MATERIAL AND METHOD OF JOINING SAND CONTROL SCREEN ASSEMBLY

Description

TECHNICAL FIELD

The disclosure generally relates to wellbores formed in subsurface formations, and in particular, to downhole tools and tubulars formed from polymer composite materials.

BACKGROUND

Conventional sand control screen assembly components such as base pipes, wire mesh, end rings, etc. may be comprised of a metal or metallic material and prone to significant corrosion in the presence of fluids. Such corrosive fluids, such as hydrogen sulfide (H₂S), may become even more aggravated at elevated temperatures. In high-temperature environments, such as a wellbore drilled into the subsurface, H₂S corrosion may become problematic. In addition to corrosion problems, there may be a requirement to lighten the components of sand control screen assemblies to meet the demands of longer and more complex well designs (e.g., extended-reach multi-lateral (MLT) wells, extended-reach multi-lateral subsea wells, etc.) having more than one branch to maximize reservoir contact. Steel components, for example, may be heavier than polymer composite pipes and may induce large frictional forces upon contact with the wellbore. The heavier steel pipes may limit the distance to which pipe and/or tool strings may slide into a lateral wellbore.

BRIEF DESCRIPTION OF THE DRAWINGS

Implementations of the disclosure may be better understood by referencing the accompanying drawings.

FIG. 1 is a first longitudinal section depicting a fusion bonded assembly including pure composite base pipes and a metallic end ring, according to some implementations.

FIG. 2 is an illustration depicting a fusion bonded assembly including pure composite base pipes and a metallic end ring, according to some implementations.

FIG. 3 is an illustration depicting an example fusion bonding process of composite base pipes, according to some implementations.

FIG. 4 is a second longitudinal section depicting a fusion bonded assembly including a pure composite base pipe and a metallic end ring, according to some implementations.

FIG. 5 is a longitudinal section depicting a fusion bonded assembly including polymer composite base pipes and a composite end ring, according to some implementations.

FIG. 6 is an illustration depicting an example fusion bonding process for a fusion bonded assembly having a composite end ring, according to some implementations.

FIG. 7 is an illustration depicting an example fusion bonding process of composite base pipes and a composite end ring, according to some implementations.

FIG. 8 is an illustration depicting an example fusion bonding process for a fusion bonded assembly having a composite end ring, according to some implementations.

FIG. 9 is a plot depicting differential scanning calorimetry (DSC) scans of example polymer composites, according to some implementations.

FIG. 10 is an illustration depicting an example filament winding technique with in-situ consolidation, according to some implementations.

FIG. 11 is a diagram depicting an example composite bladder molding process, according to some implementations.

FIG. 12 is an illustration depicting a technique for joining composite adherends using a layer of bonding agent resin, according to some implementations.

FIG. 13 is an illustration depicting a technique for joining composite adherends using powdered bonding agent resin, according to some implementations.

FIG. 14 is an illustration depicting a technique for joining thermoset composite adherends using a bonding agent coupling layer in film form, according to some implementations.

FIG. 15 is an illustration depicting a technique for joining thermoset composite adherends using a bonding agent coupling layer in powder form, according to some implementations.

FIG. 16 is a flowchart depicting an example coating process, according to some implementations.

FIG. 17 is a cross-sectional diagram depicting an example well system including one or more sand screens, according to some implementations.

FIG. 18 is a flowchart depicting an example method of operations, according to some implementations.

FIGS. 1-18 and the operations described herein are examples meant to aid in understanding example implementations and should not be used to limit the potential implementations or limit the scope of the claims. None of the implementations described herein may be performed exclusively in the human mind nor exclusively using pencil and paper. Some implementations may perform additional operations, fewer operations, operations in parallel or in a different order, and some operations differently.

The description that follows includes example systems, methods, techniques, and program flows that embody implementations of the disclosure. However, it is understood that this disclosure may be practiced without these specific details. In other instances, well-known instruction instances, protocols, structures, and techniques have not been shown in detail in order not to obfuscate the description.

DESCRIPTION

To overcome the corrosion and weight concerns of traditional sand screen assemblies, polymer composite materials may instead be used as a material solution in manufacturing one or more sand screen assembly components. Sand screen assemblies utilizing polymer composite materials may be used in applications such as producing wells, multi-lateral (MLT) wells, well completions (e.g., such as a lower completion), other applications in subsurface wellbores, etc. Polymer composites may provide excellent corrosion resistance compared to conventional metals without compromising on mechanical performance. Additionally, techniques to join these composite parts may offer a cost effective, lead time, and performance effective solution compared to conventional metallic components used in downhole tools.

The sand control screen components may be constructed from a high-performance polymer and their composites. Such polymers may be high temperature and chemical resistant with glass transition temperatures >100° C. Reinforcement materials used may include any carbon, glass, aramid, metal, thermoplastic fibers, etc.

Polymer composite may be used as a material for base pipes, end rings, shrouds, wire mesh and screens, etc. of the described sand control screen assemblies. Other materials may also be possible. Accordingly, a combination of metallic and non-metallic/composite sand control screen components may be joined via fusion bonding. The fusion bonding may include the melting and subsequent resolidification of a thermoplastic, metal, metal alloy, or other binding material and/or the curing of a vitrimer such as aromatic copolyester thermoset (ACT), without melting other composite components such as composite base pipes, a metallic or a composite end ring, and one or more screens. Vitrimers other than ACT may also be used. ACT may include a higher degree of cross-linking than other materials and may be reprocessed similar to a thermoplastic material. In some implementations, ACT may be an uncatalyzed, condensation-cure polymer system which may contain both amorphous and liquid crystal segments.

Example Assembly of Composite Base Pipes and Metallic End Ring

FIG. 1 is a first longitudinal section depicting a fusion bonded assembly 100 including pure composite base pipes and a metallic end ring, according to some implementations. A pair of fusion bonded composite base pipes 110 may be bonded with a screen 108 via a metallic end ring 102. The metallic end ring 102 may limit the travel of the screen 108. For example, the metallic end ring 102 may prevent the screen 108 from moving side to side, prevent a rotation of the screen 108, prevent sand ingress into an interior of the fusion bonded composite base pipes 110, etc. The metallic end ring 102 may also protect the composite base pipes 110 from taking damage when tripping the pipes into or out of a wellbore, as the end rings may extend beyond the diameter of the composite base pipes 110.

The fusion bonded composite base pipes 110 may include two or more polymer composite base pipes. The composite base pipes may offer benefits over traditional base pipes such as corrosion resistance, lower weight, temperature resistance, etc. The fusion bonded composite base pipes 110 may include a thermoplastic polymer matrix, a thermoset polymer matrix, etc.

The fusion bonded composite base pipes 110, metallic end ring 102, and the screen 108 may be fusion bonded at the fusion bonded areas 104 and 106 via one or more interface layers. The metallic end ring 102 may be joined to the fusion bonded composite base pipes 110 via fusion bonding. The metallic end ring 102 may also be joined with the screen 108 via fusion bonding. In some implementations, the screen 108 may include a wire mesh, a sand screen, other solids separation devices to be used downhole, etc. Other tools may also be used in place of the screen 108 to prevent sand ingress. The screen 108 may be comprised of stainless steel, although other materials may also be used. The fusion bonded composite base pipes 110 may be comprised of a polymer composite. Each of the first and second tubulars comprising the fusion bonded composite base pipes 110 may be comprised of the same material. For example, the fusion bonded composite base pipes 110 may be comprised of the same polymer composite. In some implementations, each of the fusion bonded composite base pipes 110 may be comprised of a different material. For example, a first tubular may be comprised of a polyether ether ketone (PEEK) composite, and a second tubular may be comprised of a polyetherimide (PEI) composite. A plurality of various materials and combinations may be possible.

In addition to the fusion bonded composite base pipes 110 comprised of a polymer composite, some implementations may include an end ring comprised of a polymer composite. The polymer composites used for one or more components of the assembly 100 may be comprised of one or more polymer matrices reinforced with high strength carbon, glass, Kevlar fibers, rock fibers, etc. Any combination of these or other reinforcement materials may also be used. The fibers may be in the form of continuous fibers (including but not limited to woven, non-woven, knitted, stitched, braided, wound, etc.), sheets, tapes and towpregs. The fibers may also be noncontinuous fibers such as chopped fibers and short fibers. Polymer composite components including, but not limited to the fusion bonded composite base pipes 110 may include any one or a combination of thermoset materials, thermoplastic materials, etc. For example, any one of the polymer composite components may be comprised of a thermoset polymer including, but not limited to polyester, epoxy, phenolics, vinylester resins, any combinations thereof, etc. Any one of the polymer composite components may also be comprised of a thermoplastic and/or thermoplastic resin including, but not limited to Nylon, acrylic, polyetherimide (PEI), Polyetherketoneketone (PEKK), PEEK, Polyphthalamide (PPA), any combination thereof, etc. Any one of the polymer composite components including base pipes, end rings, and applied resins may include a vitrimer such as an aromatic copolyester thermoset (ACT). Other materials which may be used for the polymer composite components may include any aliphatic polyester(s), poly(lactic acid) (PLA), poly(ϵ-caprolactone) poly(glycolic acid) (PGA), poly(lactic-co-glycolic acid), poly(hydroxyl ester ether), poly(hydroxybutyrate), poly(anhydride), polycarbonate, poly(amino acid), poly(ethylene oxide), poly(phosphazene), polyether ester, polyester amide, polyamides, sulfonated polyesters, poly(ethylene adipate), polyhydroxyalkanoate, poly(ethylene terephtalate), poly(butylene terephthalate), poly(trimethylene terephthalate), poly(ethylene naphthalate), and copolymers, blends, derivatives or any combination of any of the above polymers.

The fusion bonding process is now described in additional detail. FIG. 2 is an illustration depicting a fusion bonded assembly 200 including pure composite base pipes and a metallic end ring, according to some implementations. The fusion bonded assembly 200 may include fusion bonded composite base pipes 210, a metallic end ring 202, one or more screens 208, and a fusion bonded area 204. Similar to FIG. 1, the assembly 200 may be bonded together via fusion bonding. Various components such as the fusion bonded composite base pipes 210, the metallic end screen 202, and the screens 208 may be fusion bonded simultaneously. In some implementations, the composite base pipes 210 may be fusion bonded, followed by a fusion bonding of the screens 208 to the composite base pipes 210, followed by a fusion bonding of the end ring 202 to the assembly formed by the fusion bonded composite base pipes 210 and the fusion bonded metallic end ring 202. Other combinations and techniques regarding the order of fusion bonded components may be possible.

FIG. 3 is an illustration 300 depicting an example fusion bonding process of composite base pipes, according to some implementations. The illustration 300 includes a composite base pipe 310, a composite base pipe 320, a fusion bonded area 304, and a coil 302. Fusion bonding may comprise melting a bonding agent, such as a thermoplastic layer, a metal layer, a metal alloy layer, a metalloid alloy layer, or other layer of material to fuse two or more components upon a resolidification of the bonding agent. During fusion bonding, a bonding agent may be applied and/or positioned in one or more interface layers between one or more members. The bonding agent in the interface layers may be melted or cured (depending on the material) via at least an application of heat. In some implementations, the fusion bonding may also include an application of pressure and the application of heat. The material included within the one or more interface layers may concentrate the applied heat at the one or more interface layers. Concentrating the applied heat may refer to the one or more interface layers becoming hotter than other layers, materials, and/or components. Concentrating the applied heat may also refer to a heat flux that emanates from the material of the one or more interface layers. Accordingly, concentrating the applied heat may refer to the material of the one or more interface layers retaining the applied heat for a longer period of time than other layers, materials, and/or components. In some implementations, the applied heat may not be concentrated at the one or more interface layers. In this configuration, heat may be applied to all components until a melt or cure of the material within the interface layers is achieved for fusion bonding.

When a thermoplastic polymer is disposed as the bonding agent within the interface layers, at least the outer layers of the interface layer(s) may melt and fuse together without melting members of the assembly such as the composite base pipes 310, 320, an end ring, one or more sand screens, etc. When using a vitrimer, the vitrimer may become less viscous once the application of heat has reached the glass transition temperature. Bonds within the vitrimer may re-form upon cooling, thus forming a bond.

A metal or metal alloy may also be used within the one or more interface layers. For example, one or more bismuth alloys may be melted and resolidified within the one or more interface layers to fuse the composite base pipes 310 and 320. Other metals and/or alloys may also be used. Such materials may include a fusible metal, metal alloy, metalloid alloy, etc. with a melting point less than the melting point of tin (approximately 450° F.). In some implementations, the metal or alloy may preferably expand upon solidification or resolidification. Thus, the metal or alloy bonding agent may exert an expansive force to make the attachment between the composite base pipes 310 and 320. The seal between the composite base pipes may be enhanced by the pressure generated during the solidification of the fusible metal or metal alloy in the interface layers.

Other than alloys of bismuth, alloys which expand upon solidification may include gallium alloys, antimony alloys, etc. As a general trend, bismuth alloys with concentrations of bismuth above 40% may grow during the solidification or resolidification process (e.g., after a partial or complete melt). The volume expansion from solidification may generally be small, but the metals, metal alloys, or metalloid alloys to be utilized may be stiff materials which results in a higher sealing force when compared to other less stiff materials. Bismuth alloys may experience a 1% to 2% volume expansion as they solidify. Gallium alloys may, for example, expand up to 3% on freezing. This may compress the alloy and enhance the seal further. Other metal and metalloid alloys which may expand upon freezing may include antimony, gallium, germanium, plutonium, and silicon. Other alloys may also be used as the bonding agent.

Thus, the one or more assembly components may be bound upon the activation of a bonding agent in the one or more interface layers, such as the resolidification of a polymer, metal, metal alloy, metalloid alloy, etc. or the curing of a polymer within the one or more interface layers. To initiate fusion bonding, heat may be applied to the bonding agent via a coil or other heating device. In one example to initiate fusion bonding between the composite base pipes 310 and 320, a current 306 may be applied through the coil 302 to heat the coil 302. The coil 302 may be heated to a temperature sufficient to melt an interface layer disposed between the composite base pipes 310 and 320 at the fusion bonded area 304. This interface layer may be described with additional detail in FIG. 4.

FIG. 4 is a second longitudinal section 400 depicting a fusion bonded assembly including a pure composite base pipe and a metallic end ring, according to some implementations. The longitudinal section 400 includes composite base pipes 410 and 420, a metallic end ring 402, one or more screens 408, a fusion bonded area 404, and one or more interface layers 405. The interface layers 405 may be used to fusion bond the composite base pipes 410 and 420 to one another, the metallic end ring 402 to the composite base pipes 410, 420, the screen(s) 408 to the composite base pipes 410, 420 and the metallic end ring 402, etc. As shown, a smaller diameter composite pipe (e.g., the composite base pipe 410) may be configured to fit inside a larger diameter composite pipe (e.g., the composite base pipe 420).

Each interface layer of the interface layers 405 may refer to the region where one or more metallic, composite, etc. pieces may be joined. Optionally, the interface layer(s) may also refer to a surface of each component to be joined, each surface including an applied material. Two interface layers may fuse into a larger interface layer upon joining. For example, an interface layer of the metallic end ring 402 may be fused with an interface layer of the screens 408. Similarly, an interface layer 405 may exist between the composite base pipe 410 and the composite base pipe 420.

The composite base pipe 410 and the composite base pipe 420 may be joined via an application of heat and pressure. The pressure may be in the form of radially-applied pressure from rotary friction and rolling. However, other types of pressure may be applied during the fusion of the composite base pipes 410 and 420. In some implementations, pressure may be applied in the axial direction by incorporating a scarf cut in the composite base pipes to form a scarf joint. Force may be applied axially because of the sloped surfaces, creating a sloped interface layer. In some implementations, the composite base pipes 410 and 420 may include threaded ends. A material (also referred to as the bonding agent), such as ACT, may be applied to the threads to facilitate fusion bonding. However, the material may also be applied elsewhere. Therefore, radial, axial, and torsional forces may be used during fusion bonding to join the composite base pipes 410 and 420.

The interface layers 405 may be comprised of a bonding agent configured to concentrate externally-applied heat for fusion bonding. For example, the interface layers 405 of the fusion bonded area 404 may include ACT as the bonding agent, although other materials may also be used. The bonding agent may be used as a coating material on polymer composite sand control screen tools such as the composite base pipes 410 and 420 to join them with a similar or dissimilar material by the application of heat and pressure. The heat may be applied through a conduction heater, convection heater, ultrasonic heater, infrared heater, eddy current heater, laser etc. Each of the interface layers 405 may include bonding agent in the form of a film, a powder, a gel, a paste, a filler material, an injected resin, any other meltable material form, etc. Other configurations may also be possible. Other materials to include as the bonding agent in the interface layers 405 may include PEEK, PEKK, PEI, PPA, nylon, etc. in the form of a coating, film, powder, or any other suitable material. In some implementations, ACT, PEEK, PEKK, PEI, PPA, and other high-performance vitrimer and/or thermoplastic materials suitable for use in geothermal wells, high pressure high temperature (HPHT) wells, etc. may be preferable. An HPHT well may, for example, possess a bottomhole temperature greater than 300° F. and a bottomhole pressure in excess of 10,000 psi. The material within the interface layers 405 may be applied manually, in a laboratory environment, in a field environment proximate to a well site, via an automated system, etc.

Example Assembly of Composite Base Pipes and Composite End Ring

Some implementations of the polymer composite base pipes and sand screens may be fusion bonded with a polymer composite end ring rather than a metallic end ring. FIG. 5 is a longitudinal section 500 depicting a fusion bonded assembly including polymer composite base pipes and a composite end ring, according to some implementations. The longitudinal section 500 includes a composite end ring 502, fusion bonded area 504, interface layers 506 and 507, one or more screens 508, and fusion bonded composite base pipes 510. In some implementations, the composite end ring 502 may be comprised of a similar material to the fusion bonded composite base pipes 510. However, the composite end ring 502 may be comprised of other materials different from those of the composite base pipes 510. For example, the composite end ring 502 may be comprised of ACT, and the composite base pipes 510 may be comprised of PEEK. Other materials and combinations may be possible.

A composite end ring, such as the composite end ring 502, may be joined to the polymer composite base pipe(s) via fusion bonding. The composite end ring 502 may also be joined with a wire mesh and/or sand screen, such as the one or more screens 508, via fusion bonding. The composite end ring 502, fusion bonded composite based pipes 510, and screens 508 may be fusion bonded at the fusion bonded area 504 via the interface layers 506 and 507. The interface layers may include a bonding agent such as ACT, similar to the interface layers 405 of FIG. 4. Other bonding agents may also be used.

FIG. 6 is an illustration 600 depicting an example fusion bonding process for a fusion bonded assembly having a composite end ring, according to some implementations. The illustration 600 includes a fusion bonded base pipe 610, a composite end ring 602, one or more screens 608, and a fusion bonded area 604. During the fusion bonding of the base pipe 610, composite end ring 602, and one or more screens 608, a chemical bond between components may be achieved without altering the material and/or structural properties of the sand screen assembly components themselves.

FIG. 7 is an illustration 700 depicting an example fusion bonding process of composite base pipes and a composite end ring, according to some implementations. The illustration 700 includes a coil 702 with an electrical current 706 ran therethrough, a fusion bonded area 704, a composite base pipe 710, and a composite base pipe 720. While not shown, the composite bases pipes 710 and 720 may be fusion bonded with a composite end ring via heat emanating from the coil 702 (when energized). The heat may cause a filler material positioned within interface layers of the fusion bonded area 704, such as a bonding agent, to melt. The melted interface layers may then fuse the composite base pipe 710, the composite base pipe 720, and the composite end ring upon resolidification.

FIG. 8 is an illustration 800 depicting an example fusion bonding process for a fusion bonded assembly having a composite end ring, according to some implementations. The illustration 800 includes composite base pipes 810 and 820, a composite end ring 802, one or more screens 808, a fusion bonded area 804, and one or more interface layers 805. The composite base pipe 810, composite base pipe 810, composite end ring 802, and the one or more screens 808 may be fusion bonded at the fusion bonded area 804 via an application of heat and pressure. A material within the interface layers 805 may facilitate the fusion bonding upon the application of heat, and optionally, both heat and pressure.

Example Material Properties

Example materials which may be used to form one or more composite members, used as a binding material in the interface layers, etc. are now described with additional detail.

FIG. 9 is a plot 900 depicting differential scanning calorimetry (DSC) scans of example polymer composites, according to some implementations. The plot 900 and the description that follows may reference the example DSC scans as described in Bashandeh et al. (2021), titled “Tribology of self-lubricating high performance ATSP, PI, and PEEK-based polymer composites up to 300°C”. The plot 900 includes an X-axis 902 depicting temperature in degrees Celsius and a Y-axis 904 depicting a rate of heat flow per unit mass of various polymer composites (in Watts/gram). The plot 900 may indicate a thermal degradation of each material over their operating temperature range. The various polymer composites may include an ACT-based polymer (aromatic thermosetting copolyester, also referred to as ATSP), a polyimide (PI)-based polymer, and a PEEK-based polymer. Accordingly, the plot 900 may include an ACT DSC curve 906, a PEEK DSC curve 908, and a PI DSC curve 910. As shown, PI, ACT and PEEK may remain relatively stable over their operating temperature range.

As described with reference to FIG. 1 of Bashandeh et al., the ACT DSC curve 906 may include an endothermic peak at 332° C. corresponding to melting temperature (T_m), and a shoulder at 307° C. corresponding to the glass transition temperature, T_g. The PEEK DSC curve 908 may depict a double melting behavior with a lower endothermic peak at 212° C. and a higher endothermic peak at 341° C. For PEEK, the T_g was measured as 155° C. ACT and other ACT-based polymeric coatings may include higher glass transition temperatures when compared to other example polymeric coatings such as Lumiflon and similar fluoropolymers, silicone-based coatings, tri-glycidyl isocyanurate (TGIC) polyester, PEEK, fusion-bonded epoxies, Novolac epoxies, etc. Sand control screen tools coated with a high glass transition temperature coating, such as ACT, may have the ability to withstand elevated temperatures. Other polymeric bonding agents may also be used.

Example Manufacturing Processes

Example processes and techniques for manufacturing composite members are now described. Manufacturing techniques such as automated filament winding and bladder molding may be preferred for creating composite components such as a tubing mandrel profile to generate composite base pipes, composite end rings, etc. In some implementations, other processes like tape placement and autoclave molding may also be employed to manufacture the tubular mandrel profile. Conventional processes including, but not limited to injection molding, compression molding and extrusion may also be used to produce tubulars with fiber in-lays. The filament winding technique may be described with additional detail in FIG. 10.

FIG. 10 is an illustration 1000 depicting an example filament winding technique with in-situ consolidation, according to some implementations. The illustration 1000 includes tensioned spools 1002 and 1003, a tensioner 1004, a feed direction 1005, a carriage 1006, a heat source 1008, a compaction roller 1010, and a rotating mandrel 1012.

Filament winding is a common process used to produce a hollow composite where continuous fibers are passed through separate combs into an epoxy resin bath and guided around a rotating mandrel. Accordingly, filament may be sourced from the tensioned spools 1002 and 1003. The filament may include prepreg tapes, fiber yarns, etc. which may be filament wound around the rotating mandrel 1012. The filament may travel along the feed direction 1005 to the carriage 1006. The carriage 1006 may move parallel to a longitudinal axis of the rotating mandrel 1012 and guide the fibers when forming a tubular or tubular component. The heat source 1008 may be configured to bind fibers to one another at a point of contact as they are formed around the rotating mandrel 1012. A compaction roller 1010 may be utilized to ensure proper tension on the filament as it is wound around the rotating mandrel 1012. A thermoplastic binder may be used in the filament winding technique of FIG. 10 rather than using an epoxy as the binder.

As depicted, a two-axis filament winding technique may manufacture a constant cross-section mandrel. The two axes may be provided by the rotation of the rotating mandrel 1012 and the movement of the carriage 1006. However, other filament winding techniques with additional axes may also be used. For example, a mandrel with a more complex geometry and variable cross sections and curvatures may also be manufactured using a filament winding robot with more degree of freedoms (e.g., six to eight axes). Filament winding may be a continuous process, and the tapes or fiber yarns may remain in tension throughout the process by tensioner units, such as the tensioner 1004 and compaction roller 1010. The fibers which are wound on the rotating mandrel 1012 may preferably be in-situ consolidated using the heat source 1008, and the compaction roller 1010 may be used to apply pressure and provide uniform impregnation, curing, thickness and fiber volume fraction control. Thus, laying the fiber and curing the fiber may occur simultaneously. The heat source 1008 to be used for in-situ consolidation may include a conduction heater, convection heater, ultrasonic heater, infrared heater, eddy current heater, a laser, etc. Other devices may also be used as the heat source 1008. In some implementations, the filament winding technique of FIG. 10 may be automated, may be performed by one or more autonomous and/or robotic devices, automated systems, etc.

Conventional consolidation routes may also be adopted if in-situ consolidation is not an option. For example, if the component under construction is able to be thermally consolidated in an oven, an autoclave, or via infrared means, microwave radiations and allied processes may be used to consolidate the filament wound part. The fibers may be selectively wound in a particular orientation to optimize the mandrel performance under a particular loading scenario or to satisfy a particular load rating. Other attributes of the resulting composites may also be adjusted based on the orientation of the fibers. For example, a hoop strength of the resulting composite may be increased by including fibers laid perpendicular to the longitudinal axis of the resulting composite tubular.

The filament winding may occur until a desired number of fiber layers have been wound or a desired thickness has been achieved. In some implementations, the final thermoplastic-fiber and/or thermoset-fiber composite may be removed from the rotating mandrel 1012. In some implementations, the rotating mandrel 1012 (a metallic component) may be included in the final composite tubular to form a hybrid composite.

Another process to manufacture the composite components may incorporate bladder molding, where a tubular preform may be made by wrapping a material such as a thermoplastic prepreg around the mandrel to achieve a desired layup of the fibers. FIG. 11 is a diagram 1100 depicting an example composite bladder molding process, according to some implementations. The diagram 1100 includes a bladder 1102 which may be an inflatable mandrel. The prepreg, which may be a thermoplastic prepreg, may be individually laid around the mandrel of the bladder 1102. A preform assembly 1104 may be created by placing one or more layers on top of each other to make a preform of layers. The preform of layers may then be wound around the mandrel. This may be performed manually or using an automated preforming device to achieve a consistent compaction.

The preform assembly 1104 may be placed inside a mold cavity. The preform assembly 1104 may be draped over the inflatable bladder during draping 1106 to ensure a uniform distribution of material and eliminate voids in the preform assembly 1104 prior to compaction 1108. The bladder 1102 may be inflated and used to pressurize the preform (e.g., pressurized between 6 to 20 bars) to drape it across the wall of the cavity. Draping the preform assembly across the wall of the cavity may produce a hollow composite structure.

During compaction 1108, the mold may be closed and the bladder 1102 may be inflated to compress the preform assembly. The bladder 1102 may be inflated via at a bladder pressure, P_b. Heat may be applied to the composite at a desired temperature based on the selection of the matrix material. The heat may be used to cure the composite. During consolidation and demolding 1110, the final composite may be cooled and removed from the mold. This bladder molding process may be adopted for complex tubular profiles. For a composite with a metallic or thermoplastic base/liner, the preform may be wound around the base/liner and the hybrid tubular may be placed in an autoclave or oven for consolidation during the consolidation and demolding 1110.

Accordingly, a thermoplastic material may be used as the polymer matrix in which reinforcement materials, such as the fiber of the spools 1002-1003, may be incorporated. Other materials may also be possible. Various components such as composite base pipes, composite end rings, other composite tubulars, etc. may be created through filament winding or bladder molding. In addition to filament winding and bladder molding, other manufacturing techniques may be used such as automated tape placement, hand-layup, compression molding, extrusion molding, pultrusion, etc. The composite components may be manufactured with fiber yarns or tapes which may be pre or post mixed with different fillers such as carbon black, graphite, glass, silica, pigment, nanotubes (i.e., to create a nanocomposite), etc. These filler materials may improve the mechanical, chemical, flowability, conductivity, and other attributes of the resulting composite components which may include a composite tubular, a composite end ring, etc.

Example Fusion Bonding Processes

Accordingly, vitrimers such as ACT may be used as a coating material/bonding agent on polymer composite sand control screen tools to join them with a similar or dissimilar material by the application of heat and pressure. The heat may be applied through conduction heater, convection heater, ultrasonic heater, infrared heater, eddy current heater, laser etc. Other coating materials and/or bonding agents may be used in various forms. For example, ACT may be used for bonding in the form of a film, a powder, a paste, etc.

Metallic substrates may be coated with a bonding agent which may include one or more different thermoplastic or vitrimer polymers. The metallic substate may be comprised of one or more high-strength low-alloy (HSLA) steels, martensitic stainless steels, supermartensitic stainless steels, duplex and super duplex stainless steels, austenitic stainless steels, alloys in the Ni-Cr-Mo family, solution-strengthened nickel-based alloys and precipitation-hardening nickel-based alloys, etc. Non-metallic substrates may include PEEK, PEI, PPA, PEKK, Polyphenylene sulfide (PPS), Polytetrafluoroethylene (PTFE), Polyamide (PA), or the parts manufactured with thermosetting resins like epoxy, phenolic resins, Bismaleimide (BMI) resin, etc.

Fusion bonding processes may include vibrational welding, rotational welding, ultrasonic welding, laser beam welding, induction welding, resistance welding, friction stir welding, etc. Other techniques may also be used. FIGS. 12-15 depict different scenarios for joining different sand control screen composite tubulars using various fusion bonding techniques.

FIG. 12 is an illustration 1200 depicting a technique for joining composite adherends using a layer of bonding agent resin, according to some implementations. The illustration 1200 may include a first tubular 1202, a second tubular 1204, a fusion zone 1206, heat and pressure 1208, and one or more interface layers 1210. Top and bottom adherends, such as the first and second tubulars 1202 and 1204, may be comprised of a thermoplastic or a thermoset-based composite. The interface layers 1210 may be used to join the first tubular 1202 and the second tubular 1204 at the fusion zone 1206 via the application of the heat and pressure 1208. Accordingly, the interface layers 1210 may include a polymer film or coating layer used to join the top and bottom adherends. The interface layers 1210 may include a bonding agent such as ACT, although other materials may also be used. When applied as a coating material, the bonding agent may possess a coating thickness between 25 and 300 microns (μm). When applied as a film, the bonding agent film may possess a thickness of <1 millimeter (mm).

FIG. 13 is an illustration 1300 depicting a technique for joining composite adherends using powdered bonding agent resin, according to some implementations. The illustration 1300 may include a first tubular 1302, a second tubular 1304, a fusion zone 1306, heat and pressure 1308, and one or more interface layers 1310. Similar to FIG. 12, top and bottom adherends such as the first and second tubulars 1302-1304 may be comprised of a thermoplastic or a thermoset-based composite. The interface layers 1310 may be used to join the first tubular 1302 and the second tubular 1304 at the fusion zone 1306 via the application of the heat and pressure 1308.

In FIG. 13, the interface layers 1310 may instead comprise a polymer powder to be used during the fusion bonding of the first tubular 1302 and second tubular 1304. For example, an ACT resin may be used as a powder or in a powdered form on the top and bottom adherends (which may include the first tubular 1302, a second tubular 1304, and end ring, one or more screens, etc.) during the fusion bonding process. The volume of powder to be used in the interface layers 1310 may be such that the total melt volume results in a thickness <1 mm. Powdered bonding agents other than ACT may also be used.

FIG. 14 is an illustration 1400 depicting a technique for joining thermoset composite adherends using a bonding agent coupling layer in film form, according to some implementations. The illustration 1400 may include a first tubular 1402, a second tubular 1404, a fusion zone 1406, heat and pressure 1408, one or more interface layers 1410, and one or more coupling layers 1412. Top and bottom adherends, such as the first and second tubulars 1402 and 1404, may be comprised of a thermoset-based composite. The interface layers 1410 may be used to join the first tubular 1402 and the second tubular 1404 at the fusion zone 1406 via the application of the heat and pressure 1408. The adherends may be fusion bonded via the interface layers 1410 and the coupling layers 1412. The coupling layers 1412 may couple the tubulars 1402-1404 to the interface layers 1410. Both the interface layers 1410 and coupling layers 1412 may be comprised of a polymer film. However, other configurations may also be possible.

Thermoset based composite materials may not bond well with the polymer of the interface layers 1410 once heated. A coupling layer and/or inter-layer, such as the coupling layers 1412, may be included to help facilitate fusion bonding of the thermoset composite components. For example, the one or more coupling layers 1412 may be added during the manufacturing of the thermoset composite adherends such as the first tubular 1402 and second tubular 1404. The coupling layers 1412 may be comprised of a powder, a gel, a paste, a film, etc. The coupling layers 1412 may be added on the final and penultimate layers of the thermoset composites (tubulars 1402-1404) out of n layers of composite material. Therefore, the coupling layers 1412 may be created as part of the tubulars 1402-1404 or otherwise added to the tubulars 1402-1404 during the manufacturing process.

In some implementations, the coupling layers 1412 may include a thermoplastic material. For example, a thermoplastic layer of a certain thickness may be added to the thermoset composite tubular, and the thermoplastic layer may be cured and fused with the thermoset composite tubular during the formation of the thermoset composite tubular. Some implementations of the coupling layers 1412 may instead include a metal or metal/metalloid alloy. Some implementations may instead include a vitrimer, such as ACT. The coupling layers 1412 may provide a coupling surface for bonding agent resin to be applied. In some implementations, the coupling layers 1412 may be configured to impinge the polymeric material within the interface layers 1410. Whereas the coupling layers 1412 may be added during the creation of tubulars 1402-1404, the interface layers 1410 may be added later. For example, the material of the interface layers 1410 may be induced on to the coupling layers 1412 prior to joining one or more components through fusion bonding.

Therefore, each coupling layer 1412 created on the surface of the adherends may be configured to couple with bonding agent resin which may assist fusion bonding thermoset-based composites with other thermoset composites, thermoplastic composites, vitrimer composites, etc. The thickness of each of the one or more coupling layers 1412 may be <300 μm when used in a film configuration. The one or more interface layers 1410 may comprise a thickness between 25-300 μm when using a bonding agent coating and <1 mm when using a bonding agent film. Other materials and thicknesses may also be possible.

FIG. 15 is an illustration 1500 depicting a technique for joining thermoset composite adherends using a bonding agent coupling layer in powder form, according to some implementations. The illustration 1500 may include a first tubular 1502, a second tubular 1504, a fusion zone 1506, heat and pressure 1508, one or more interface layers 1510, and one or more coupling layers 1512. Top and bottom adherends, such as the first and second tubulars 1502 and 1504, may be comprised of a thermoset-based composite. The interface layers 1510 may be used to join the first tubular 1502 and the second tubular 1504 at the fusion zone 1506 via the application of the heat and pressure 1508. The adherends may be fusion bonded via the interface layers 1510 and the coupling layers 1512. The coupling layers 1512 may couple the tubulars 1502-1504 to the interface layers 1510. Both the interface layers 1510 and coupling layers 1512 may be comprised of a polymer powder. However, other configurations and combinations thereof may also be possible. For example, some implementations of the interface layers 1510 may include a powder, and the coupling layers 1512 may include a film.

Additional bonding agent layers may be added during the manufacturing of thermoset composite adherends, such as the tubular 1502. The thickness of the bonding agent layer within each of the coupling layers 1512 after melting may be <300 μm. Other configurations, such as the film of FIG. 14, may include other thicknesses in their application. For example, polymeric bonding agent coatings (e.g., such as ACT) may be between 25 um-300 um, while a polymeric bonding agent applied as a film may have a thickness <1 mm.

Example Coating Process

An example coating process is now described. FIG. 16 is a flowchart 1600 depicting an example coating process, according to some implementations. The flowchart 1600 may include steps to apply durable and high-quality coatings of a bonding agent for use in one or more interface layers. The coating may be a thermoplastic, metal, alloy, or vitrimer material for use in fusion bonding. The flowchart 1600 may include surface preparation 1602, coating spraying 1604, melting 1606, and curing 1608. Some implementations of the surface preparation 1602 may include sandblasting, grit blasting, etc. and cleaning a surface in which a coating is to be applied. For example, the surfaces of the composite tubulars 810 and 820 which contact the interface layer 805 may be sandblasted and cleaned prior to applying a polymer film, coating, powder, etc. Other surface treatment processes may include laser treatment, plasma treatment, etc. for optimal surface preparation.

At step 1604, the coating may be sprayed or otherwise applied to the prepared surface. Some implementations may apply a bonding agent coating as a solvent borne coating or powder coating (as low as 25 μm). In some implementations, ACT may be used as the bonding agent. ACT oligomers may typically solvate in polar aprotic solvents if a solvent borne deposition route is chosen. If the coating of step 1604 is applied as a powder coating, at room temperature, the oligomers may exist in a solid state and may be produced in micro-scale powders which may be amenable via hot melt processes, slurry, powder coating, etc.

At step 1606, the coating may be melted or softened on to a surface via an application of heat, and optionally, pressure. For example, FIG. 3's coil 302 may be used to melt a polymer coating comprised of a thermoplastic to fusion bond one or more sand screen components. Other devices may also be used. In some implementations, the coil 302 may be used to soften and/or melt a vitrimer such as ACT. For example, ACT may soften between 170-180° C. and become an uncured liquid between 230-240° C.

At step 1608, the coating may be cured. For example, an applied bonding agent coating may be cured using methods including, but not limited to convection heating, ultrasonic heating, induction heating, infrared heating, eddy current heating, laser heating, etc. via one or more applicable devices. In some implementations, a vitrimer such as ACT may begin curing at approximately 270° C. and become fully cured at approximately 340° C. Once cured, the vitrimer may become hardened and form the fusion bond between sand screen assembly components.

Example Well System

An example well system is now described. FIG. 17 is a cross-sectional diagram depicting an example well system including one or more sand screens, according to some implementations. A well system 1700 may comprise a wellbore 1712 which intersects a subsurface formation 1720. The wellbore 1712 may include a vertical section 1714 (which is at least partially cemented with a casing string 1716) and a horizontal section 1718. The horizontal section 1718 may be an open-hole section of the wellbore 1712 or a cased section. Other wellbore configurations may also be possible. For example, the well system 1700 may include a multi-lateral (MLT) well having multiple wellbores similar to the wellbore 1712. The well system 1700 may further comprise surface equipment 1728. The surface equipment 1728 may comprise a wellhead, a choke, one or more production vessels, a power generator, a compressed air unit, etc.

A tubing string 1722 may be positioned within the wellbore 1712 and extend from the surface. The tubing string 1722 may provide a conduit for formation fluids to travel from the subsurface formation 1720 to the surface and for stimulation fluids to travel from the surface to the subsurface formation 1720. In some implementations, the tubing string 1722 may include one or more tubulars comprised of a composite material. For example, the tubing string 1722 may be comprised of thermoplastic composite tubulars, thermoset composite tubulars, any combination thereof, etc. The tubing string 1722 may include one or more screen systems 1725. The screen systems 1725 (also referred to as a screen section) may be part of a lower completion. The screen systems 1725 may comprise sections of metal screens, sand screens, wire mesh, other downhole tools, etc. used to mitigate the migration of unconsolidated reservoir sands or other solids into the wellbore 1712. Thus, fluids from a reservoir within the subsurface formation 1720 may be produced without introducing solids into the tubing string 1722. In some implementations, the one or more screen systems 1725 may be comprised of non-metallic materials. The one or more screen systems 1725 may be connected to tubulars of the tubing string 1722 via fusion bonding, as described above.

Example Method of Operations

FIG. 18 is a flowchart depicting an example method of operations, according to some implementations. Operations of a method 1800 may be performed by software, firmware, hardware, or a combination thereof. Such operations are described with reference to FIGS. 1-17. However, such operations may be performed by other systems or components. The operations of the method 1800 begin at block 1802.

At block 1802, the method 1800 includes joining at least a portion of a first tubular comprised of a first material with at least a portion of a second tubular comprised of a second material at one or more interface layers including a third material. For example, at least a portion of the composite tubular 410 and at least a portion of the composite tubular 420 may be fused at the one or more interface layers 405. The interface layers 405 may include a third material as a bonding agent, the bonding agent comprised of one or more vitrimers (e.g., ACT), metals, alloys, and/or thermoplastics. An end ring, one or more sand control screen components, and other downhole tools may also be joined with the polymer composite tubulars via the interface layers including a bonding agent in the form of a coating, film, powder, gel, paste, etc. Other materials may also be used as the bonding agent for fusion bonding in the interface layers 405, such as PEEK, PEKK, PEI, PPA, nylon, acrylic, etc. in at least the forms (coating, powder, film, etc.) described. Accordingly, other materials may also be possible. Flow progresses to block 1804.

At block 1804, the method 1800 includes applying heat, via a heat source external to the first and second tubulars, to the third material to fuse the first and the second tubulars. The third material may include a polymeric material. If the third material is a thermoplastic, metal, alloy, etc. material, the first tubular and second tubulars may be configured to fuse upon a melting and resolidifying of the third material. If the third material is a vitrimer, the first and second tubulars may be configured to fuse upon a curing of the vitrimer. The vitrimer may behave similar to a liquid near its glass transition temperature and harden upon curing. The fusion bond may be complete once the thermoplastic and/or vitrimer have cooled and resolidified.

For example, a heat source such as the coil 302 may be used to apply heat to the one or more interface layers 405. The third material, which may include a vitrimer such as ACT, may concentrate the applied heat at the interface layers 405 and soften without melting the composite tubulars 310 and 320. In some implementations, the vitrimer may melt, similar to a thermoplastic, prior to curing. The composite tubular 310 and the composite tubular 320 may fuse at the interface layers 405 upon a curing of the vitrimer within the interface layers 405. If a thermoplastic material, such as PEEK, is used in the interface layers 405, the composite tubulars 310 and 320 may fuse upon a melting and resolidification of the thermoplastic material.

While traditional methods of joining components, such as interference fits created through large temperature deltas between components, may provide a mechanical bond, fusion bonding techniques with the use of a vitrimer, metal, alloy and/or thermoplastic material may chemically bond the composite tubulars, an end ring, one or more sand screens, etc. In some implementations, pressure may be applied in addition to heat to facilitate the fusion bonding of block 1804. Flow of the method 1800 ceases.

Various modifications to the implementations described in this disclosure may be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other implementations without departing from the spirit or scope of this disclosure. Thus, the claims are not intended to be limited to the implementations shown herein but are to be accorded the widest scope consistent with this disclosure, the principles and the novel features disclosed herein.

Certain features that are described in this specification in the context of separate implementations also may be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation also may be implemented in multiple implementations separately or in any suitable sub-combination. Moreover, although features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination may in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

While operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. Further, the drawings may schematically depict one more example process in the form of a flow diagram. However, some operations may be omitted and/or other operations that are not depicted may be incorporated in the example processes that are schematically illustrated. For example, one or more additional operations may be performed before, after, simultaneously, or between any of the illustrated operations. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the implementations described should not be understood as requiring such separation in all implementations, and the described program components and systems may generally be integrated together in a single software product or packaged into multiple software products. Additionally, other implementations are within the scope of the following claims. In some cases, the actions recited in the claims may be performed in a different order and still achieve desirable results.

Plural instances may be provided for components, operations or structures described herein as a single instance. Finally, boundaries between various components, operations and data stores are somewhat arbitrary, and particular operations are illustrated in the context of specific illustrative configurations. Other allocations of functionality are envisioned and may fall within the scope of the disclosure. In general, structures and functionality presented as separate components in the example configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements may fall within the scope of the disclosure.

Use of the phrase “at least one of” preceding a list with the conjunction “and” should not be treated as an exclusive list and should not be construed as a list of categories with one item from each category, unless specifically stated otherwise. A clause that recites “at least one of A, B, and C” may be infringed with only one of the listed items, multiple of the listed items, and one or more of the items in the list and another item not listed. Similarly, “at least one of: a, b, or c” is intended to cover: a, b, c, a-b, a-c, b-c, and a-b-c.

Unless otherwise specified, use of the terms “up,” “upper,” “upward,” “uphole,” “upstream,” or other like terms shall be construed as generally away from the bottom, terminal end of a well; likewise, use of the terms “down,” “lower,” “downward,” “downhole,” or other like terms shall be construed as generally toward the bottom, terminal end of the well, regardless of the wellbore orientation. Use of any one or more of the foregoing terms shall not be construed as denoting positions along a perfectly vertical axis. In some instances, a part near the end of the well can be horizontal or even slightly directed upwards. Unless otherwise specified, use of the terms “subsurface formation” or “subterranean formation” shall be construed as encompassing both areas below exposed earth and areas below earth covered by water such as ocean or fresh water.

Example Implementations

Implementation #1: An apparatus configured for use in a wellbore, the apparatus comprising: a first tubular comprised of a first material; a second tubular comprised of a second material; and one or more interface layers including a third material, wherein the first tubular and the second tubular are configured to couple at the one or more interface layers via an application of heat to the third material.

Implementation #2: The apparatus of Implementation 1, wherein the third material is configured to concentrate the application of heat, and wherein the first tubular and the second tubular are configured to couple via a chemical bond.

Implementation #3: The apparatus of any one or more of Implementations 1-2, wherein the third material is configured to melt via the application of heat, and wherein the first tubular and the second tubular are configured to couple upon a resolidification of the third material.

Implementation #4: The apparatus of any one or more of Implementations 1-3, wherein the third material is comprised of a vitrimer.

Implementation #5: The apparatus of any one or more of Implementations 1-4, wherein the first material and the second material are composite materials, and wherein the first and second tubulars are comprised of at least one of a thermoplastic composite and a thermoset composite.

Implementation #6: The apparatus of any one or more of Implementations 1-5, wherein the first material and the second material are the same material, and wherein the third material is comprised of a different material than the first and second materials.

Implementation #7: A system comprising: a sand screen assembly to be positioned in a wellbore, the sand screen assembly including, a first tubular comprised of a first material; a second tubular comprised of a second material; one or more downhole tools; and one or more interface layers including a third material, wherein the first tubular, the second tubular, and the one or more downhole tools are configured to couple at the one or more interface layers via an application of heat to the third material.

Implementation #8: The system of Implementation 7, further comprising: an end ring configured to couple with the first tubular, the second tubular, and the one or more downhole tools, wherein the one or more downhole tools includes a sand screen.

Implementation #9: The system of any one or more of Implementations 7-8, wherein the third material is configured to concentrate the application of heat, and wherein the first tubular and the second tubular are configured to couple via a chemical bond.

Implementation #10: The system of any one or more of Implementations 7-9, wherein the third material is configured to melt via the application of heat, and wherein the first tubular and the second tubular are configured to couple upon a resolidification of the third material.

Implementation #11: The system of any one or more of Implementations 7-10, wherein the third material is comprised of a vitrimer.

Implementation #12: The system of any one or more of Implementations 7-11, wherein the first material and the second material are composite materials, and wherein the first and second tubulars are comprised of at least one of a thermoplastic composite and a thermoset composite.

Implementation #13: The system of any one or more of Implementations 7-12, further comprising: a coupling layer formed on an exterior surface of the thermoset composite of at least the first tubular and the second tubular, wherein the third material is applied to the coupling layer.

Implementation #14: The system of any one or more of Implementations 7-13, wherein the first material and the second material are the same material, and wherein the third material is comprised of a different material than the first and second materials.

Implementation #15: A method for combining tubulars configured for use in a wellbore, the method comprising: joining at least a portion of a first tubular comprised of a first material with at least a portion of a second tubular comprised of a second material at one or more interface layers including a third material; and applying heat, via a heat source external to the first and second tubulars, to the third material to fuse the first and second tubulars.

Implementation #16: The method of Implementation 15, further comprising: concentrating the applied heat via the third material, wherein the first tubular and second tubular are configured to fuse upon a melting and resolidifying of the third material, and wherein joining at least the portion of the first tubular with at least the portion of the second tubular comprises chemically bonding the first tubular and the second tubular.

Implementation #17: The method of any one or more of Implementations 15-16, further comprising: joining an end ring and one or more downhole tools with the first tubular and the second tubular, wherein the one or more downhole tools includes a sand screen, and wherein the third material is a vitrimer.

Implementation #18: The method of any one or more of Implementations 15-17, further comprising: forming at least one of the first tubular, the second tubular, and the end ring via a manufacturing process including at least one of a filament winding process and a bladder molding process, wherein the first material and the second material are composite materials.

Implementation #19: The method of any one or more of Implementations 15-18, further comprising: forming a coupling layer on an exterior surface of at least the first tubular and the second tubular, wherein at least one of the first tubular and the second tubular are comprised of a thermoset composite, and wherein the third material is applied to the coupling layer.

Implementation #20: The method of any one or more of Implementations 15-19, wherein the first material and the second material are the same material, and wherein the third material is comprised of a different material than the first and second materials.