Heat-Deployable Screen Assembly for Borehole Conformity
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Solution Overview
Problem
Existing downhole screen expansion techniques face challenges with wellbore shape irregularities, leading to annular gaps and potential sand production, and existing heat delivery methods are inefficient or corrosive, making precise deployment of compliant layers difficult.
Innovation Solution
A deployable screen assembly with a porous conforming material that swells upon heat exposure, using a catalytic reaction to generate steam and deploy the conforming layer to bridge annular gaps without expanding the screen, eliminating the need for gravel packing and reducing weld stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed swage is used to expand the screen, then the screen can be expanded to a fixed amount, but wellbore shape irregularities cause annular gaps and potential sticking
Solution Approach 1:
The patent employs a dynamic expansion system where the swage can adjust its expansion force and position. The system includes a expandable screen with controlled expansion capability that can adapt to varying wellbore diameters and irregularities, transforming the static fixed-swage approach into a dynamic system that responds to real-time wellbore conditions.
Solution Approach 2:
The invention changes the expansion parameters by using a controlled expansion mechanism that can vary the expansion force and extent along the screen length. This allows the screen to expand to different degrees in different zones, matching the wellbore shape variations and eliminating annular gaps without causing sticking.
2Adaptability or versatility
If a flexible swage is used to expand the screen, then compliance with tight spots is improved, but annular gaps still remain in void areas
Solution Approach 1:
The flexible swage is enhanced with a dynamic control system that can adjust the expansion force distribution. The system allows the swage to flex in tight spots while simultaneously applying sufficient force in void areas to eliminate annular gaps, achieving both compliance and gap elimination through controlled dynamic expansion.
Solution Approach 2:
The expansion system applies different expansion characteristics to different zones of the screen. In tight spot areas, the swage flexes inward with reduced expansion force, while in void areas, the system maintains or increases expansion force to eliminate annular gaps. This localized quality variation resolves the contradiction between compliance and gap elimination.
3Duration of action of moving object
If the conforming layer is heated in advance during trip into the hole, then deployment readiness is improved, but premature deployment occurs making dislodge difficult
Solution Approach 1:
The system prepares the conforming layer for deployment during the trip into the hole by heating it to near-deployment temperature, but controls the heating to prevent actual deployment. The layer is pre-conditioned with the heat source in position, ready for immediate deployment upon reaching the target zone, while maintaining the ability to be dislodged if needed.
Solution Approach 2:
The conforming layer utilizes a phase transition material that changes properties at a specific temperature threshold. During tripping, the layer is heated below this threshold, maintaining its removable state. At the deployment zone, additional heating triggers the phase transition, causing the layer to expand and conform to the wellbore, at which point it becomes firmly attached and difficult to dislodge.
4Temperature
If heated medium is injected to supply heat downhole, then heat delivery is achieved, but heat dissipation during transmission reduces effectiveness
Solution Approach 1:
The system extracts the heat generation function from the surface equipment and places it directly at the deployment site downhole. A heater is positioned within the screen assembly or wellbore at the target location, eliminating the need to transport heat through the wellbore fluid column. This local heat generation prevents heat dissipation during transmission and ensures sufficient temperature for conforming layer deployment.
Solution Approach 2:
The patent introduces a heat-generating intermediary device (heater or heat-generating chemical reaction system) that converts chemical or electrical energy directly into heat at the deployment location. This intermediary eliminates the inefficient thermal transmission process by generating heat in-situ, using the heater as a mediator between the power source and the conforming layer.
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
The solution effectively conforms to the borehole shape, reduces annular gaps, and ensures reliable filtration by using a heat-generated conforming material that maintains its expanded state, improving sand control and reducing operational risks.
Implementation Method 1
The heat is provided locally downhole by a catalytic reaction that produces steam
Implementation Method 2
A deployable screen assembly with a porous conforming material that swells upon heat exposure
Implementation Method 3
a catalytic reaction that produces steam
Data Source
AI summary
A screen assembly has a material that conforms to the borehole shape after insertion. The assembly comprises a compliant layer that takes the borehole shape on expansion. The outer layer is formed having holes to permit production flow. The selected conforming material swells with heat, and in one non-limiting embodiment comprises a shape memory foam that is thermoset or thermoplastic. Heat is provided by supplying a fuel (including an oxidant) to a catalyst in close proximity to the compliant layer so that the product from the catalytic reaction is heated steam which contacts and deploys the conforming material. The base pipe can have a screen over it to act as an underlayment for support of the conforming layer or alternatively for screening.