Expanded Tubular String for Larger Screen Assemblies
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Solution Overview
Problem
The use of smaller screen assemblies in downhole drilling and completions to maintain radial clearance limits the maximum size of screen assemblies, restricting production and stimulation rates, and requires larger casing and boreholes, increasing material costs.
Innovation Solution
A method and system that involves selectively expanding a tubular string to form expanded portions with a larger internal dimension, allowing for larger screen assemblies to be positioned with a radial clearance of at least 0.5 inches, enabling larger screen assemblies to be used within a given casing size without compromising production and stimulation rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If larger screen assemblies are used to increase production and stimulation rates, then productivity is improved, but the radial clearance between the screen assembly and casing becomes too small, causing premature screen outs and sand bridging
Solution Approach 1:
The tubular string is divided into multiple sections with different internal dimensions. Expanded portions have larger internal dimensions to accommodate larger screen assemblies, while unexpanded portions maintain the original smaller internal dimension. This segmentation allows different zones to have optimized screen sizes based on local requirements without compromising the overall system's reliability through adequate radial clearance in all sections.
Solution Approach 2:
Different portions of the tubular string are given different internal dimensions to match the specific needs of each zone. The expanded portions provide larger clearance specifically where larger screen assemblies are positioned, while unexpanded portions maintain appropriate clearance for smaller screens. This local differentiation resolves the contradiction by providing the necessary radial clearance exactly where needed rather than uniformly throughout the entire string.
2Reliability
If smaller screen assemblies are used to maintain radial clearance of at least 0.5 inches, then reliability is improved, but the maximum size of screen assemblies is limited, reducing productivity
Solution Approach 1:
The tubular string is segmented into expanded and unexpanded portions, allowing smaller screen assemblies to be used in unexpanded portions where they maintain adequate radial clearance, while larger screen assemblies can be used in expanded portions where the increased internal dimension provides the necessary clearance. This segmentation enables both reliability and productivity to be optimized in different zones simultaneously.
Solution Approach 2:
The internal dimension parameter of the tubular string is changed selectively in expanded portions to accommodate larger screen assemblies. By changing this geometric parameter in specific zones rather than uniformly, the system enables larger screens (higher productivity) where needed while maintaining the original dimensions (ensuring reliability) in other zones where smaller screens are used.
3Productivity
If larger casing is used to accommodate larger screen assemblies while maintaining radial clearance, then productivity is improved, but material costs and borehole size increase
Solution Approach 1:
Instead of using uniformly larger casing throughout the entire tubular string, the invention applies local quality by expanding only the specific portions where larger screen assemblies are needed. The unexpanded portions continue to use the original, smaller casing size. This localized approach allows productivity to be improved in specific zones without the penalty of increased material costs and borehole size associated with uniformly larger casing.
Solution Approach 2:
The internal dimension parameter of the tubular string is changed only in the expanded portions rather than throughout the entire string. This selective parameter change allows larger screen assemblies to be accommodated in specific zones to improve productivity, while the majority of the tubular string maintains its original, more cost-effective dimensions, thus avoiding the material cost increases associated with uniformly larger casing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the use of larger screen assemblies within existing casing sizes, maintaining acceptable production and stimulation rates while reducing material costs by creating an enlarged radial gap between the screen assemblies and the tubular string, thus avoiding premature screen outs and sand bridging.
Implementation Method 1
selectively expanding a tubular string having a substantially continuous first dimension to form at least one expanded portion of the tubular string having a second dimension greater than the first dimension
Data Source
AI summary
A completion system, including a tubular string initially having an substantially constant first dimension and configured to include at least one unexpanded portion having the first dimension and at least one expanded portion having a second dimension larger than the first dimension. The tubular string has at least one opening therein formed at the at least one expanded portion. At least one screen assembly is included having a third dimension and positioned radially adjacent the at least one expanded portion. A radial clearance is formed between the outer dimension of the at least one screen assembly and the second internal dimension of the at least one second portion of the outer tubular string. A method of completing a borehole is also included.