Expandable Sand Screen Self-Unrolling for Wellbore Bonding
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Solution Overview
Problem
Existing expandable sand screens face challenges in efficiently expanding and securing to the wellbore wall, particularly in terms of diameter adjustment and adhesive bonding, which can be compromised by wellbore conditions.
Innovation Solution
An expandable sand screen device with resilient screen material that self-unrolls and is adhesively bonded using temperature-activated adhesive, facilitated by a running tool with inflatable structures and heaters to ensure secure expansion and bonding to the wellbore wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the sand screen is expanded using an expansion tool with large outer diameter, then the sand screen can be forced outwardly towards the wellbore wall, but the device complexity and difficulty of running into the wellbore increases
Solution Approach 1:
The sand screen is designed with self-expanding capability through resilient material properties. The screen material naturally urges itself to unroll and expand outwardly towards the wellbore wall without requiring a complex expansion tool, thereby reducing device complexity while maintaining expansion force capability
Solution Approach 2:
The expansion function is extracted from a separate complex expansion tool and integrated into the sand screen structure itself through resilient material design. This eliminates the need for a dedicated expansion tool with large outer diameter, simplifying the overall device
2Strength
If adhesive is applied to bond overlapping sections of screen material, then bonding strength is improved, but the adhesive may set too quickly or not set properly under wellbore conditions
Solution Approach 1:
The adhesive properties are modified to be temperature-activated. The adhesive remains inactive during installation and only sets when exposed to the elevated temperature conditions of the wellbore, ensuring reliable bonding under actual operating conditions rather than during installation
Solution Approach 2:
The adhesive is pre-applied to the screen material before installation, but remains inactive until exposed to wellbore temperature. This preliminary preparation ensures the adhesive is ready to bond immediately when the temperature condition is met, without setting too quickly during handling
3Strength
If the screen material thickness is increased to 0.1-0.5 mm for durability, then strength is improved, but the ability to expand and conform to wellbore irregularities decreases
Solution Approach 1:
The screen material is designed as a composite structure combining thickness (0.1-0.5 mm) for strength with resilient properties for expansion. This composite material approach allows the screen to maintain durability while still being able to unroll and conform to wellbore irregularities
Solution Approach 2:
The screen material transitions from a rigid thick structure during installation to a dynamic, expandable structure when deployed. The resilient properties enable the thick material to unroll and adapt to wellbore conditions while maintaining its strength characteristics
4Ease of operation
If the sand screen is made self-unrollable to simplify installation, then ease of operation is improved, but control over expansion timing and position is reduced
Solution Approach 1:
The sand screen is designed with self-unrolling capability through resilient material properties, automatically expanding when deployed without requiring external expansion tools. This simplifies installation operations while the controlled release mechanism maintains positioning precision
Solution Approach 2:
The screen is pre-configured in a rolled-up state with controlled release mechanisms that allow precise positioning before activation. Once positioned, the self-unrolling action occurs, combining precise initial placement with simplified subsequent operation
Data Source
AI summary
An expandable sand screen device is described comprising in various examples a rolled-up piece of screen material which is configured to be at least partially unrollable to expand diametrically when located in a wellbore. A piece of screen material may be rolled up to form an expandable roll. In some examples, the expandable sand screen device is run into the wellbore on a running tool and allowed to partially unroll once released from the running tool.