Completion System

Abstract

An expandable completion system and method of completing a well in which gravel packing of multiple completion zones is achieved by morphing a sleeve across a gravel packed annulus to secure it to a well bore wall by the use of fluid pressure to provide a zonal isolation barrier between two gravel packed zones in a wellbore. An embodiment provides gravel packing for multiple completion zones by circulation. A further embodiment allows selective isolation barriers to be created along the length of the completion string after the gravel has been pumped into the annulus.

1 . A method of completing a well, comprising:
 locating a sleeve member on the exterior of a tubular body and sealing it thereto to create a chamber therebetween,   using the tubular body to connect two sand screens together in an assembly;   running the assembly on a string into a wellbore and positioning the sleeve member at a position between zones within a larger diameter structure;   pumping fluid through a port in the tubular body to access the chamber;   causing the sleeve member to move radially outwardly to morph against an inner surface of the larger diameter structure; and   providing a gravel mixture through at least one portion of the assembly to locate between the tubular body and the larger diameter structure.   
     
     
         2 . A method according to  claim 1  wherein the method includes locating multiple assemblies on the string and undertaking the morphing of the sleeve and the provision of a gravel mixture at any desired locations where an isolation barrier is required. 
     
     
         3 . A method according to  claim 1  wherein the method includes the step of inserting an inner completion string into the string and isolating the sand screens by sealing between the inner completion string and the tubular body. 
     
     
         4 . A method according to  claim 1  wherein the step of providing a gravel mixture includes pumping gravel slurry through the string to exit at an end of the tubular body and circulate up an annulus between the assembly and the larger diameter structure. 
     
     
         5 . A method according to  claim 1  wherein the step of pumping of fluid through a port in the tubular body to access the chamber and cause the sleeve member to move radially outwardly occurs after the gravel slurry is pumped through the string into the annulus. 
     
     
         6 . A method according to  claim 5  wherein the sleeve moves radially outwardly to crush the gravel and morph against the inner surface of the large diameter structure. 
     
     
         7 . A method according to  claim 1  wherein the method comprises causing the sleeve member to move radially outwardly to morph against an inner surface of the larger diameter structure before providing a gravel mixture by pumping gravel slurry through at least one shunt tubular component of the assembly to an exit located between the morphed sleeve member and an end of the tubular body such that the gravel slurry circulates around an annulus between the assembly and the larger diameter structure. 
     
     
         8 . A method according to  claim 7  wherein the at least one shunt tubular component is provided with a valve. 
     
     
         9 . A method according to  claim 1  wherein the step of providing a gravel mixture includes pumping gravel slurry through the string to exit at an end of the tubular body and circulate up an annulus between the assembly and the larger diameter structure and pumping gravel slurry through at least one shunt tubular component of the assembly to an exit located between the sleeve member and an end of the tubular body such that the gravel slurry circulates around an annulus between the assembly and the larger diameter structure. 
     
     
         10 . A method according to  claim 9  wherein the step of pumping of fluid through a port in the tubular body to access the chamber and cause the sleeve member to move radially outwardly occurs after the gravel slurry is pumped into the annulus. 
     
     
         11 . A method according to  claim 10  wherein the sleeve moves radially outwardly to crush the gravel and morph against the inner surface of the large diameter structure. 
     
     
         12 . An expandable completion system, comprising:
 an assembly comprising two sand screens connected via a tubular body, the assembly including connections for location in a tubular string to be run in and secured within a larger diameter generally cylindrical structure;   wherein a sleeve member is positioned on the exterior of the tubular body, to create a chamber therebetween;   the tubular body including a port to permit the flow of fluid into the chamber to cause the sleeve member to move outwardly and morph against an inner surface of the larger diameter structure wherein the assembly is operable to provide a gravel slurry into an annulus between the assembly and the larger diameter structure.   
     
     
         13 . An expandable completion system according to  claim 12  wherein the sleeve member has a first end which is affixed and sealed to the tubular body and a second end which includes a sliding seal to permit longitudinal movement of the second end over the tubular body. 
     
     
         14 . An expandable completion system according to  claim 12  wherein the sand screens are slotted liners. 
     
     
         15 . An expandable completion system according to  claim 12  wherein the system includes a plurality of assemblies. 
     
     
         16 . An expandable completion system according to  claim 15  wherein the assemblies are separated by a tubular body, wherein a sleeve member is positioned on the exterior of the tubular body, to create a chamber therebetween; the tubular body including a port to permit the flow of fluid into the chamber to cause the sleeve member to move outwardly and morph against an inner surface of the larger diameter structure. 
     
     
         17 . An expandable completion system according to  claim 12  wherein the assembly(ies) comprises a string exit at an end. 
     
     
         18 . An expandable completion system according to  claim 12  wherein the assembly(ies) comprises at least one shunt tubular having at least one shunt exit located between the sleeve member and an end of the tubular body. 
     
     
         19 . An expandable completion system according to  claim 18  wherein the at least one shunt tubular is provided with a valve. 
     
     
         20 . An expandable completion system according to  claim 18  wherein the assembly comprise string exit at an end and at least one shunt tubular having at least one shunt exit located between the sleeve member and an end of the tubular body.