilling bit to drill a wellbore, filling wellbore with drilling fluid, removing drilling bit, inserting pipe in connection with downhole wellbore expansion tool, expanding the wellbore expansion tool, using a decouplable barrier device to prevent sea water from entering pipe, allowing for further expansion later on.

[0030] Like reference symbols in the various drawings indicate like elements.DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0031] To aid understanding, this document is organized as follows. First, to help introduce discussion of various embodiments, an illustrative use-case scenario utilizing an exemplary downhole radial expansion tool is introduced with reference to FIGS. 1A-2B. Second, that introduction leads into a description with reference to FIG. 2C-2E of some exemplaryembodiments of the downhole radial expansion tool’s opposing collar and attachment-releasement mechanism. Third, with reference to FIGS. 3A-3C an exemplary shifter and cross sectional is described. Fourth, with reference to FIG. 4-8, this document describes exemplary apparatus, exemplary systems, and methods useful for operating and manufacturing the downhole expansion tool.

[0032] FIG. 1A depicts an exemplary downhole expansion tool and exemplary gravel pack employed in an illustrative use-case scenario 100. The exemplary use-case scenario 120 includes an exemplary downhole radial expansion tool 100. The radial expansion tool may, for example, be used in an exemplary sand control system. The radial expansion tool may, for example, be used in an exemplary sand control system method. The method of formation of the radial expansion tool may, for example, contribute to an exemplary sand control system.

[0033] The exemplary use-case scenario 120 includes an offshore oil platform 125. The offshore oil-platform is situated in a body of water 130. The body of water may, for example, be a sea. The body of water may, for example, be an ocean. The body of water may, for example, be a lake. The offshore oil platform may, for example, be situated near the coast. The offshore oil platform may, for example, be situated far from the coast.

[0034] The body of water 130 includes a surface 130a. The offshore oil platform 125 is coupled to a pipe 135. The pipe 135 is coupled to a wellbore 140. The wellbore 140 is situated at a subterranean surface 145.

[0035] The downhole radial expansion tool 100 may, for example, be delivered at and / or beneath the subterranean surface 140. The downhole radial expansion tool may, for example, be delivered in an unexpanded state as depicted in a undeployed sand control system 100 A. The downhole radial expansion tool may, for example, be depicted in an expanded state as depicted as a deployed sand control system 100B.

[0036] FIG. IB depicts an exemplary downhole expansion tool and a sand control system in an undeployed configuration and / or ready to place configuration. FIG. 1C depicts the downhole expansion tool and the sand control system in a deployed configuration.

[0037] FIGS. 1A-1C illustrate an example of a downhole radial expansion tool 100. FIG. IB illustrates the undeployed or ready to place sand control system 100 A; and FIG. 1C illustrates the deployed sand control system 100B. The downhole radial expansion tool 100 provides an elegant and quick method to expand screens and a solution that carries a sized sand depth filter.

[0038] Further, the downhole radial expansion tool 100 uses unique pieces of expansion which will also allow isolation packers to be quickly set. The downhole radial expansion tool 100 may, for example, advantageously expand without the requirement of pressure or chemicals to expand.

[0039] For example, the expansion of the downhole radial expansion tool 100 may, for example, be described as mechanical. The downhole radial expansion tool may, for example, expand very quickly with the uncoiling of springs which saves operational costs. Finally, the downhole radial expansion tool 100 does not require extensive rig time to deploy and validation of expansion is easily proved with logging tools.

[0040] For example, acoustic, gamma ray, neutron density or any other desired logging tool can be used. The downhole radial expansion tool 100 is fully compliant with ISO 13503-2 and ISO 13503-5. The downhole radial expansion tool may, for example, be used in a system. The system may, for example, facilitate the process of extracting oil and / or natural gas from a wellbore. The downhole radial expansion tool may, for example, be used in a method. The method may, for example, facilitate the process of extracting oil and / or natural gas from a wellbore.

[0041] FIG. IB & FIG. 1C shows that downhole radial expansion tool 100 can include a pipe 102. The pipe may, for example, be a perforated base pipe 102a. The perforated base pipe 102a is a pipe with holes or slots along the length of the pipe. For example, the perforated base pipe 102a can include tubing with a series of slots cut through a wall of the tube in an axial orientation. The width of the slots is designed to create inter-particle bridging across the slots. There are two types of slots which can be used: straight and keystone slots. Keystone slots are considered to be a better choice than straight slots because of their self-flush ability. However, keystone slots are generally more expensive than straight slots. In general, slots may, for example, be 1.5 to 2.5 inches long and their width varies from 0.012 to 0.250 inches.

[0042] The perforated base pipe 102a may, for example, make up the central portion of the wellbore. Therefore, the perforated base pipe needs to be strong enough to withstand the forces of being placed and the forces of the expansion of the sand control system 100 (as the expansion system pushes outward during deployment). Therefore, the perforated base pipe 102a may be made of chrome 22, carpenter 20, 316 SS or carbon steel or any other desired material that is suitable for the wellbore parameters.

[0043] The perforated base pipe 102a may, for example, be of sufficient length and diameter to serve within the wellbore. Therefore, the perforated base pipe 102a may, for example, be between 4 feet and 40 feet long. The perforated base pipe 102a may, for example, be between 1.5 and 7.0 inches in diameter, or even larger depending on borehole size. In particular, the perforated base pipe 102a can be approximately 40 feet and 5.5 inches in diameter. The values given may, for example, mean that the value is within 10% of the stated value, unless otherwise specified.

[0044] FIG. IB depicts the downhole expansion tool 100 in the expanded state, as used in a deployed sand control system 100B. The downhole expansion tool may, for example, include a energized spring. The energized spring may, for example, be unenergized and be energized bybeing wound on the pipe. The energized spring 104 may, for example, include a coiled spring 104a.

[0045] For context, a spring may, for example, comprise of an elastic, but largely rigid, material (typically metal) bent or molded into a form (especially a coil) that can return to its original shape after being compressed, extended, wound, etc. Springs may, for example, be made from a variety of elastic materials. Springs may, for example, be made of spring steel. Small springs may, for example, be wound from pre-hardened stock. Larger springs may, for example, be made from annealed steel and hardened after manufacture.

[0046] The coiled spring 104a may, for example, include a resting inner diameter that is larger than the outer diameter of the perforated base pipe 102a. The resting inner diameter of the coiled spring being larger than the outer diameter of the perforated base allows the coiled spring 104a to be placed around the perforated base pipe 102a then loaded, as described below.

[0047] FIGS. 2A-2B depicts an exemplary block diagram of the exemplary radial expansion tool 100. FIGS. 1A-2B further depict that the downhole radial expansion tool 100 may, for example, include a set of screens 245. The set of screens may, for example, include a screen jacket 106 (also called an internal screen 245a). The screen jacket 106 may, for example, be placed around the loaded coiled spring 104a.

[0048] For example, the inner diameter of the screen jacket 106 may be larger than the outer diameter of the coiled spring 104a. The inner diameter of the screen jacket being larger than the outer diameter of the coiled spring, advantageously allows the coiled spring 104a to expand and push out on the screen jacket 106 when being deployed, as described below. The screen jacket can be stamped, laser cut, or water jet cut and can include slots or other patterns which allows the greatest amount of flow.

[0049] FIG. 1A-2B depicts that the exemplary expansion tool 100 may, for example, include a downhole expandable payload 235. The expandable payload 235 may, for example, include a gravel pack 235a and / or a porous material pack 235a. The porous material pack 235a (e.g., a gravel pack) include a gravel layer 108 (e.g., a layer of porous material).

[0050] For context, gravel is a loose aggregation of rock fragments. Gravel occurs naturally throughout the world as a result of sedimentary and erosive geologic processes; it is also produced in large quantities commercially as crushed stone. Gravel is classified by particle size range and includes size classes from granule-to boulder-sized fragments. In the Udden-Wentworth scale gravel is categorized into granular gravel (2-4 mm or 0.079-0.157 in) and pebble gravel (4-64 mm or 0.2-2.5 in). ISO 14688 grades gravels as fine, medium, and coarse, with ranges 2-6.3 mm to 20-63 mm.

[0051] The gravel layer 108 is designed and sized based on specifics of the wellbore. The gravel layer 108 is placed on the inside of the screen jacket 106.

[0052] FIGS. 1A-2B moreover shows that the downhole radial expansion tool 100 may, for example, include a permeable membrane 110. The permeable membrane may, for example, be placed above and below the gravel layer 108. When the coiled spring 104a is allowed to expand it presses on the permeable membrane 110. For example, the whole diameter of the radial expansion tool 100 will expand within the wellbore. The permeable membrane could be wire, mesh or cloth, slotted pipe, composite material or even plastic. The permeable elastic membrane is % inch by ’A inch wire mesh.

[0053] A membrane with round openings may, for example, work. A membrane with different types of openings may, for example, work better than a membrane with round openings. For example, from testing it was discovered oval shape openings may, for example, work better than round shapes. The permeable membrane may, for example, does not necessarily have to contain a gravel and could be used alone as the primary sand control media.

[0054] FIGS. 1A-2B depicts that the downhole radial expansion tool 100 may, for example, include end caps 112. The end caps may, for example, be part of an end cap assembly 250. The end caps 112 hold the coiled spring 104a, screen jacket 106, gravel layer 108 and permeable membrane 110 in place relative to the perforated base pipe 102a. In particular, the end caps 112 extend out radially from the perforated base pipe 102a. The end caps 112 are sloped on the external surface to allow for ease of insertion into the wellbore.

[0055] FIGS. 1 A-2B further depicts that the radial expansion tool 100 may, for example, include a spring lock ring 114. The spring lock ring 114 holds a first end of the coiled spring 104a relative to the perforated base pipe 102a. The first end of the coiled spring 104a is held both laterally and radially. I.e., the first end of the coiled spring 104a cannot move between the end caps 112 or rotate about the perforated base pipe 102a.

[0056] FIGS. 1 A-2B further depict that the downhole radial expansion tool 100 may, for example, include an attachment-rotating mechanism 116. The attachment-rotating mechanism may, for example, include a rotating ring 116a. The rotating ring 116a holds the second end of the coiled spring 104a when the coiled spring 104a is in its unexpanded position. For example, when the coiled spring 104a is under tension the second end of the coiled spring 104a is placed in the rotating ring 116a to keep it under tension until deployment.

[0057] FIGS. 1A-2B depicts that the downhole radial expansion tool 100 may, for example, include opposing collars 118. The opposing collars may, for example, include a spring release mechanism 118a. The spring release mechanism 118a shifts relative to rotating ring 116a when the coiled spring 104a is under tension. This releases the coiled spring 104a, allowing the springto expand radially, pushing on the screen jacket 106, the gravel layer 108 and the permeable membrane 110 causing them to expand.

[0058] FIG. 1C shows that deployed sand control system 100B has a larger radius than the undeployed sand control system 100A of FIG. IB. That is because the coiled spring 104a has expanded radially and pushed out the screen jacket 106, the gravel layer 108 and the permeable membrane 110. For example, the stored energy of the wound spring is converted to expansion forces. This presses the downhole radial expansion tool 100 against the wellbore 140.

[0059] For context, gravel pack may, for example, use sized sands as a filter media to prevent sand production. The annulus - region between two concentric circles - between the wellbore and a sand control screen (wire wrapped or premium screen) is filled with sized gravel particles which prevent sand from flowing into the wellbore.

[0060] For context, open hole gravel pack (external gravel pack) is useful for controlling sand in heterogeneous formations. Alternatively, cased hole gravel pack (internal gravel pack) is utilized for controlling sand and protecting sand screens from erosion flow. Frack pack is a combined gravel pack with fracturing technique which creates wide and long conductive fractures. This technique will control sand production and improve productivity of a wellbore.

[0061] For context, in some wells which need sand control, it is very difficult to gravel pack the open hole due to low gravel pack margins (i.e., small annulus size, low fracture gradient / exposed shales) without the advantage of a downhole radial expansion tool.

[0062] For context, without an downhole radial expansion tool expandable sand screens may, for example, suffer from a number of drawbacks. For example, expandable sand screens without the radial expansion tool may, for example, be cumbersome and slow to expand. Expandable sand screens without the configuration of the downhole radial expansion tool may, for example, rely on sized screens to control sand production or have a depth filter that cannot be tuned for a particular formation.

[0063] For context, pumping sized sand gravel packs can be a complex and long process and there is risk that the screens do not get covered fully which could lead to sand retention failure during the life of the well without a radial expansion tool being used. Further, expansion devices, as an alternative to the downhole radial expansion tool, may, for example, be slow, expensive or require high pressure pumping operations.

[0064] In some embodiments, the downhole radial expansion tool may, for example, be used to control sand. For context, sand control is a method to control sand production within a wellbore. Sand control may, for example, be a common requirement for oil and gas producing wells around the world. Sand control may, for example, be used when there is a rock mechanical failure near the wellbore. Sand control may, for example, be used when there is a dragging force from oil andgas production or from injection fluid. For context, sand production can lead to several issues such as production impairment due to sand plugging, damage to down well materials, damage to surface facilities, etc.

[0065] In some embodiments, the downhole radial expansion tool may be used in different sand control methods and / or be used to replace or reduce other sand control methods. There are different methods of controlling sand production and reducing the impact of sand production within the wellbore. Some methods include passive reduction which are non-intrusive measures to control, mitigate or avoid sand production from the reservoir, such as oriented perforation, selective perforation and sand management. Other methods include active sand control which relies on the use of filters to control sand production and is an intrusive measure. Active sand control methods include stand-alone screens (slotted liner, wire-wrapped screen, prepacked screen and premium screen), expandable sand screens, gravel pack & frack pack and chemical consolidation.

[0066]

[0067] FIGS. 2C-2E illustrate an example of an exemplary opposing collar 118. The opposing collar may, for example, include a spring release mechanism 118a. FIG. 2C illustrates the spring release mechanism 118a when ready to deploy; FIG. 2D illustrates the spring control mechanism 118 within a perforated base pipe; and FIG. 2E illustrates a closeup view of the spring release mechanism 118a with a pinned coiled spring 104a. Spring release mechanism 118a allows the coiled spring 104a to begin moving freely relative to the perforated base pipe 102a. When this occurs, the coiled spring 104a can “unwind” which starts the coiled spring 104a expanding radially which deploys the sand control system 100. The spring release mechanism 118a needs to be deployed remotely because the sand control system will be located inside the wellbore when being deployed.

[0068] FIGS. 2C-2E depict that rotating ring 116a has a retention member 202. The retention member 202 may, for example, include a pin 202a extending to the interior of the perforated base pipe 102a. The retention member 202 prevents the rotating ring from moving relative to the perforated base pipe 102a. The tension on the wound coiled spring 104a wants to cause the rotating ring 116a to spin relative to the perforated base pipe 102a but the pin 202a extends through the rotating ring 116a and the perforated base pipe 102a, preventing the rotation.

[0069] FIGS. 2C-2E depict that the pin 202a has a break point 204. The break point 204 is a weak point in pin 202a which allows the pin to be sheared more easily by the spring release mechanism 118a. The break point 204 can be a groove or scoring on pin 202a. Break point 204 ensures that pin 202a breaks at a set point every time, which is crucial to deployment, as described below.

[0070] FIG. 2C-2E further depict that the spring release mechanism 118a includes a pin retaining wedge 206. Pin 202 passes through rotating ring 116a and perforated base pipe 102a into pinretaining wedge 206. Break point 204 is located approximately at the same level as perforated base pipe 102a. For example, the break point 204 is between rotating ring 116a and pin retaining wedge 206. This allows for a more reliable release, as explained below. The retention member 202 (e.g., the pin 202a) can have a head on a first end which will be retained in rotating ring 116a and a second end threaded into pin retaining wedge 206.

[0071] FIG. 2C-2E additionally depicts a pin retaining wedge 206. The pin retaining wedge 206 includes a tapered edge 208. The tapered edge 208 slopes away from the interior surface of perforated base pipe 102a. This creates a space on the leading edge of tapered edge 208 and the interior of perforated base pipe 102a. Tapered edge 208 is near the retention member 202.

[0072] FIG. 2C-2E depicts that the opposing collars 118 (e.g., the spring release mechanism 118a) includes an insertion wedge 210. The insertion wedge 210 is configured to push on the tapered edge 208, causing pin retaining wedge 206 to move away from the interior surface of the pipe 102 (e.g., the perforated base pipe 102a).

[0073] For example, the insertion wedge causes pin retaining wedge 206 to move away from the attachment-rotating mechanism 116 (e.g., rotating ring 116a). Because one end of pin 202a remains in rotating ring and the other end remains in pin retaining wedge 206, pin 202a breaks along break point 204. This allows rotating ring 116a to rotate freely relative to the perforated base pipe 102a. This allows all the stored energy in the wound coiled spring 104a to be converted to energy pushing out on the screen jacket, the gravel layer and the permeable elastic membrane.

[0074] FIG. 2C-2E depicts that the spring release mechanism 118a can include insert 212. Insert 212 is fixed in position relative to the perforated base pipe 102a. Insert 212 is fixed so that when insertion wedge 210 pushes on tapered edge 208 of pin retaining wedge 206, the only direction in which pin retaining wedge 206 can move is toward the center of perforated base pipe 102a. This ensures that pin 202a shears at break point 204 rather than bending, which could prevent rotating ring 116a from rotating freely (i.e., if pin 202a bends it could bind the rotating ring 116a, preventing expansion).

[0075] FIG. 2A-2B depict a shear release mechanism 255. The shear release mechanism may, for example, be used to release the deployable downhole radial expansion device by a shear release. FIG. 2A-2B depicts a shroud 260. The shroud 260 may, for example, be used to secure the downhole expandable payload 235. The shroud 260 may, for example, be used to secure the gravel payload 235a.

[0076] FIG. 2A-2E further depict that the opposing collars 118 (e.g., the spring release mechanism 118a) can include a shifter 214. The shifter 214 pulls insertion wedge 210 into tapered edge 208 of pin retaining wedge 206 causing retention member 202 (e.g., pin 202a) to break. The shifter 214 then makes contact with insert 212 and retracts, losing contact with insertion wedge 210. That is,in practice, shifter 214 is inserted past insertion wedge 210 then pulled back engaging insertion wedge and deploying spring release mechanism 118a.

[0077] FIGS. 3 A-3C illustrate an example of a shifter 214. FIG. 3 A illustrates the shifter 214 when ready to deploy a sand control system 100. FIG. 3B illustrates a cutaway view of FIG. 3 A. FIG. 3C illustrates the shifter 214 when deactivated.

[0078] The shifter 214 is inserted into an exemplary downhole expansion tool 100 in an unexpanded state (e.g., in the undeployed sand control system 100 A) to deploy exemplary downhole expansion tool 100 to an expanded state (e.g., the deployed sand control system 100B) then is removed, clearing the interior of the perforated base pipe. The shifter 214 needs to reliably deploy the exemplary radial expansion downhole tool 100.

[0079] FIGS. 3A-3C depicts that shifter 214 can include housing 302. Housing 302 has an outer diameter smaller than the inner diameter of a perforated base pipe. This allows housing 302 to be inserted within a perforated base pipe and freely move laterally within the perforated base pipe. This may, for example, to allow the shifter 214 to be inserted into a sand control system (e.g., the radial expansion tool).

[0080] FIGS. 3A-3C depicts that a shifter 214 can include clasp 304. Clasp 304 is configured to engage an insertion wedge when shifter 214 is activated. In particular, clasp 304 has an inclined edge 304a allowing clasp 304 to pass insertion wedge. I.e., inclined edge 304a slides past the insertion wedge. Straight edge 304b then rests against the insertion wedge. When the clasp 304 is pulled back then the straight edge 304b pulls the insertion wedge, deploying the sand control system.

[0081] FIGS. 3A-3C depicts that the shifter 214 can include chock 306. Chock 306 is wedge shaped. While chock 306 pushes on interior of clasp 304 the wedge shape provides an outward force, causing clasp 304 to extend outward relative to housing 302 when shifter 214 is activated.

[0082] FIG. 3A-3C depicts that the shifter 214 can include loading mechanism 308. Loading mechanism 308 provides a force on clasp 304. This causes clasp 304 to move up the inclined surface of chock 306 during activation or remain near the top of inclined surface of chock 306 while activated. This keeps clasp 304 extended past housing 302.

[0083] FIG. 3A-3C may, for example, include the shifter 214 can include cover 310. Cover 310 has one or more openings, which allow clasp 304 to protrude from housing 302. Cover 310 can move laterally relative to housing 302, which allows cover 310 to cover clasp 304 when shifter 214 is deactivated, as described below.

[0084] FIGS. 3A-3C depicts the shifter 214 can include spring 312. When spring 312 is released, it begins to expand laterally. Spring 312 then pushes cover 310 relative to housing 302 and pushes chock 306 relative to clasp 302. This allows clasp 302 to retract (slide down the inclined edge ofcheck 306). Simultaneously, cover 310 passes over clasp 302 preventing it from extending out of housing 302. This allows shifter 214 to be retracted from the sand control system.

[0085] FIG. 4 is a flow chart illustrating a method 400 of deploying a sand control system. In at least one implementation, the sand control system can be the sand control system 100 of FIG. s 1- 3. Therefore, the method 400 will be described, exemplarily, with reference to the downhole radial expansion tool 100 of FIGS. 1A-3C. Nevertheless, the method 400 can be used to deploy sand control systems other than the radial expansion tool 100 of FIGS. 1 A-3C.

[0086] FIG. 4 shows that the method 400 can include securing 402 a coiled spring to a perforated base pipe using a spring lock ring. The spring lock ring holds a first end of the coiled spring relative to the perforated base pipe. The first end of the coiled spring is held both laterally and radially. I.e., the first end of the coiled spring cannot move between the end caps or rotate about the perforated base pipe.

[0087] For context, the perforated base pipe will make up the central portion of the wellbore. Therefore, it needs to be strong enough to withstand the forces of being placed and the forces of the expansion of the sand control system (as the expansion system pushes outward during deployment). Therefore, the perforated base pipe can be made of metal, fiberglass or composite or any other desired material that is suitable for the wellbore parameters. Likewise, it is important that the perforated base pipe be of sufficient length and diameter to serve within the wellbore. Therefore, the perforated base pipe is typically between 4 feet and 40 feet long and typically between 1.5 and 7.0 inches in diameter. In particular, the perforated base pipe can be approximately 40 feet long and 5.5 inches in diameter.

[0088] FIG. 4 depicts that the method 400 can include winding 404 the spring. That is, the free end of the coiled spring (the end not attached to the spring lock ring) is turned until all of the coils are compressed and are wound directly onto the perforated base pipe to decrease its overall running diameter. This provides a large amount of stored energy. The spring is wound using a vice or any equipment such as a lathe that can generate enough torque to wind the spring onto the perforated base pipe.

[0089] FIG. 4 depicts that the method 400 can include securing 406 the second end of the coiled spring to the perforated base pipe via a rotating ring. The rotating ring holds the second end of the coiled spring when the coiled spring is in its unexpanded position. I.e., when the coiled spring is under tension the second end of the coiled spring is secured 406 in the rotating ring to keep it under tension until deployment.

[0090] FIG. 4 depicts that the method 400 can include placing 408 a pin in the rotating ring, rotating ring has pin extending to the interior of the perforated base pipe. Pin prevents the rotating ring from moving relative to the perforated base pipe. I.e., the tension on the wound coiled springwants to cause the rotating ring to spin relative to the perforated base pipe but the pin extends through the rotating ring and the perforated base pipe, preventing the rotation.

[0091] The pin has a break point. Break point is a weak point in pin which allows the pin to be sheared more easily by the spring release mechanism. The break point can be a groove or scoring on pin. Break point ensures that pin breaks at a set point every time, which is crucial to deployment, as described below.

[0092] The pin passes through the rotating ring and perforated base pipe into a pin retaining wedge. Break point is located approximately at the same level as perforated base pipe. I.e., the break point is between rotating ring and pin retaining wedge. This allows for a more reliable release, as explained below. The pin can have a head on a first end which will be retained in rotating ring and a second end threaded into retaining wedge.

[0093] FIG. 4 depicts that the method 400 can include placing 410 a screen jacket over the coiled spring. The screen jacket is placed around the loaded coiled spring. I.e., the inner diameter of the screen jacket is larger than the outer diameter of the coiled spring. This allows the coiled spring to expand and push out on the screen jacket when being deployed, as described below. The screen jacket can be stamped, laser cut, or water jet cut and can include slots or other patterns which allows the greatest amount of flow.

[0094] FIG. 4 depicts that the method 400 can include placing 412 a gravel layer over the screen jacket. FIG. 1 additionally shows that the sand control system 100 can include a gravel layer. Gravel is a loose aggregation of rock fragments. Gravel occurs naturally throughout the world as a result of sedimentary and erosive geologic processes; it is also produced in large quantities commercially as crushed stone. Gravel is classified by particle size range and includes size classes from granule- to boulder-sized fragments. In the Udden- Wentworth scale gravel is categorized into granular gravel (2-4 mm or 0.079-0.157 in) and pebble gravel (4-64 mm or 0.2-2.5 in). ISO 14688 grades gravels as fine, medium, and coarse, with ranges 2-6.3 mm to 20-63 mm. The gravel layer is designed and sized based on specifics of the wellbore. The gravel layer is placed on the inside of the screen jacket.

[0095] FIG. 4 further depicts that the method 400 can include placing 414 a permeable membrane over the gravel layer. The permeable membrane is placed above and below the gravel layer. When the coiled spring is allowed to expand it presses on the permeable elastic membrane. I.e., the whole diameter of the sand control system 100 will expand within the wellbore. The permeable membrane could be wire, mesh or cloth, slotted pipe, composite material or even plastic. The permeable elastic membrane is % inch by i inch wire mesh. A membrane with round openings was tried but worked poorly. Therefore, other configurations were tried, and it was discovered that oval shapes work better than round shapes. One of skill in the art will appreciate that the permeablemembrane does not necessarily have to contain a gravel and could be used alone as the primary sand control media.

[0096] FIG. 4 depicts that the method 400 can include mounting 416 endcaps on the perforated base pipe. FIG. 1 also shows that the sand control system 100 can include end caps. The end caps hold the coiled spring, screen jacket, gravel layer and permeable elastic membrane in place relative to the perforated base pipe. In particular, the end caps extend out radially from to the perforated base pipe. The end caps are sloped on the external surface to allow for ease of insertion into the wellbore.

[0097] FIG. 4 depicts that the method 400 can include installing 418 the sand control system in a wellbore. A wellbore is a hole that is drilled to aid in the exploration and recovery of natural resources, including oil, gas, or water. A wellbore is the actual hole that forms the well. Installing 418 the sand control system in a wellbore can be done simultaneously with drilling the wellbore or can be done after the wellbore has been drilled..

[0098] FIG. 4 depicts that the method 400 can include triggering 420 a spring release mechanism. The spring release mechanism is triggered 420 by

[0099] The spring release mechanism shifts relative to rotating ring when the coiled spring is under tension. This releases the coiled spring, allowing the spring to expand radially, pushing on the screen jacket, the gravel layer and the permeable membrane causing them to expand.

[0100] Spring release mechanism allows the coiled spring to begin moving freely relative to the perforated base pipe. When this occurs, the coiled spring can “unwind” which starts the coiled spring expanding radially which deploys the sand control system 100. The spring release mechanism needs to be deployed remotely because the sand control system will be located inside the wellbore when being deployed.

[0101] Spring release mechanism includes tapered edge. Tapered edge slopes away from the interior surface of perforated base pipe. This creates a space on the leading edge of tapered edge and the interior of perforated base pipe. Tapered edge is near the pin.

[0102] The spring release mechanism includes an insertion wedge. Insertion wedge pushes on the tapered edge, causing pin retaining wedge to move away from the interior surface of perforated base pipe. I.e., insertion wedge causes pin retaining wedge to move away from rotating ring. Because one end of pin remains in rotating ring and the other end remains in pin retaining wedge, pin breaks along break point. This allows rotating ring to rotate freely relative to the perforated base pipe. This allows all the stored energy in the wound coiled spring to be converted to energy pushing out on the screen jacket, the gravel layer and the permeable membrane.

[0103] Spring release mechanism can include insert. Insert is fixed in position relative to the perforated base pipe. Insert is fixed so that when insertion wedge pushes on tapered edge of pinretaining wedge, the only direction in which pin retaining wedge can move is toward the center of perforated base pipe. This ensures that pin shears at break point rather than bending, which could prevent rotating ring from rotating freely (i.e., if pin bends it could bind the rotating ring, preventing expansion).

[0104] Spring release mechanism can include shifter. Shifter pulls insertion wedge into tapered edge of pin retaining wedge causing pin to break. Shifter then makes contact with insert and retracts, losing contact with insertion wedge. That is, in practice, shifter is inserted past insertion wedge then pulled back engaging insertion wedge and deploying spring release mechanism. The shifter is inserted into a sand control system 100 to deploy the system then is removed, clearing the interior of the piping. The shifter needs to reliably deploy the sand control system 100.

[0105] Shifter can include housing. Housing has an outer diameter smaller than the inner diameter of a perforated base pipe. This allows housing to be inserted within a perforated base pipe and freely move laterally within the perforated base pipe. This is critical to allow the shifter to be inserted into a sand control system.

[0106] Shifter can include clasp. Clasp is configured to engage an insertion wedge when shifter is activated. In particular, clasp has an inclined edge allowing clasp to pass insertion wedge. I.e., inclined edge slides past the insertion wedge. Straight edge then rests against the insertion wedge. When the clasp is pulled back then the straight edge pulls the insertion wedge, deploying the sand control system.

[0107] Shifter can include chock. Chock is wedge shaped. While chock pushes on interior of clasp the wedge shape provides an outward force, causing clasp to extend outward relative to housing when shifter is activated.

[0108] Shifter can include loading mechanism. Loading mechanism provides a force on clasp. This causes clasp to move up the inclined surface of chock during activation or remain near the top of inclined surface of chock while activated. This keeps clasp extended past housing.

[0109] Shifter can include cover. Cover has one or more openings, which allow clasp to protrude from housing. Cover can move laterally relative to housing, which allows cover to cover clasp when shifter is deactivated, as described below.

[0110] The shifter can include a spring. When spring is released, it begins to expand laterally. Spring then pushes cover relative to housing and pushes chock relative to clasp. This allows clasp to retract (slide down the inclined edge of chock). Simultaneously, cover passes over clasp preventing it from extending out of housing. This allows shifter to be retracted from the sand control system.

[0111] FIG. 5 depicts an exemplary method flowchart 500 illustrating the process of assembly and manufacture, pre-configuration to a ready to deploy mode; and a deployment mode. In step 505, auser of the method secures a coiled spring to a perforated base pipe. The user may, for example, use a spring lock ring. In step 510, a user of the method secures the second end of the coiled spring to the perforated base pipe. The user of the method may, for example, use an attachment-rotating mechanism, such as a rotating ring to secure the second end of the coiled spring. In step 515, a user of the method determines whether the coiled spring is secured. If the coiled spring is secured the user of the method proceeds to step 520. If not the user of the method returns to step 505 to secure the coiled spring, and / or step 510 to secure the second end. In step 520, a user of the method primes the spring. A user of the method may, for example, prime the spring by placing the pin a rotating ring. The user of the method may, for example, then place the screen jacket over the coiled ring. In step 525, a user of the method compiles the porous material pack. The porous material pack may, for example, include a gravel pack. A user of the method may, for example, place the gravel layer over the screen jacket, and the place the permeable elastic member over the gravel layer. In step 530, a user of the method determines whether the coiled spring and the gravel pack is secured. If the user of the method determines the coiled spring and the gravel pack are not secure they may, for example, return back to step 520 to secure the coiled spring. If the user of the method determines the gravel pack is not secured, a user of the method may, for example, return to step 525 to secure the gravel pack. If the user of the method determines in step 530, that both the gravel pack and the spring are secure the user of the method may, for example, proceed to step 535. In step 535, the user of the method mounts the endcaps on the perforated base pipe.

[0112] FIG. 6 depicts an exemplary method flowchart 600 illustrating method of determining wellbore parameters and deploying an exemplary downhole expansion tool. In step 605, a user of the method may, for example, determine the wellbore parameters. The wellbore parameters may, for example, include the wellbore depth. The wellbore parameters may, for example, include the wellbore soil composition. The wellbore parameters may, for example, include the wellbore type.

[0113] In step 610, a user of the method selects the downhole radial expansion tool based on the hole parameters. In step 615, a user of the method deploys the downhole expansion tool by actuating the energized spring mechanism. A user of the method may, for example, actuate the spring mechanism by using a shifter.

[0114] FIG. 7 depicts an exemplary method flowchart 700 of operating a downhole radial expansion tool in a system. In step 705, a user of the method drills to the total depth (TD). For context, the total depth is the maximum depth drilled in the earth's subsurface to explore or extract oil, gas, or other mineral resources. This depth is predetermined based on geological data, including the depth at which the hydrocarbon reserves are estimated to be located. Reaching the total depth is a critical milestone in the drilling process, as it signifies the completion of the drillingphase and the beginning of evaluation and, potentially, production phases if the well is deemed viable.

[0115] In step 710, a user of the method circulates the hole clean. A user may, for example, use drilling fluid to circulate the hole clean. For context, circulating a hole clean after drilling to total depth (TD) is a critical step in the oil and gas drilling process to ensure the wellbore's integrity and facilitate subsequent operations, such as casing and cementing. This process involves pumping drilling fluid through the drill string and up the annulus, effectively removing cuttings, debris, and any other obstructions from the wellbore. A clean wellbore is essential for accurate downhole logging measurements, which are crucial for evaluating the geological formations and hydrocarbon potential. Moreover, circulating the hole clean helps to stabilize the wellbore walls, prevent the risk of stuck pipe, and ensure a good bond between the casing and formation during cementing, ultimately enhancing the safety and efficiency of the drilling operation and the productivity of the well.

[0116] In step 715, a user of the method runs a check trip. For context, a "check trip" in oil and gas drilling is a precautionary procedure undertaken to ensure the integrity and safety of the drilling operation. It involves partially or fully removing the drill string from the wellbore and then running it back in. This process is critical for assessing the condition of the wellbore, inspecting the drill string for wear or damage, lubricating the drill string, cleaning the wellbore of any debris, and evaluating the properties of the drilling fluid. Conducted at strategic points before reaching total depth or when potential issues are suspected, check trips help in early identification of problems, thereby reducing the risk of equipment failure, ensuring the well's structural integrity, and minimizing non-productive time, particularly in challenging drilling environments.

[0117] In step 720, a user of the method displaces the OH + 1000’ into the casing with SF SB screen running fluid. For context, displacing the open hole (OH) in oil and gas drilling involves replacing the drilling fluid in the uncased section of the wellbore with a different fluid, usually to optimize drilling operations, enhance safety, or prepare for subsequent steps like casing and cementing. This process is critical for adjusting mud weight to manage wellbore pressures effectively, ensuring well control by mitigating gas influx risks, improving conditions for downhole logging and testing by introducing cleaner fluids for clearer data acquisition, and optimizing the cementing process by using fluids that promote better adhesion between the casing and formation. Careful planning and execution of fluid displacement are essential to maintain wellbore stability, ensure the accuracy of geological assessments, and uphold the overall integrity and safety of the drilling operation.

[0118] In step 725, displace the OH above the SRF to brine. For context, displacing the open hole (OH) section above the sandface (SRF) to brine is a critical operation in oil and gas drilling aimedat enhancing well integrity, optimizing production, and ensuring environmental safety. This displacement is conducted to minimize formation damage by using brine, a particle-free fluid that preserves reservoir permeability and maximizes hydrocarbon flow. Additionally, brine's density can be precisely controlled to balance formation pressures, thereby maintaining wellbore stability and preventing blowouts. Preparing the well for completion activities, such as the installation of screens or hydraulic fracturing, is facilitated by brine's compatibility with reservoir conditions and completion materials. Moreover, brine solutions reduce the environmental impact and mitigate corrosion of downhole and surface equipment, ensuring the longevity and efficiency of the well's production lifecycle. This strategic displacement step is crucial for a seamless transition from drilling to production, safeguarding the well's productivity and environmental compliance.

[0119] In step 730, a user of the method RIH SCGP filling DP. For context, "RIH SCGP filling DP” refers to the procedure of Running In Hole (RIH) with a Surface Controlled Gas lift Valve Pipe (SCGP) while concurrently filling the Drill Pipe (DP) with fluid. This multifaceted operation is essential for preparing a well for enhanced oil recovery through artificial lift techniques. By inserting the gas lift valve assembly into the wellbore (RIH), operators aim to install a system that allows for the efficient regulation of gas injection to lighten the fluid column and facilitate oil flow to the surface. The simultaneous filling of the drill pipe with drilling fluid (filling DP) is crucial for maintaining the well's hydrostatic pressure, ensuring wellbore stability, and preventing the influx of formation fluids. This integrated process is critical for setting up a successful gas lift system, optimizing production efficiency, and maintaining safety and control over the well during its transition to the production phase.

[0120] In step 735, a user of the method runs the screens to the bottom. For context, running screens to the bottom of a well is a strategic completion technique in oil and gas operations aimed at optimizing hydrocarbon production while minimizing the ingress of sand and other formation solids. Screens act as a filtration mechanism, allowing fluids to flow into the wellbore while retaining sand and fine particles that could otherwise obstruct the flow pathways, damage downhole and surface equipment, and significantly reduce the well's productive lifespan. By extending these screens to the well's bottom, operators ensure comprehensive coverage and protection of the entire producing interval, enhancing the well's overall efficiency and stability. This approach is particularly crucial in reservoirs prone to sand production, where maintaining the integrity of the wellbore and ensuring uninterrupted fluid flow are paramount for maximizing recovery and prolonging the well's operational life.

[0121] In step 740, a user of the method set the packer and the release service tool. For context, "set the packer and release the service tool" refers to a critical phase in well completion or intervention processes where a packer — a device used to isolate certain sections of the wellbore —is deployed and secured in its targeted position within the well. Setting the packer ensures that specific zones can be isolated for production, injection, or treatment, effectively controlling fluid flow in or out of those zones and protecting the casing from pressure. After the packer is set and confirmed to be in place and operational (effectively sealing the designated section of the well), the service tool, which is used to deploy, set, and sometimes test the packer, is released. This release is a crucial step, as it signifies the completion of the packer setting operation, allowing the service tool to be retrieved to the surface. This operation is pivotal for operational integrity, enabling subsequent production or injection activities to proceed under controlled and optimized conditions.

[0122] In step 745, a user of the method POOH with WP. For context, "POOH with WP" (Pull Out Of Hole with Wet Pipe) refers to the procedure of removing the drill string or other downhole tools from the wellbore while the drill pipe remains filled with drilling fluid. This technique is employed to maintain the hydrostatic pressure within the well, which is essential for well control and the prevention of formation fluids influx. Keeping the pipe "wet" ensures that the necessary pressure balance is preserved, mitigating the risks associated with wellbore instability and ensuring the safety and integrity of the drilling operation. This approach is particularly vital in drilling environments where precise pressure management is crucial for avoiding well control issues and ensuring the smooth progression of drilling activities.

[0123] In step 750, a user of the method expands the screens with the downhole expansion tool, closes the wellbore with a barrier device, and circulates brine above the packer. For context, expanding screens with a downhole expansion tool, closing the wellbore with a barrier device, and circulating brine above the packer is a method employed to enhance wellbore stability, optimize hydrocarbon production, and ensure environmental safety. The expansion of screens using a downhole tool directly in the wellbore ensures a tight, custom fit against the formation, effectively filtering sand and fine particles while allowing for optimal fluid flow. Introducing a barrier device to close the wellbore helps maintain control over the well's pressure and fluid dynamics, essential for operational safety and efficiency. Circulating brine above the packer, a technique used to stabilize the wellbore environment, further aids in controlling formation pressures, reducing the risk of wellbore collapse, and preparing the well for production or further intervention. This comprehensive approach ensures the integrity of the well, maximizes the extraction of hydrocarbons, and minimizes environmental impact by preventing the uncontrolled release of formation fluids.

[0124] In step 755, a user of the method may, for example, continue to with POOH. For context, continuing with "POOH after screen expansion" refers to the process of Pulling Out Of Hole following the expansion of screens within the wellbore. Screen expansion, a crucial step in wellcompletion, involves deploying expandable screens downhole and then enlarging them to ensure a tight fit against the formation, thereby enhancing sand control and optimizing fluid flow from the reservoir into the wellbore. Once these screens are successfully expanded and set in place, continuing with POOH signifies the subsequent withdrawal of the drill string and any related downhole tools used during the screen expansion process. This phase is vital for transitioning the well from the completion stage to production readiness, facilitating the installation of further production equipment, or performing additional well interventions. It marks a pivotal moment in ensuring the well's structural integrity, productivity, and longevity by effectively managing formation sand and minimizing potential production issues related to sand ingress.

[0125] FIG. 8 depicts an exemplary diagram 800 of an exemplary method of operation, using a drilling bit to drill a wellbore, filling wellbore with drilling fluid, removing drilling bit, inserting pipe in connection with downhole wellbore expansion tool, expanding the wellbore expansion tool, using a decouplable barrier device to prevent sea water from entering pipe, allowing for further expansion later on. FIG. 8 depicts the method described in FIG. 7.

[0126] The illustrative diagram 800 includes a drilling pipe 805. The illustrative diagram 800 includes an anchor point 810. The anchor point may, for example, be the location at which the screens will be inserted. The illustrative diagram 800 includes a subterranean area surrounding soil 805. The illustrative diagram 800 includes a drilling bit 820. In step 715, drilling fluid 825 is circulated in the wellbore.

[0127] In step, 720, the drilling bit is removed. The illustrative diagram 800, depicts brine 830. In step 725, an exemplary downhole radial expansion device is inserted 850 into the wellbore. The radial expansion device is unexpanded when inserted in an unexpanded stated 835. In the step 730, the radial expansion tool is inserted past the brine into the drilling fluid. The radial expansion device is expanded in step 745, as depicted in an expanded state 835a. A barrier 840 is inserted in step 745. The illustrative diagram depicts deployed fluid pipe 865a, where the drilling fluid may be released. The illustrative diagram depicts the retracting fluid pipe as a barrier device is secured, allowing the pipe to be retracted.

[0128] Although various embodiments have been described with reference to the figures, other embodiments are possible.

[0129] Although an exemplary system has been described with reference to FIG. 1-6, other implementations may be deployed in other industrial, scientific, medical, commercial, and / or residential applications.

[0130] In an illustrative aspect a radial expansion tool 100 includes an energized spring 104 disposed and wound around a pipe 102 and attached at opposing ends to collars 118) that, when released, permit rotation of the spring about the pipe to induce radial expansion of the spring, while constraining axial contraction or expansion of the spring.

[0131] Some embodiments may, for example, include a radial expansion tool system including a radial expansion tool including an energized spring 104 disposed and wound around a pipe 102 and attached at opposing ends to collars 118, that, when released permit rotation of the spring about the pipe to induce radial expansion of the spring, while constraining axial contraction or expansion of the spring; a screen jacket wherein the screen jacket is placed outside the wound coiled spring; and a gravel layer positioned between an inner permeable membrane and an outer permeable membrane.

[0132] Some embodiments may, for example, include a method of deploying a radial expansion tool, the method including: securing and disposing an unenergized spring to a base pipe using a spring lock ring; winding the spring around the base pipe to transform the unenergized spring into an energized spring; securing the second end of the wound coiled spring to the base pipe via an attachment-rotation mechanism; placing a retention member in the rotating ring, wherein the retention member prevents motion of the attachment-rotating mechanism relative to the base pipe; placing a screen jacket over the coiled spring; placing a gravel layer under the screen jacket; placing a permeable membrane over the gravel layer; mounting endcaps on the base pipe; installing the sand control system in a wellbore; and triggering the opposing collars, wherein the opposing collars releases the attachment-rotation mechanism.

[0133] Some embodiments of the radial expansion tool, system, and / or method, may, for example, include a pipe (102) that may, for example, include a perforated base pipe (102a).

[0134] Some embodiments of the radial expansion tool, system, and / or method may, for example, include the energized spring (104) including a coiled spring 104a.

[0135] Some embodiments of the radial expansion tool, system, and / or method, may include the pipe having a length be between 4 feet and 40 feet. The radial expansion tool, system, and / or apparatus may, for example, not be limited by these dimensions.

[0136] Some embodiments of the radial expansion tool, system, and / or method may, for example, include the pipe having an outer diameter of between 4.5 and 6.5 inches. The radial expansion tool, system, and / or apparatus may, for example, not be limited by these dimensions.

[0137] Some embodiments of the radial expansion tool, system, and / or method may, for example, further include an attachment-rotation mechanism (116) and a retention member (202).

[0138] Some embodiments of the radial expansion tool, system, and / or method, may, for example, include the attachment-rotation mechanism (116) including a rotating ring (116a) wherein therotating rings holds a second end of the wound energized spring relative to the pipe and the retention member (202) including a pin (202a).

[0139] Some embodiments of the radial expansion tool, system, and / or method, may, for example, include the pin (202a) including a break point configured for tensile shear of the pin and the attachment-rotation mechanism is pined to the pipe.

[0140] Some embodiments of the radial expansion tool, system, and / or method, may, for example, include the opposing collars including a spring release mechanism. The attachment-rotation mechanism may, for example, include a pin retaining wedge and a rotating ring. The retention member may, for example, include a pin configured to pass through a portion of the rotating ring, pass through the pipe, wherein the pipe is a perforated base pipe, and be threaded into the pin retaining wedge.

[0141] Some embodiments of the radial expansion tool, system, and / or method may, for example, include the spring release mechanism further including an insertion wedge, wherein the insertion wedge is configured to push on a tapered edge of the pin retaining wedge, urging the pin retaining wedge away from the interior surface of the perforated base pipe.

[0142] Some embodiments of the radial expansion tool, system, and / or method, may, for example, include the spring release mechanism further including an insert, wherein the insert is fixed relative to the perforated base pipe, and prevents lateral movement of the pin retaining wedge relative to the perforated base pipe.

[0143] Some embodiments of the radial expansion tool, system, and / or method, may, for example, include the spring release mechanism further including a shifter, wherein the shifter is configured to move the insertion wedge.

[0144] Some embodiments of the radial expansion tool, system, and / or method, may, for example, include the shifter including a housing having an outer diameter smaller than the inner diameter of the pipe.

[0145] Some embodiments of the radial expansion tool, system, and / or method may, for example, include the shifter further including: a clasp, wherein the clasp is configured to engage the insertion wedge when the shifter is activated; a chock, wherein the chock pushes on an interior surface of the clasp; a loading mechanism, wherein the loading mechanism pushes the clasp on the chock, causing the clasp to extend beyond the housing; and a cover, wherein the cover has one or more openings which allow the clasp to protrude from the housing; and a spring, wherein the spring is compressed initially, releasing the spring pushes the chock relative to the clasp, and the chock moving relative to the clasp causes the clasp to retract into housing; and a cover relative to the housing, wherein the cover moving relative to the housing prevents the clasp from extending outside the housing.

[0146] Some embodiments of the radial expansion tool, system, and / or method may, for example, include the attachment-rotation mechanism including a spring lock ring, wherein the spring lock ring holds a first end of the wound coiled spring relative to the pipe.

[0147] Some embodiments of the radial expansion tool may, for example, include a downhole expandable payload (235).

[0148] Some embodiments of the radial expansion tool, system, and / or method may, for example, include the downhole expandable payload (235) including a porous material pack (235a) including porous material (240) disposed over the pipe, a set of screen jackets (245) disposed around the porous material, a permeable membrane (110) placed above and below a layer formed from the porous material, and an end cap assembly (250) disposed around the porous material and the screen jackets.

[0149] Some embodiments of the radial expansion tool, system, and / or method may, for example, include the set of screen jackets overlap as disposed over the porous material such that the screen jackets are configured to be held in place so the porous material pack may be coupled to the pipe.

[0150] Some embodiments of the radial expansion tool, system, and / or method, may, for example, include one or more end caps, wherein the one or more end caps are attached to the pipe and hold the wound energized spring, the screen jacket, the porous material layer and the permeable membrane in place relative to the pipe.

[0151] Some embodiments of the radial expansion tool, system, and / or method may, for example, include the opposing collar further comprising a spring release mechanism configured to release the attachment-rotation mechanism, allowing the second end of the wound coiled spring to move relative to the pipe.

[0152] Some embodiments of the radial expansion tool, system, and / or method, may, for example, include the one or more end caps are sloped on an external surface.

[0153] Some embodiments of the radial expansion tool, system, and / or method, may, for example, further comprise a shear release mechanism (255).

[0154] Some embodiments of the radial expansion tool, system, and / or method may, for example, include a shroud (260).

[0155] Some embodiments of the radial expansion tool, system, and / or method, may, for example, be configured when the opposing collars are released to permit rotation of the spring about the pipe to induce radial expansion of the spring, while constraining axial contraction or expansion of the spring

[0156] Some embodiments of the radial expansion tool, system, and / or method, may, for example, be configured such that the opposing collars include a spring release mechanism.

[0157] Some embodiment of the radial expansion tool, system, and / or method, may, for example, include triggering the opposing collars further including breaking the retention member.

[0158] The radial expansion tool, system, and / or method, may, for example, include installing the sand control system in a wellbore further including installing the sand control system after drilling the wellbore.

[0159] The radial expansion tool, system, and / or method, may, for example, including installing the sand control system in a wellbore further including installing the sand control simultaneously with drilling the wellbore.

[0160] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made. For example, advantageous results may be achieved if the steps of the disclosed techniques were performed in a different sequence, or if components of the disclosed systems were combined in a different manner, or if the components were supplemented with other components. Accordingly, other implementations are contemplated within the scope of the following claims.

Claims

CLAIMSWhat is claimed is:

1. A radial expansion tool (100) comprising: an energized spring (104) disposed and wound around a pipe (102) and attached at opposing ends to collars (118) that, when released, permit rotation of the spring about the pipe to induce radial expansion of the spring, while constraining axial contraction or expansion of the spring.

2. The radial expansion tool of claim 1, wherein the pipe (102) comprises a perforated base pipe (102a).

3. The radial expansion tool of claim 1, wherein the energized spring (104) comprises a coiled spring 104a.

4. The radial expansion tool of claim 1, wherein the length of the pipe is between 4 feet and 40 feet.

5. The radial expansion tool of claim 1, wherein the pipe has an outer diameter of between 4.5 and 6.5 inches.

6. The radial expansion tool of claim 1, further comprising an attachment-rotation mechanism (116) and a retention member (202).

7. The radial expansion tool of claim 1, wherein the attachment-rotation mechanism (116) comprises a rotating ring (116a) wherein the rotating rings holds a second end of the wound energized spring relative to the pipe and the retention member (202) comprises a pin (202a).

8. The radial expansion tool of claim 1, wherein the pin (202a) includes a break point configured for tensile shear of the pin and the attachment-rotation mechanism is pined to the pipe.

9. The radial expansion tool of claim 1, wherein: the opposing collars comprise a spring release mechanism, the attachment-rotation mechanism comprises a pin retaining wedge and a rotating ring, and the retention member comprises a pin configured to: pass through a portion of the rotating ring, pass through the pipe, wherein the pipe is a perforated base pipe, and be threaded into the pin retaining wedge.

10. The radial expansion tool of claim 9, the spring release mechanism further comprises an insertion wedge, wherein the insertion wedge is configured to push on a tapered edge of the pin retaining wedge, urging the pin retaining wedge away from the interior surface of the perforated base pipe.

11. The radial expansion tool of claim 9, wherein the spring release mechanism further comprises: an insert, wherein the insert is: fixed relative to the perforated base pipe, and prevents lateral movement of the pin retaining wedge relative to the perforated base pipe-12. The radial expansion tool of claim 10, wherein the spring release mechanism further comprises a shifter, wherein the shifter is configured to move the insertion wedge.

13. The radial expansion tool of claim 12, wherein the shifter comprises a housing having an outer diameter smaller than the inner diameter of the pipe.

14. The radial expansion tool of claim 12, wherein the shifter further comprises: a clasp, wherein the clasp is configured to engage the insertion wedge when the shifter is activated; a chock, wherein the chock pushes on an interior surface of the clasp; a loading mechanism, wherein the loading mechanism pushes the clasp on the chock, causing the clasp to extend beyond the housing; and a cover, wherein the cover has one or more openings which allow the clasp to protrude from the housing; and a spring, wherein: the spring is compressed initially, releasing the spring pushes the chock relative to the clasp, and the chock moving relative to the clasp causes the clasp to retract into housing; and a cover relative to the housing, wherein the cover moving relative to the housing prevents the clasp from extending outside the housing.

15. The radial expansion tool of claim 1, wherein the attachment-rotation mechanism comprises a spring lock ring, wherein the spring lock ring holds a first end of the wound coiled spring relative to the pipe.

16. The radial expansion tool of claim 1, further comprising a downhole expandable payload (235).

17. The radial expansion tool of claim 16, wherein the downhole expandable payload (235) comprising a porous material pack (235a) comprising porous material (240) disposed over the pipe, a set of screen jackets (245) disposed around the porous material, a permeable membrane (110) placed above and below a layer formed from the porous material, and an end cap assembly (250) disposed around the porous material and the screen jackets.

18. The radial expansion tool of claim 16, wherein the set of screen j ackets overlap as disposed over the porous material such that the screen jackets are configured to be held in place so the porous material pack may be coupled to the pipe.

19. The radial expansion tool of claim 16, further comprising one or more end caps, wherein the one or more end caps are attached to the pipe and hold the wound energized spring, the screen jacket, the porous material layer and the permeable membrane in place relative to the pipe.

20. The radial expansion tool of claim 16, wherein the opposing collar further comprises a spring release mechanism configured to release the attachment-rotation mechanism, allowing the second end of the wound coiled spring to move relative to the pipe.

21. The radial expansion tool of claim 16, wherein the one or more end caps are sloped on an external surface.

22. The radial expansion tool of claim 1, further comprising a shear release mechanism (255).

23. The radial expansion tool of claim 1, further comprising a shroud (260).

24. A radial expansion tool system comprising: a radial expansion tool comprising an energized spring 104 disposed and wound around a pipe 102 and attached at opposing ends to collars 118, that, when released permit rotation of the spring about the pipe to induce radial expansion of the spring, while constraining axial contraction or expansion of the spring; a screen jacket wherein the screen jacket is placed outside the wound coiled spring; and a gravel layer positioned between an inner permeable membrane and an outer permeable membrane.

25. The radial expansion tool system of claim 24, wherein the pipe (102) comprises a perforated base pipe (102a).

26. The radial expansion tool system of claim 24, wherein the energized spring (104) comprises a coiled spring 104a.

27. The radial expansion tool system of claim 24, wherein the length of the pipe is between 4 feet and 40 feet.

28. The radial expansion tool system of claim 24 wherein the pipe has an outer diameter of between 4.5 and 6.5 inches.

29. The radial expansion tool system of claim 24, further comprising an attachment-rotation mechanism (116) and a retention member (202).

30. The radial expansion tool system of claim 24, wherein the attachment-rotation mechanism (116) comprises a rotating ring (116a) wherein the rotating rings holds a second end of the wound energized spring relative to the pipe and the retention member (202) comprises a pin (202a).

31. The radial expansion tool system of claim 24, wherein the pin (202a) includes a break point configured for tensile shear of the pin and the attachment-rotation mechanism is pined to the Pipe-32. The radial expansion tool system of claim 24, wherein: the opposing collars comprise a spring release mechanism, the attachment-rotation mechanism comprises a pin retaining wedge and a rotating ring, and the retention member comprises a pin configured to: pass through a portion of the rotating ring, pass through the pipe, wherein the pipe is a perforated base pipe, and be threaded into the pin retaining wedge.

33. The radial expansion tool system of claim 32, the spring release mechanism further comprises an insertion wedge, wherein the insertion wedge is configured to push on a tapered edge of the pin retaining wedge, urging the pin retaining wedge away from the interior surface of the perforated base pipe.

34. The radial expansion tool system of claim 32, wherein the spring release mechanism further comprises: an insert, wherein the insert is: fixed relative to the perforated base pipe, and prevents lateral movement of the pin retaining wedge relative to the perforated base pipe-35. The radial expansion tool system of claim 33, wherein the spring release mechanism further comprises a shifter, wherein the shifter is configured to move the insertion wedge.

36. The radial expansion tool system of claim 35„ wherein the shifter comprises a housing having an outer diameter smaller than the inner diameter of the pipe.

37. The radial expansion tool system of claim 35„ wherein the shifter further comprises: a clasp, wherein the clasp is configured to engage the insertion wedge when the shifter is activated; a chock, wherein the chock pushes on an interior surface of the clasp; a loading mechanism, wherein the loading mechanism pushes the clasp on the chock, causing the clasp to extend beyond the housing; and a cover, wherein the cover has one or more openings which allow the clasp to protrude from the housing; and a spring, wherein: the spring is compressed initially, releasing the spring pushes the chock relative to the clasp, and the chock moving relative to the clasp causes the clasp to retract into housing; and a cover relative to the housing, wherein the cover moving relative to the housing prevents the clasp from extending outside the housing.

38. The radial expansion tool system of claim 24„ wherein the attachment-rotation mechanism comprises a spring lock ring, wherein the spring lock ring holds a first end of the wound coiled spring relative to the pipe.

39. The radial expansion tool system of claim 24, further comprising a downhole expandable payload (235).

40. The radial expansion tool system of claim 39, wherein the downhole expandable payload (235) comprising a porous material pack (235a) comprising porous material (240) disposed over the pipe, a set of screen jackets (245) disposed around the porous material, a permeable membrane(110) placed above and below a layer formed from the porous material, and an end cap assembly (250) disposed around the porous material and the screen jackets.

41. The radial expansion tool system of claim 39, wherein the set of screen jackets overlap as disposed over the porous material such that the screen jackets are configured to be held in place so the porous material pack may be coupled to the pipe.

42. The radial expansion tool system of claim 39further comprising one or more end caps, wherein the one or more end caps are attached to the pipe and hold the wound energized spring, the screen jacket, the porous material layer and the permeable membrane in place relative to the pipe- 43. The radial expansion tool system of claim 39, wherein the opposing collar further comprises a spring release mechanism configured to release the attachment-rotation mechanism, allowing the second end of the wound coiled spring to move relative to the pipe.

44. The radial expansion tool system of claim 39, wherein the one or more end caps are sloped on an external surface.

45. The radial expansion tool system of claim 24, further comprising a shear release mechanism(255).

46. The radial expansion tool system of claim 24, further comprising a shroud (260).

47. A method of deploying a radial expansion tool, the method comprising: securing and disposing an unenergized spring to a base pipe using a spring lock ring; winding the spring around the base pipe to transform the unenergized spring into an energized spring; securing the second end of the wound coiled spring to the base pipe via an attachmentrotation mechanism; placing a retention member in the rotating ring, wherein the retention member prevents motion of the attachment-rotating mechanism relative to the base pipe; placing a screen jacket over the coiled spring; placing a gravel layer under the screen jacket; placing a permeable membrane over the gravel layer; mounting endcaps on the base pipe; installing the sand control system in a wellbore; and triggering the opposing collars, wherein the opposing collars releases the attachmentrotation mechanism.

48. The method of deploying a radial expansion tool of claim 47 wherein the base pipe is perforated.

49. The method of deploying a radial expansion tool of claim 47, when the opposing collars are released to permit rotation of the spring about the pipe to induce radial expansion of the spring, while constraining axial contraction or expansion of the spring50. The method of deploying a radial expansion tool of claim 47, wherein the opposing collars comprise a spring release mechanism.

51. The method of deploying a radial expansion tool of claim 47, wherein triggering the opposing collars further comprises breaking the retention member.

52. The method of deploying a radial expansion tool of claim 47, wherein installing the sand control system in a wellbore further comprises installing the sand control system after drilling the wellbore.

53. The method of deploying a radial expansion tool of claim 47, wherein installing the sand control system in a wellbore further comprises installing the sand control simultaneously with drilling the wellbore.

54. The method of deploying a radial expansion tool of claim 47, wherein the length of the base pipe is between 4 feet and 40 feet.

55. The method of deploying a radial expansion tool of claim 47, wherein the base pipe has an outer diameter of between 4.5 and 6.5 inches.

56. The method of deploying a radial expansion tool of claim 47, wherein the attachment-rotation mechanism (116) comprises a rotating ring (116a) wherein the rotating rings holds a second end of the wound coiled spring relative to the pipe and the retention member (202) comprises a pin (202a).

57. The method of deploying a radial expansion tool of claim 56, wherein the (pin 202a) includes a break point which allows for tensile shear of the pin and the attachment-rotation mechanism is pined to the pipe.

58. The method of deploying a radial expansion tool claim 56, further comprising the use of opposing collars that further comprise a spring release mechanism, wherein the attachmentrotation mechanism comprises a pin retaining wedge and a rotating ring, and the retention member further comprises a pin configured to: pass through a portion of the rotating ring, pass through the pipe, wherein the pipe is a perforated base pipe, and be threaded into the pin retaining wedge.

59. The method of deploying a radial expansion tool of claim 56, the spring release mechanism further comprises an insertion wedge, wherein the insertion wedge is configured to push on a tapered edge of the pin retaining wedge, causing pin retaining wedge to move away from the interior surface of the perforated base pipe.

60. The method of deploying a radial expansion tool of claim 56, wherein the spring release mechanism further comprises: an insert, wherein the insert is: fixed relative to the perforated base pipe; and prevents lateral movement of the pin retaining wedge relative to the perforated base pipe.

61. The method of deploying a radial expansion tool of claim 59, wherein the spring release mechanism further comprises a shifter, wherein the shifter is configured to move the insertion wedge.

62. The method of deploying a radial expansion tool of claim 59, wherein the shifter comprises a housing configured to have an outer diameter smaller than the inner diameter of the pipe.

63. The method of deploying the sand control system of claim 59, wherein the shifter further comprises: a clasp, wherein the clasp is configured to engage insertion wedge when the shifter is activated; a chock, wherein the chock pushes on an interior surface of the clasp; a loading mechanism, wherein the loading mechanism pushes the clasp on the chock, causing clasp to extend beyond the housing; and a cover, wherein the cover has one or more openings which allow the clasp to protrude from the housing; and a spring, wherein: the spring is compressed initially;releasing the spring pushes the chock relative to the clasp, wherein chock moving relative to the clasp causes the clasp to retract into housing; and a cover relative to the housing, wherein cover moving relative to the housing prevents clasp from extending outside the housing.

64. The method of deploying the sand control system of claim 47, wherein the attachment-rotation mechanism comprises a spring lock ring, wherein the spring lock ring holds a first end of the wound coiled spring relative to the pipe.

65. The method of deploying the sand control system of claim 47, wherein the screen jackets overlap as disposed over the porous material such that the screen jackets are configured to be held in place so the porous material pack may be coupled to the pipe.

66. The method of deploying the sand control system of claim 47, wherein the further comprising providing a spring release mechanism configured to release the attachment-rotation mechanism, allowing the second end of the wound coiled spring to move relative to the pipe.

67. The method of deploying the sand control system of claim 47, wherein the one or more end caps are positioned to be sloped on an external surface.

68. The method of deploying the sand control system of claim 47, further comprising providing a shear release mechanism (255).

69. The method of deploying the sand control system of claim 47, further comprising providing a shroud (260).

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