Screen Assembly Having Permeable Handling Area

Abstract

A gravel pack assembly for a borehole has first and second joints and a foil. The basepipes of the joints connect end-to-end, and both of the basepipes having filters for filtering fluid passage from a borehole into bores of the basepipes. Transport tubes are disposed along the first and second joint, and a jumper tube expands across the connected ends of the basepipes and connects the transport tubes together. The foil encloses an area across the connected ends. The foil has an external surface defining an annulus thereabout with the borehole. The foil has end rings abutting the filters of the joints. At least a section of the foil leaks fluid from the borehole to the area enclosed by the foil, and at least a filter portion of the assembly filters the leaked fluid from the area to at least one of the first and second bores.

Claims

1. A completion assembly being assembled by grips of rig components at a rig and being configured to position in a borehole, the assembly comprising: a plurality of wellscreens, each of the wellscreens comprising a basepipe, each of the basepipes defining a bore and comprising: ends configured to couple adjoining ones of the basepipes together, an intermediate section disposed between the ends and defining a plurality of intermediate perforations in communication with the bore, and a primary filter disposed at the intermediate section and being configured to filter communication from the borehole to the intermediate perforations, the ends of the adjoining ones of the basepipes coupled together defining a blank area between the primary filters, wherein at least one of the wellscreens comprises a plurality of end perforations defined in at least one of the ends and being disposed in communication with the bore, the at least one end comprising: a foil disposed adjacent the end perforations and being configured to filter communication from the blank area to the bore; and a gripping section disposed adjacent the end perforations and being configured to be gripped by one of the grips of the rig components in assembling the completion assembly.

2. The assembly of claim 1, wherein each of the basepipes comprises: support rings disposed on the ends of the basepipe, each of the support rings defining one or more passages; and one or more transport tubes disposed along the basepipe and extending between the one or more passages in the support rings.

3. The assembly of claim 2, further comprising one or more jumper tubes disposed across the blank annular area between the ends of the adjoining ones of the basepipes and connecting the one or more transport tubes together.

4. The assembly of claim 2, wherein each of the basepipes comprises a shroud disposed along the basepipe and extending between the support rings, the shroud defining a plurality of flow openings therethrough.

5. The assembly of claim 1, wherein the at least one foil comprises a secondary filter disposed about the end perforations on the at least one end of the at least one basepipe and being supported with end rings affixed to the at least one basepipe at the at least one end, the secondary filter configured to filter communication from the blank annular area to the end perforations; and wherein the gripping section comprises a sleeve disposed about the secondary filter and being supported on the end rings, the sleeve defining a plurality of flow openings configured to communicate the blank annular area with the secondary filter.

6. The assembly of claim 5, wherein the plurality of flow openings comprises perforations defined through the sleeve.

7. The assembly of claim 5, wherein the plurality of flow openings comprises elongated slots defined along the sleeve.

8. The assembly of claim 5, wherein each of the basepipes comprises: support rings disposed on the ends of the basepipe, each of the support rings defining one or more passages; and one or more transport tubes disposed along the basepipe and extending between the one or more passages in the support rings, wherein the support ring on at least one end is disposed in abutment between one of the end rings of the secondary filter and another end ring of the primary filter or is disposed in spaced relation relative to one of the end rings of the secondary filter.

9. The assembly of claim 1, wherein the at least one foil comprises a sleeve disposed on the at least one end of the at least one basepipe about the end perforations, the sleeve defining a plurality of elongated slits communicating therethrough, the sleeve providing an exterior gripping surface for the gripping section.

10. The assembly of claim 9, wherein the sleeve comprises edges welded to the at least one end of the at least one basepipe.

11. The assembly of claim 9, wherein an interior of the sleeve comprises a plurality of channels defined longitudinally therealong.

12. The assembly of claim 9, wherein the elongated slits are defined circumferentially about the sleeve, longitudinally along the sleeve, or a combination thereof.

13. The assembly of claim 1, wherein the at least one foil comprises a plurality of plugs disposed in the end perforations, the plugs being configured to filter communication from the blank annular area to the end perforations; and wherein the gripping section comprises a sleeve disposed on the at least one end of the at least one basepipe and having flow openings exposed to the end perforations, the plugs being recessed in the flow openings, the sleeve providing an exterior gripping surface for the gripping section.

14. The assembly of claim 13, wherein the sleeve comprises edges welded to the at least one end of the at least one basepipe.

15. The assembly of claim 13, wherein each of the plugs comprises a support ring affixed to the at least one basepipe; and an insert disposed in the end perforation and supported by the support ring, wherein the insert comprises a secondary filter.

16. The assembly of claim 1, wherein the at least one foil comprises a secondary filter disposed inside the bore of the at least one end; and wherein the gripping section comprises an exterior gripping surface provided on the at least one end of the at least one basepipe.

17. The assembly of claim 16, wherein the secondary filter comprises a screen comprising wire wrapped about ribs disposed longitudinally inside the bore of the at least one end.

18. The assembly of claim 17, wherein the secondary filter is disposed inside the bores of the ends of the adjoining ones of the basepipes coupled together.

19. The assembly of claim 18, wherein the secondary filter comprises end caps disposed respectively in the bores, each of the end caps disposed between an end of the secondary filter and a shoulder in the bore of the adjoining ones of the basepipes coupled together.

20. A method for running wellscreens from a rig into a borehole, the rig having at least one grip of a rig component, each of the wellscreens having a basepipe, each basepipe having a primary filter disposed about intermediate perforations defined in the basepipe between ends of the basepipe, the method comprising: supporting a first of the wellscreens at the rig; making up a second of the wellscreens to the first wellscreen at the rig by connecting the ends of the first and second wellscreens together; and passing the first and second connected wellscreens downhole from the rig, wherein at least one of supporting the first wellscreen and making up the second wellscreen to the first wellscreen comprises gripping the at least one grip of the rig component on a gripping section disposed adjacent end perforations on at least one of the ends of at least one of the basepipes, the gripping section having foil disposed adjacent the end perforations, the foil being configured to filter communication through the end perforations.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0049] FIG. 1A is a side view, partially in cross-section, of a horizontal wellbore with a wellscreen assembly therein.

[0050] FIG. 1B illustrates a side view of an open hole wellscreen assembly according to the prior art for an open hole.

[0051] FIG. 1C illustrates an end view of the open hole wellscreen assembly of FIG. 1B.

[0052] FIG. 2A illustrates a wellscreen assembly according to the present disclosure in cross-section.

[0053] FIG. 2B illustrates the wellscreen assemblies according to the present disclosure being connected together at a rig floor using mechanical grips of pipe handling components.

[0054] FIG. 3A illustrates a wellscreen assembly according to a first embodiment of the present disclosure in partial cross-section.

[0055] FIG. 3B illustrates a detailed cross-section of a portion of the wellscreen assembly in FIG. 3A.

[0056] FIG. 3C illustrates an end-section of the wellscreen assembly in FIG. 3A.

[0057] FIG. 4A illustrates a wellscreen assembly according to a second embodiment of the present disclosure in partial cross-section.

[0058] FIG. 4B illustrates a detailed cross-section of a portion of the wellscreen assembly in FIG. 4A.

[0059] FIG. 4C illustrates an end-section of the wellscreen assembly in FIG. 4A.

[0060] FIG. 5A illustrates a wellscreen assembly according to a third embodiment of the present disclosure in partial cross-section.

[0061] FIG. 5B illustrates a detailed cross-section of a portion of the wellscreen assembly in FIG. 5A.

[0062] FIG. 5C illustrates an end-section of the wellscreen assembly in FIG. 5A.

[0063] FIG. 6A illustrates a wellscreen assembly according to a fourth embodiment of the present disclosure in partial cross-section.

[0064] FIG. 6B illustrates a detailed cross-section of a portion of the wellscreen assembly in FIG. 6A.

[0065] FIG. 6C illustrates an end-section of the wellscreen assembly in FIG. 6A.

[0066] FIG. 7A illustrates a wellscreen assembly according to a fifth embodiment of the present disclosure in partial cross-section.

[0067] FIG. 7B illustrates a detailed cross-section of a portion of the wellscreen assembly in FIG. 7A.

[0068] FIG. 7C illustrates an end-section of the wellscreen assembly in FIG. 7A.

[0069] FIG. 8A illustrates a wellscreen assembly according to a sixth embodiment of the present disclosure in partial cross-section.

[0070] FIG. 8B illustrates a detailed cross-section of a portion of the wellscreen assembly in FIG. 8A.

[0071] FIG. 8C illustrates an end-section of the wellscreen assembly in FIG. 8A.

[0072] FIG. 9A illustrates a wellscreen assembly according to a seventh embodiment of the present disclosure in partial cross-section.

[0073] FIG. 9B illustrates a detailed cross-section of a portion of the wellscreen assembly in FIG. 9A.

[0074] FIG. 9C illustrates an end-section of the wellscreen assembly in FIG. 9A.

[0075] FIGS. 10A-10B illustrate alternative embodiments of a wellscreen as in FIG. 9A.

DETAILED DESCRIPTION OF THE DISCLOSURE

[0076] FIG. 2A schematically illustrates a wellscreen assembly 100 according to the present disclosure in cross-section. The wellscreen assembly 100, which can be a downhole/sand screen assembly, has a joint, tubular, or basepipe 110 that longitudinally couples to other tubulars and assemblies (not shown) to create a completion string for running in a borehole (not shown).

[0077] The basepipe 110 defines a bore 112 for conveying production fluids once the assembly 100 is installed in the borehole. Ends 111a-b of the basepipe 110 are configured to couple to the basepipes (not shown) of other assemblies using couplings 106. For example, threads on the ends 111a-b of the basepipe 110 couple together with threaded couplings 106 to join the wellscreen assembly 100 with other wellscreen assemblies or tubulars. Typically, a completion has multiple wellscreen assemblies 100 connected in series by such couplings 106 to form a completion string for use in a cased or open borehole (not shown).

[0078] An intermediate section 102 of the assembly 100 is disposed on the basepipe 110 between the ends 111a-b. The intermediate section 102 defines a plurality of intermediate perforations 114 in communication with the bore 112. A primary filter 120 is disposed about the basepipe 110 at the intermediate section 102 and is configured to filter communication from a borehole annulus to the basepipe's bore 112 through the intermediate perforations 114. The primary filter 120 can include any type of filter media for use downhole, including metal mesh, pre-packed screens, protective shell screens, wire screen, or filters of other construction. As shown here, the primary filter 120 can be a wire-wrapped screen.

[0079] Shunt or transport tubes 130 can run along the length of the primary filter 120 and can deliver or transport slurry in an alternate path during gravel pack or frack pack operations. Support rings 116 support the transport tubes 130 at the opposing ends of the wellscreen assembly 100 and hold the shunt tubes 130 in place. For example, each support ring 116 can define one or more passages 117 through which ends of one or more transport tubes 130 disposed along the basepipe 110 extend. Although not shown, pack tubes can communicate off the transport tubes 130 in the intermediate section to deliver slurry around the filter 120. These pack tubes can also exit at passages 117 of the support ring 116. As is known, such pack tubes communicate with the transport tubes 130 and receive portion of the transported slurry. The pack tubes (140) have exits or nozzles along their length to distribute the slurry along the primary screens 120. Slurry may also exit the open end of the pack tube into the blank annular area 108.

[0080] Ends of the transport tubes 130 extend from the support rings 116, and jumper tubes 135 are disposed inside a blank annular area 108a-b between the coupled ends 111a-b of the basepipe 110 to interconnect the ends of the transport tubes 130 on the adjoining assemblies (not shown) together across the couplings 106. Connectors 132 having seals can connect the ends of the jumper tube 135 with the ends of the transport tubes 130.

[0081] A shroud 104 can be disposed along the basepipe 110 and can extend between the support rings 116 to cover the primary filter 120. The shroud 104 typically defines a plurality of coarse flow openings 105 therethrough. Such a shroud 104 may be preferred when the assembly 100 is used in an open hole.

[0082] At least one of the ends 111a-b of the basepipe 110 defines a plurality of end perforations 115 in communication with the blank annular area 108a-b. Additionally, at least one permeable gripping section 107a-b is disposed on the at least one end 111a-b at the end perforations 115. As shown here, both ends 111a-b include perforations 105 and permeable gripping section 107a-b, but other arrangements are possible.

[0083] The size, number, and distribution of the perforations 115 are configured to provide enough fluid flow from the blank annular area 108a-b for the purposes of leak off of carrier fluid, but are configured to retain the integrity of the basepipe 110a-b for handling and running in a completion string.

[0084] As noted in more detail below, the at least one permeable gripping section 107a-b is configured to filter communication from the blank annular area 108a-b into the end perforations 115. As also noted below, an external surface of the at least one permeable gripping section 107a-b is configured to be handled by mechanical grips of pipe handling components, such as completion slips, jaws of a tong device, slips of an elevator, and the like (FIG. 2B), used to connect the basepipe 110 of the assembly 100 to the basepipes of other assemblies on a rig. The permeable gripping section 107a-b can be reinforced to facilitate engagement with the mechanical grips (e.g., slips and jaws (FIG. 2B)).

[0085] FIG. 2B illustrates two wellscreen assemblies 100a-b according to the present disclosure being connected at a rig floor 40 using a tong device 50, completion slip 42, elevator (not shown), and other rig components for handling pipe. As will be appreciated, various types of tong device 50 can be used to make up the connection of the wellscreen assemblies 100a-b. As diagrammed here, the tong device 50 includes a power tong 52 and a backup tong 56 operatively connected by a carriage assembly 55. A hydraulic lift stand 51 may be connected to the power tong 52, with the carriage assembly 55 being supported by the power tong 52 and with the backup tong 56 being supported by the carriage assembly 55. The lift stand 51 can move the tong device 50 on the rig floor 40 relative to the assemblies 100a-b. For its part, the carriage assembly 55 can change the separation between the power tong 52 and the backup tong 56 so the vertical distance between them can be adjusted to the assemblies 100a-b to be connected.

[0086] The power tong 52 includes two or more sections movable relative to each other to open and close a central opening 53. A rotor (not shown) disposed in the power tong 52 is coupled to a motor assembly (not shown), and jaws 54 are attached to the rotor. During operation, the jaws 54 of the power tong 52 can move radially being driven hydraulically to secure against (grip) and release from an end 111b of a wellscreen's tubular, a coupling 106, or the like and to accommodate tubulars of various diameters. With the jaws 54 secured against the tubular's end 111b, the jaws 54 rotate with the rotor to rotate the wellscreen 100b about a longitudinal axis during make up and break out of a tubular connection.

[0087] As shown, the backup tong 56 is disposed underneath the power tong 52 in a manner so that a longitudinal axis extends through the central openings 53, 57 of the power tong 52 and backup tong 56. Similar to the power tong 52, the backup tong 56 can include two or more sections movable relative to each other to open and close the central opening 57. The backup tong 56 also further include jaws 58 that can be driven hydraulically to secure against (grip) and release from an end 111a of a wellscreen's tubular, a coupling 106, or the like and to accommodate tubulars of various diameters.

[0088] To run the wellscreens 100a-b in the borehole, a first (lower) one of the wellscreens 100a can be supported in completion slips 42 of the rig floor 40. In particular, the completion slips 42 can be used to grip directly on a reinforced external surface of a permeable gripping section 107a disposed about end perforations (115) on the wellscreen's end 111a. Gripping of other portions of the wellscreen 100a, such as the shroud, filter 120a, and the like are not possible to support the weight of the wellscreen 100a and any connected completion string.

[0089] The first wellscreen 100a can have the coupling 106 already made up on the end 111a. A second (upper) one of the wellscreens 100b is then made up to the first wellscreen 100a by threading its end 111a to the coupling 106. Handling of this upper wellscreen 100b involves gripping an upper end (not shown) of this wellscreen 100b using an elevator (not shown).

[0090] Different types of elevator can be used for handling the wellscreens 100a-b, including collar-type and slip-type elevators. The slip-type elevator can grip directly on a reinforced external surface of an upper permeable gripping section 107a disposed on the upper end 111a of the wellscreens 100a-b. The collar-type elevator may use features of the coupling 106 to support handling the wellscreens 100a-b.

[0091] As an alternative, a collar system can be used in the handling of the wellscreens 100a-b. An example of such a collar system is disclosed in U.S. Pat. No. 10,337,263, which is incorporated herein by reference. The collar system includes an application-specific collar (not shown), a sliding collar table 42 at the rig floor 40, and a hydraulically operated automated side-door (ASD) elevator (not shown). The collar fits on the upper end 111a of the wellscreen 100a-b and acts as the interface between basepipe 110 and handling equipment. The sliding collar table 42 has a larger pass-through diameter to enable the pass-through of completion assemblies. The elevator engages the collar to handle the wellscreen 100a-b, and the collar is landed onto the sliding collar table 42. The elevator is opened, and the next connection is picked up and made up to the string. Once the connection is done, the sliding table 42 is opened, and the completion string is lowered into the well.

[0092] Either way, the tong device 50 can be used to tighten the connection between the wellscreens 100a-b. In particular, once the connection is initially made, the ends 111b of the wellscreen 100b and the coupling 106 are then gripped using mechanical jaws 56, 58 of the tong device 50. As noted previously, the tong device 50 includes power and backup tongs 52, 56 that can have their separation adjusted and that can be moved horizontally on the rig floor 40 to fit the wellscreen assemblies 100a-b and coupling 106 through their central openings 53, 57. The tongs' mechanical jaws 54, 58 can then be hydraulically driven to secure against (grip) and tighten the assemblies 100a-b and coupling 106 together. As will be appreciated, alternative steps and an alternative order of steps can be performed to make up the connection between the ends 111a-b and coupling 106.

[0093] As noted, at least one of the mechanical jaws 56, 58 can grip on a reinforced external surface of a permeable handling or gripping section 107a-b disposed about end perforations (115) on at least one of the ends 111a-b. As noted, the permeable gripping section 107a-b is configured to filter communication to the end perforations (115). As shown here, both ends 111a-b may have a permeable gripping section 107a-b that can be gripped with the mechanical jaws 56, 58, elevators, completion slips 42, etc.

[0094] Using the tong device 50, the connection of the ends 111a-b of the wellscreens 100a-b by the coupling 106 is then tightened. For example, the end 111a of the lower wellscreen 100a can be held stationary with the completions slips 42 that engages the gripping section 107a. The backup tong 56 can grip the coupling 106 with its jaws 58, and the power tong 52 can grip the gripping section 107b with its jaws 54. By operating the tong device 50, the end 111b of the upper wellscreen 100b can be rotated with the mechanical jaws 54 that engage the section 107b to make up the connection to the coupling 106.

[0095] Once tightened to the proper torque, the mechanical jaws 54, 58 are released, and the tong device 50 is moved away. Further steps can then be performed. In particular, one or more jumper tubes (135) can be connected between opposing ends of one or more transport tubes (130) disposed along the wellscreens 100a-b that extend from the support rings 116. An intermediate shroud (not shown) can be placed in the blank area 108 between the support rings 116. For example, a cylindrical shroud (not shown) can slid down the upper wellscreen 100b and can be affixed to the support rings 116, such as by threading to the support rings 116 or affixing to the support rings 116 with set screws, cap screws, or the like (not shown). Alternatively, a split cover shroud can be positioned in the blank area 108, enclosed around the connection, and affixed to the support rings 116.

[0096] The completion slips 42 can be released, and the connected wellscreens 100a-b can then be passed through the rig floor 40 until the end of the second wellscreen 100b is at the rig floor 40. At this point, the assembly steps can be repeated to connect another wellscreen assembly (100) or a tubing stand to the completion string being run in the borehole.

[0097] Having an understanding of the wellscreen assembly 100 according to the present disclosure with its at least one permeable gripping section 107, discussion now turns to particular embodiments of the present disclosure.

[0098] FIG. 3A illustrates wellscreen assemblies 100a-b according to a first embodiment of the present disclosure in partial cross-section. FIG. 3B illustrates a detailed cross-section of a portion of the wellscreen assembly 100a in FIG. 3A. Meanwhile, FIG. 3C illustrates an end-section of the wellscreen assembly 100a in FIG. 3A.

[0099] In FIG. 3A, two wellscreen assemblies 100a-b are being coupled together using a coupling 106 connecting the ends 111a-b of the assemblies' basepipes 110a-b together as before. Like reference numerals are used in FIGS. 3A-3C for comparable components to the arrangement in FIG. 2A.

[0100] As before, each of the assemblies 100a-b includes a basepipe 110a-b having a primary filter 120a-b disposed about the intermediate perforations 114 in the basepipe 110a-b. As shown here, the primary filters 120a-b on the assemblies 100a-b include wire-wrapped screens. For example, the primary filter 120a in FIG. 3B includes a wire 122 wrapped about (and welded to) ribs 124 that run longitudinally along the outside of the basepipe 110a. End rings 126 affixed to the basepipe 110a hold the ends of wire-wrapped screen 120a on the basepipe 110a. In use, the primary filters 120a-b filter fluid communication from the borehole annulus outside the basepipe 110a-b into the intermediated perforations 114 of the basepipe 110 that communicate with the bore 112.

[0101] As before, each of the assemblies 100a-b includes support rings 116, 116′ disposed thereon for supporting shrouds 104. In FIG. 3A, two types of support rings 116, 116′ can be provided for the shrouds 104 that run along the primary filters 120a-b of the basepipes 110a-b. One (lower) support ring 116 at one end of the blank area 108 is shown in FIG. 3A, while the other (upper) support ring 116′ at the other end of the blank area 108. The support rings 116, 116′ can be affixed to the basepipes 110a-b with welding or the like, as part of the assembly process of the joint before connections are made at the rig. The support rings 116, 116′ can have openings (117) for passage of the ends of the transport tubes 130. One support ring 116 has ledges on opposing sides of a rim against which ends of shrouds 104 can abut. The other support ring 116′ has a unitary ledge without a rim, which can enable shrouds 104 to be passed over the ring 116′ during assembly.

[0102] As before, each of the assemblies 100a-b includes shunt tubes 130 that are supported along the primary screens 120a-b. As shown in FIG. 3C, for example, the support ring 116′ includes slots or openings 117 for passage of the one or more transport tubes 130. In general, the assembly 100 can have any number of transport tubes 130, and the tubes 130 may transport the slurry further along the assemblies 100a-b to other locations. As shown here, the assembly 100 can include two transport tubes 130 for transporting slurry for gravel packing. Connectors 132 are provided for connecting ends of the shunt tubes 130 to jumper tubes 135 that extend across the blank area 108 between the assemblies 100a-b.

[0103] Additionally, the assembly 100 can also include two pack tubes 140 for dispersing slurry during gravel pack operations. These pack tubes 140 can be used to deliver slurry out of nozzles (not shown) adjacent the primary filters (120a-b) of the wellscreens 100a-b. As shown in FIG. 3C, ends of pack tubes 140 can exit at passages 117 of the support ring 116′. As is known, such pack tubes 140 communicate with the transport tubes 130 to receive portion of the transported slurry, and the pack tubes 140 have exits or nozzles along their length to distribute the slurry along the primary filters 120a-b. Slurry may also exit the open ends of the pack tubes 140 into the blank annular area 108.

[0104] As noted previously, the wellscreen assemblies 100a-b have permeable gripping sections 107a-b where leak-off fluid can be filtered from the blank annular area 108 between the connected ends 111a-b of the basepipes 110a-b and where mechanical grips (e.g., slips, jaws, and the like (FIG. 2B)) can engage and handle the basepipes 110a-b during assembly at the rig. In the present embodiment, the permeable gripping sections 107a-b include reinforced foils 150 disposed about the surfaces of the basepipes 110a-b at the ends 111a-b near where the coupling 106 is made.

[0105] Both ends 111a-b of the connected basepipes 110a-b may have a reinforced foil 150 as shown. Alternatively, one reinforced foil 150 may be provided at one end 111a-b and not the other of the connected basepipes 110a-b. As best shown in FIG. 3A, the reinforced foils 150 are disposed between the support rings 116, 116′ and in the blank area 108 between the connected ends 111a-b, and the reinforced foils 150 cover portions of the blank ends 111a-b of the basepipes 110a-b where the coupling 106 connects the basepipes 110a-b together.

[0106] As disclosed herein, these reinforced foils 150 are configured to filter fluid communication from the borehole annulus (and annular blank area 108) through the end perforations 115 and into the bores 112 of the basepipes 110a-b. For example, the reinforced foils 150 at least partially include secondary filters 151. Other arrangements can be used.

[0107] The fluid communication through the foils 150 is first used for leak-off of carrier fluid in the slurry used to gravel pack about the wellscreen assemblies 100a-b so that the blank annular area 108 can be more evenly packed with gravel. The fluid communication through the reinforced foils 150 may then also provide additional production flow into the bore 120 once the assemblies 100a-b are packed in the borehole with annular gravel pack.

[0108] As also disclosed herein, these reinforced foils 150 are also configured for handling the wellscreen assemblies 100a-b during assembly steps. In particular, the reinforced foils 150 provide reinforced areas or surfaces on the ends 111a-b of the basepipes 110a-b for engagement by grips (e.g., slips, jaws, and the like (FIG. 2B)). As will be appreciated with the benefit of the present disclosure, the foils 150 are suited for the typical gripping and handling forces encountered when handling the wellscreens 100a-b and running in hole.

[0109] Accordingly, the reinforced foils 150 provide a leak-off path and provide a reinforced gripping surface for the assemblies 100a-b when used in gravel pack and frac pack operations. The foils 150 are already affixed to the basepipes 110a-b before handling, before the connections are made up between the adjoining wellscreen assemblies 100a-b, and before the jumper tubes 135 have been installed. In fact, the foils 150 are preassembled on the basepipes 110a-b along with the primary filters 120a-b, support rings 116, and the like.

[0110] In the present embodiment and as best shown in FIG. 3B, the foil 150 includes a secondary filter 151 disposed about the end perforations 115 on the pipe end 111a-b. The secondary filter 151 can include any type of filter media for use downhole, including metal mesh, pre-packed screens, protective shell screens, wire screen, or filters of other construction. As shown here, the secondary filter 151 can include a wire-wrapped screen having wire 154 disposed about (and welded to) ribs 152 extending longitudinally along the surface of the pipe end 111a-b. The secondary filter 151 is supported with end rings 155 affixed (welded) to the pipe end 111a-b. The external surface of the at least one foil 150 includes a sleeve 156 supported on (and welded to) the end rings 155 about the secondary filter 151. The sleeve 156 defines a plurality of flow openings 158 configured to communicate the blank annular area 108 with the secondary filter 151. The sleeve 156 and end rings 155 can help distribute handling loads to the basepipe 110a and away from the filter 151.

[0111] As shown in FIGS. 3A-3B, these flow openings 158 in the foils 150 can include perforations defined through the sleeve 156. To control leak-off and production, the screening provided by the secondary filters 151 of the foils 150 can be the same as or different from the screening provided by the primary filters 120a-b, which are used for production. In this regard, the secondary filters 151 of the foils 150 may be wire-wrapped screens or the like and may have gaps or slots to prevent passage of gravel. However, the size of the wire, the number of gaps, the number of slots, etc. may differ from that used on the primary filters 120a-b.

[0112] Alternatively, the amount of surface area for screening provided by the secondary filters 151 of the foils 150 may be configured to be less than provided by the primary filters 120a-b. In this way, using any of these various differences, the foils 150 can provide leak-off capabilities during gravel pack operations, but wellbore fluids would tend to flow more preferentially through the primary filters 120a-b during production operations due to the greater amount of open surface area of the primary filters 120a-b. Other configurations can be used and can be configured for a particular implementation.

[0113] As noted herein, the disclosed assemblies 100a-c are disposed in a borehole with gravel packed in the annulus. Gravel, proppant, or the like is packed in the annulus between the assemblies 100a-b and the borehole. As the slurry travels in the annulus, the return fluid leaks off through the primary filters 120a-b to pack the gravel about the primary filters 120a-b.

[0114] The foils 150 cover the blank connection in the annular area 108 between the basepipes 110a-b. In addition to providing a gripping surface for gripping and handling the basepipes 110a-b, the foils 150 provides a surface to hold or retain the gravel in the annular space between the foils 150 and the borehole. As will be appreciated with the benefit of the present disclosure, the foils 150 are suited for the typical gripping and handling forces encountered when handling the wellscreens 100a-b and running in hole.

[0115] As best shown in the detail of FIG. 3B, the foil 150 can abut the support ring 116 on the basepipe 110a-b, just as the primary filter 120a-b can abut the support ring 116. In particular, the end ring 122 of the primary filter 120a can be welded to the basepipe 110a, and the support ring 116 can be welded to the basepipe 110a against the end ring 122. The foil's end ring 155 can be welded to the basepipe 110a against the support ring 116.

[0116] The wellscreen assembly 100a-b provides more open area for the gravel to dehydrate. Additionally, the foils 150 provides an external tubular wall on the assembly 100a-b that can help the gravel packing to be more uniform at the coupling 106. The external tubular wall of the foils 150 may be concentric or eccentric to the primary filter 120 and to the surrounding borehole. Either way, the external tubular wall of the foil 150 provides a consistent annular space to fill with gravel with reduced variations that could cause premature bridging in the casing and/or open hole. In this way, the foils 150 provide a secondary sand control function for the standard screens of the primary filters 120a-b.

[0117] FIGS. 4A-4C illustrate a second embodiment of wellscreen assemblies 100a-b similar to those disclosed before in FIGS. 2A-2B and 3A-3C so that like reference numerals are used for comparable elements. In contrast to the previous embodiments, the foils 150 for the permeable gripping sections 107a-b do not abut the support rings 116. Instead, the end ring 155 of the foil's secondary filter 151 is spaced in relation relative to the support ring 116.

[0118] FIGS. 5A-5C illustrate a third embodiment of wellscreen assemblies 100a-b similar to those disclosed in FIGS. 2A-2B, 3A-3C, and 4A-4C so that like reference numerals are used for comparable elements. In contrast to previous embodiments, however, the sleeves 156 of the foils 150 for the permeable gripping sections 107a-b include one or more flow openings 159 in the form of elongated slots defined along the sleeve 156. As an example, four such elongated slots 159 can be defined at every 90-degrees about the sleeve 156. More or less of these slots 159 can be used. Compared to the size of gravel and other particulates, these slots 159 can have increased width because filtering is provided by the secondary filter 151 of the foil. Either way, the external surface of the sleeves 156 can provide more gripping area for mechanical grips, slips, jaws and the like for handling the wellscreen assemblies 100a-b.

[0119] As discussed above, the foils 150 of FIGS. 3A through 5C have the form of a filter or screen disposed in the blank annular area 108 between the primary screens 120a-b of the assemblies 100a-b. In these arrangements, the foils 150, which can include a short extent of wire-wrapped screen 151, provide a flow path for the carrier fluid and production fluid to pass through the foils 150 into the bores 112 of the assemblies 100a-b. In this way, the foils 150 provide a leak-off path between the assemblies 100a-b to screen fluid when used in gravel pack and frac pack operations. Moreover, the foils 150 provide a reinforced tubular sleeve affixed before the basepipes 110a-b are made up between the adjoining wellscreen assemblies 100a-b for mechanical grips to engage.

[0120] FIG. 6A illustrates a fourth embodiment of wellscreen assemblies 100a-b according to the present disclosure in partial cross-section. FIG. 6B illustrates a detailed cross-section of a portion of the wellscreen assembly 100a in FIG. 6A. FIG. 6C illustrates an end-section of the wellscreen assembly 100a in FIG. 6A.

[0121] These wellscreen assemblies 100a-b are similar to those disclosed previously so that like reference numerals are used for comparable elements. Again, reinforced foils 160 are used for the permeable gripping sections 107a-b where leak off fluid can be filtered from the blank annular area 108 between the connected ends 111a-b of the basepipes 110a-b and where mechanical grips, slips, jaws, etc. (FIG. 2B) can engage and handle the basepipes 110a-b during assembly at the rig. As will be appreciated with the benefit of the present disclosure, the foils 160 are suited for the typical gripping and handling forces encountered when handling the wellscreens 100a-b and running in hole.

[0122] In the present embodiment, the reinforced foils 160 include sleeves 170 disposed on the end 111a-b of the basepipe 110a-b about the end perforations 115. As shown in FIG. 6B, ends of the sleeve 170 are attached to the basepipe end 111a using welds, which can close off the gap between the sleeve 170 and the basepipe end 111a. The sleeve 170 defines a set of thin slits 172 formed about the circumference of the sleeve 170 and arranged along the length of the sleeve 170. As shown in FIG. 6C, the sleeve 170 is shown having three slits 172 about the circumference, which encompass less than about 120-degrees each. Other arrangements are possible. The size and width of the slits 172 can be controlled to facilitate dehydration of the slurry during gravel pack. For example, depending on the proppant used in the slurry, the slits 172 can be machined to a slit width of 0.09-in. The angular extent and number of the slits 172 can also be configured to maintain structural integrity of the sleeve 170 for gripping and handling purposes.

[0123] The inner circumference of the sleeve 170 can include a plurality of scalloped channels 176 or the like defined longitudinally therealong. These channels 176 can allow fluid to pass between the sleeve 170 and basepipe end 111a so the fluid entering through the slits 174 can communicate with the end perforations 115. The channels 176 may not extend to the ends of the sleeves 170. For manufacturing purposes, however, the channels 176 may be formed to extend to the ends of the sleeves 170. Either way, the welds at the end of the sleeve 172 will close off the channels 176 and any annular gap between the sleeve 170 and end 111a so that proppant cannot pass.

[0124] FIG. 7A illustrates a fifth embodiment of wellscreen assemblies 100a-b according to the present disclosure in partial cross-section. FIG. 7B illustrates a detailed cross-section of a portion of the wellscreen assembly in FIG. 7A. FIG. 7C illustrates an end-section of the wellscreen assembly in FIG. 7A.

[0125] These wellscreen assemblies 100a-b are similar to those disclosed previously so that like reference numerals are used for comparable elements. Again, reinforced foils 170 are used for the permeable gripping sections 107a-b where leak off fluid can be filtered from the blank annular area 108 between the connected ends 111a-b of the basepipes 110a-b and where mechanical grips, slips, jaws, etc. (FIG. 2B) can engage and handle the pipes 110a-b during assembly at the rig.

[0126] In the present embodiment, the foils 160 include a sleeve 170 disposed on the end 111a-b of the basepipe 110a-b about the end perforations 115. The sleeve 170 defines a plurality of flow openings 172 communicating therethrough. As shown in this example, the flow openings 170 can be elongated, thin slits defined longitudinally along the sleeve 170 and arranged about the circumference of the sleeve 170. Other shapes or arrangement of the flow slits 172 could be used. The size and width of the slits 172 can be controlled to facilitate dehydration of the slurry during gravel pack. For example, depending on the proppant used in the slurry, the slits 172 can be machined to a slit width of 0.09-in. The length and number of the slits 172 can also be configured to maintain structural integrity of the sleeve 170 for gripping and handling purposes.

[0127] The inner circumference of the sleeve 170 can include a plurality of scalloped channels 176 or the like defined longitudinally therealong. These channels 176 can allow fluid to pass between the sleeve 170 and basepipe end 111a so the fluid can communicate with the end perforations 115. The channels 176 may not extend to the ends of the sleeves 170. For manufacturing purposes, the channels 176 may be formed to extend to the ends of the sleeves 170. Either way, the welds at the end of the sleeve 172 will close of the channels 176 and any annular gap between the sleeve 170 and end 111a so that proppant cannot pass

[0128] From FIGS. 6A-6C and 7A-7C, it can be seen that the elongated slits 172 can be defined circumferentially about the sleeve 170 or longitudinally along the sleeve 170. Any variation and combination thereof can be used. For example, the slits 172 can be arranged in a helical or spiral about the sleeve 170.

[0129] FIG. 8A illustrates a sixth embodiment of wellscreen assemblies 100a-b according to the present disclosure in partial cross-section. FIG. 8B illustrates a detailed cross-section of a portion of the wellscreen assembly in FIG. 8A. FIG. 8C illustrates an end-section of the wellscreen assembly in FIG. 8A.

[0130] These wellscreen assemblies 100a-b are similar to those disclosed previously so that like reference numerals are used for comparable elements. Again, foils 180 are used for the permeable gripping sections 107a-b where leak off fluid can be filtered from the blank annular area 108 between the connected ends 111a-b of the basepipes 110a-b and where mechanical grips, slips, jaws, etc. (FIG. 2B) can engage and handle the pipes 110a-b during assembly at the rig. As will be appreciated with the benefit of the present disclosure, the foils 180 are suited for the typical gripping and handling forces encountered when handling the wellscreens 100a-b and running in hole.

[0131] In the present embodiment, the foils 180 include a sleeve 182 disposed on the end 111a-b of the basepipe 110. For example, the sleeve 182 can have edges welded to the basepipe 110. The sleeve 182 has openings 184 exposed to the end perforations 115. A plurality of plugs 186 are disposed in the end perforations 115 and are exposed to the blank annular area 108 through the openings 184 in the sleeve 182.

[0132] Each of the plugs 186 can include a support 188a and an insert 188b. The support 188a is affixed to a surface of the basepipe 110 around the end perforation 115, is affixed in the end perforation 115, is affixed in the exposed openings 184 in the sleeve 180, or is affixed in a combination of these. For example, the support 188a can have a threaded or interference fit with the perforation 115, or the support 188a can be bonded, welded, etc. to the basepipe 110, perforation 115, or the like. The insert 188b is supported in the end perforation 115 by the support 188a. The insert 188b can include a filter material, mesh, sintered metal, or the like. Either way, the insert 188b can provide a secondary filter that allows for leakoff of carrier fluid from the gravel pack slurry so the proppant can dehydrate in the annular blank area 108 during gravel pack operations.

[0133] During operations to make up the toolstring and run the wellscreen assemblies 100 of FIGS. 3A through 8C downhole, operators connect the upper basepipe 110a to the lower basepipe 110b with the coupling 106. The wellscreen assemblies 100a-b already have the primary filters 120a-b, support rings 116, 116′, shrouds 104, transport tubes 130, pack tubes 140, and foils (150, 160, 170, and 180) arranged thereon. Operators tighten the connection of the coupling 106 between the ends 111a-b of the basepipes 110a-b using the reinforced surfaces of the foils (150, 160, 170, and 180) on the basepipes 110a-b for handling and gripping with the grips, slips, and jaws of the devices on the rig.

[0134] Once the connection is made, operators then position the jumper tubes (135) and connectors (132) in the blank area 108 to interconnect the shunt tubes 130 between the assemblies 100a-b. At this point, any further split cover or shroud can be installed, and the wellscreen assemblies 100a-b can be run through the rig floor to set up for the next connection.

[0135] FIG. 9A illustrates a seventh embodiment of wellscreen assemblies 100a-b according to the present disclosure in partial cross-section. FIG. 9B illustrates a detailed cross-section of a portion of the wellscreen assembly 100a in FIG. 9A. FIG. 9C illustrates an end-section of the wellscreen assembly 100a in FIG. 9A.

[0136] These wellscreen assemblies 100a-b are similar to those disclosed previously so that like reference numerals are used for comparable elements. Again, a foil 190 is used for the permeable gripping sections 107a-b where leak off fluid can be filtered from the blank annular area 108 between the connected ends 111a-b of the basepipes 110a-b and where mechanical grips, slips, jaws, etc. (FIG. 2B) can engage and handle the pipes 110a-b during assembly at the rig.

[0137] In the present embodiment, the foil 190 include a secondary filter 191 disposed inside the bores 112 of the connected basepipes 110a-b. The secondary filter 191 can include a wire-wrapped screen having wire 192 wrapped about ribs 194, which are affixed to opposing end sleeves 196. Other types of filter media can be used for the foil 190, such as mesh, etc.

[0138] The end sleeves 196 are disposed in the bores 112. Each of the end sleeves 196 is disposed between an end of the secondary filter 191 and a shoulder 113 in the bore 112. The end sleeve 196 can have a seal 198 (e.g., O-ring) for sealing inside the bore 112.

[0139] As shown in FIG. 9A, the outer surfaces of the end 111a-b of the basepipe 110a-b may provide the external surface of the permeable gripping section 107a-b used for handling and connecting the basepipes 110a-b during assembly. Should additional reinforcement be desired, an external component, such as a sleeve 156, 172, 182 of previous embodiments, can be affixed to the outside of the basepipe 110a-b for direct engagement by the mechanical grips, slips, jaws, etc.

[0140] To run the wellscreens 100a-b of FIGS. 9A-9C into a borehole, a first wellscreen 100a is supported at a rig floor. The secondary filter 191 is inserted in the bore 112 for the end 111 of one of the basepipes 110—preferably the first basepipe 110a of the wellscreen assembly 100a supported at the rig floor. The second wellscreen assembly 100b is made up to the first wellscreen assembly 100a. For example, the second wellscreen assembly 100b is stabbed over the exposed end of the secondary filter 191 extending beyond the coupling 106 already threaded onto the end 111a of the wellscreen assembly 100a. Then, the end 111b of the assembly 100b can be threaded to the coupling 106.

[0141] Mechanical grips, slips, jaws, etc. (FIG. 2B) grip external surfaces of the permeable sections 107a-b on the ends 111a-b of the basepipes 110a-b (or grip any reinforcement component or sleeve), and the connection of the ends 111a-b is completed using the gripping. Once the connection is complete, the mechanical gripping is released from the connected ends of the wellscreens 100a-b so they can be run through the rig floor. The secondary filter 190 disposed in the bores 112 between the coupled ends 111a-b is thereby configured to filter communication from the end perforations 115 on ends of the basepipes 110a-b during gravel pack and production operations.

[0142] As shown in FIGS. 9A-9C, one secondary filter 190 can be used to extend between the coupled ends 111a-b of the connected assemblies 100a-b. Other arrangements are possible in which more than one filter 190 is used, such as one in each end of each assembly 100a-b. Alternatively, only one of the ends 111a of the basepipes 110a-b may have the end perforations 115 and only one secondary filter 190 may be disposed and held in the bore 112 of the one end 111a-b.

[0143] For example, FIG. 10A illustrates a secondary filter 190 disposed and held in only one end 111a of a basepipe 110a that has the end perforations 115. The filter 190 fits in the bore 112 (or a counterbore) in the end 111a, and one end sleeve 196 can engage against an internal shoulder 113. Another end sleeve 196 can be arranged at the coupling 106. Such a filter 190 can be preinstalled on the wellscreen 100a prior to handling so that the filter 190 would not need to be inserted into the basepipe 110a at the rig during make up connections.

[0144] In the other example, FIG. 10B illustrates secondary filters 190 disposed and held in both ends 111a-b of the basepipes 110a-b, which have the end perforations 115. The filters 190 fit in the bores 112 (or counterbores) in the ends 111a-b. For each, one end sleeve 196 can engage against a shoulder 113. Another end sleeve 196 can be arranged at the coupling 106. Such filters 190 can be preinstalled on the wellscreens 100a-b prior to handling so that the filters 190 would not need to be inserted into the basepipes 110a-b at the rig during make up connections. The lower filter 190 can be preinstalled and initially held by the coupling 106 already made up to the end 111a. The upper filter 190 can be installed at the time of make-up and can be held in the end 111b at least with some temporary affixing while the end 111a is made up to the coupling 106.

[0145] As will be appreciated, any of the internal secondary filters 190 disclosed above may need to float or have some clearance inside the bores (counterbores) between shoulders to avoid buckling when the connections are made up between the basepipes 110a-b. Although it may not be necessary, the reinforced sections 107a-b of the basepipes 110a-b as disclosed herein can be treated with surface hardening or other surface treatment to facilitate the handling disclosed herein.

[0146] As disclosed herein, improved open area of the wellscreens provides better dehydration of the gravel pack slurry allowing for a more complete pack of the annulus between the wellbore to the wellscreens. The permeable gripping sections of the present disclosure overcome the problem found in most wellscreens for long horizontal open hole wells, which tend to have significant pipe handling blank section often exceeding 10% of each basepipe or of the entire deployed length. The increasing permeable length of the wellscreens provided by permeable gripping sections of the present disclosure can create a longer effective screen length and can improve productivity of the well or if rate stays the same reduce the risk of erosion.

[0147] To do this, the blank non-permeable areas on the wellscreens are converted to permeable areas, in effect maximize the open area or permeable area of the screen joints. At the same time, the permeable gripping sections retain the functionalities of pipe handling while providing additional sand control.

[0148] The permeable gripping sections of the wellscreens are made more robust to endure the gripping force and torque of slips, tongs, and the like without damaging the secondary filters or screens. The permeable gripping sections can include a permeable metal sleeve disposed over a screen secured to the basepipe through welded rings, such as end rings. In another method, the handling areas of the basepipe can be perforated with or without a counter sink. Sand retention buttons can then installed or secured in the perforations to provide sand control while enduring the forces and torques applied during make up or break out of the connection. In yet another method, the handling areas of the basepipes can be perforated and can be machine inside their diameter to retain secondary filters or screens inside the basepipes that provide sand retention capabilities.

[0149] Reference to gravel packing herein may equally refer to frack packing. Use of the terms such as screen and filter may be used interchangeably herein. The foregoing description of preferred and other embodiments is not intended to limit or restrict the scope or applicability of the inventive concepts conceived of by the Applicants. For example, although the assemblies 100 disclosed herein have shown use of shunt tubes, it will be appreciated that assemblies can lack shunt tubes and jumper tubes. It will also be appreciated with the benefit of the present disclosure that features described above in accordance with any embodiment or aspect of the disclosed subject matter can be utilized, either alone or in combination, with any other described feature, in any other embodiment or aspect of the disclosed subject matter.

[0150] In exchange for disclosing the inventive concepts contained herein, the Applicants desire all patent rights afforded by the appended claims. Therefore, it is intended that the appended claims include all modifications and alterations to the full extent that they come within the scope of the following claims or the equivalents thereof.