A new technology recently introduced to the oilfieldexpandable-sand-screens -has focused on providing solutions for the inherent weaknesses in traditional sandcontrol completion techniques that can affect borehole stabilization, production rate, and completion costs. Gravelpack operations can also increase logistical requirements, and in many wellbore scenarios, can be difficult to perform. Finally, stand-alone screen completions are subject to borehole collapse. This problem can lead to sand production and screen-erosion during production. This paper will review a new expandable sand screen system that has the capability to provide a solution for some of the inherent problems discussed above. The discussion will focus on 1) the development of the technology required to expand perforated pipe plastically, 2) the tools and techniques employed, 3) the development of the screen, 4) the testing results, and 5) the first field trial of system.The innovative sand screen system provides the capability for the screen to be expanded against the borehole ID. The annulus around the screen is then virtually eliminated, which in turn, eliminates the need for gravel packing. Also, this increases the sand screen surface area, thus reducing pressure drop across the filter and increasing production rates. Because of its high strength, the expanded screen can provide superior support to stabilize the borehole, which then minimizes the potential for sand production. Finally, the new screen provides a larger production ID than is normally possible with traditional screens.

Many traditional sand-control completion techniques have inherent weaknesses that can significantly affect borehole stabilization and completion costs. Also, gravel-pack operations can increase logistical requirements in horizontal and extended reach wellbores. Finally, stand-alone screen completions are subject to borehole collapse and screen-erosion during production. A new technology recently introduced to the oilfield - expandable-sand-screens - has focused on providing solutions for these problems. This paper will review a new expandable sand screen and associated expansion tool that shows promise of solving some of the inherent problems discussed above. The innovative sand screen system allows the screen to be expanded toward the borehole ID. This principally increases the sand screen surface area, thus reducing pressure drop across the filter and increasing production rates. Secondly, expansion helps to stabilize the borehole to minimize the potential for sand production. The new screen eliminates the need for gravel packing operations in many wells and provides a larger production ID than is normally possible with traditional screens. The discussion will reviewthe development of the technology required to expand perforated pipe plastically,the tools and techniques employed,the development of the screen, andthe testing results. The discussion will also include a review of the first field trial of the expandable sand screen system. Introduction To prevent sand production in horizontal wells, screens are typically inserted into the openhole-producing zone.1,2,3,4 After the well has been on production for a period of time, the formation can become somewhat unstable resulting in excess sand production and hole-sloughing. Hole-sloughing can lead to plugging and subsequent erosion of the screens. In some cases, significant external loads can be applied to the screen as a result of wellbore collapse. These external loads can collapse the screen if it does not have sufficient structural integrity. To provide the best level of sand control and wellbore support, the annular space between the screens and wellbore can be gravel packed. However, to create a reliable horizontal gravel pack completion with a high probability of success is difficult in some well conditions.5,6,7,8,9,10 Also, the installation of a sand-control screen reduces the production ID that is otherwise available, and designing for gravel pack placement around the screen may reduce the ID still further. The solution chosen to address this problem was an expandable filtration system with enhanced collapse-strength integrity. The completed product should be an expandable sand screen that can be expanded inside a 6–1/8-in. open hole and provide sand control during production. The system will include a screen, running tool, screen hanger, and screen-expansion tool. (Fig 1) The successful development of this system would result in the following measurable results:Reduced failure rate due to elimination of hot spots (erosion) over timeIncreased hole size for re-entry and work-over capabilitiesIncreased production ratesPossible reduction in bore size for drilling-cost reductionImproved reliability due to greater installation successInstalled cost comparable to horizontal gravel packed wells. Because of the complexity of the solution and the commitment required, the decision was made to use the "Product Development and Commercialization" (PD&C) method for this project. The PD&C method involves the creation of a development team made up of Technology personnel that are entirely dedicated to the development of the product. In addition, representatives are included from manufacturing, procurement, sales, and operations on the team.

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In a groundwater reservoir, pollutants generated by various industrial processes can be present, and in many cases, can be radioactive or hazardous for other reasons. Operational trends in the oilfield have continuously stressed operational efficiency, and with it, safety of personnel and the environment. Now, however, a pronounced increase in regulatory requirements has been noted, which attests to the fact that there is increased governmental awareness throughout the world of the existence of these potential dangers. Subsequently, the need to monitor groundwater sources to ensure that contamination resulting from pollutants does not exceed levels of safety has reached new levels of importance in industrial operations. A system that can respond to this need has recently been developed from proven oilfield technology. This system has the capability to monitor groundwater sources by sampling groundwater from potentially contaminated aquifers without damaging the wellbore or the well formation and efficiently segregating the sample into a safe, clean, and controlled environment. The system incorporates a subsurface-actuated isolation device, which is permanently installed as part of a borehole/well completion. Suspect groundwater sources can be sampled by running a multi-function electro-mechanical tool on electric line into this isolation device. Once the locking profile in the isolation device has been located, a sequence of events is initiated from the surface that ultimately results in a sample being captured within the isolation device. Since many contaminants are hazardous, the sampling system operates in a manner such that the well bore is protected from exposure to any of the sampled fluids, and at the same time, the formation is protected from exposure to wellbore fluids. After the sample(s) is captured, it is brought to the surface and transported in an intrinsically-safe, pressurized container to a laboratory for analysis.