Expandable liner and associated methods of regulating fluid flow in a well

Abstract

A method of regulating flow through a first tubular structure in a well provides flow control by use of an expandable second tubular structure inserted into the first tubular structure and deformed therein. In a described embodiment, a liner has sealing material externally disposed thereon. Expansion of the liner within a screen assembly may be used to sealingly engage the liner with one or more well screens of the screen assembly, and may be used to regulate a rate of fluid flow through one or more of the well screens.

What is claimed is:  
     
         1 . A method of controlling fluid flow through a first tubular structure positioned in a well, the method comprising the steps of: 
 positioning a second tubular structure within the first tubular structure in the well; and    deforming the second tubular structure, thereby altering a flowpath for flow of fluid through a first sidewall of the first tubular structure.    
     
     
         2 . The method according to  claim 1 , wherein in the positioning step the second tubular structure is in a radially contracted configuration, and in the deforming step the second tubular structure is deformed to a radially enlarged configuration thereof.  
     
     
         3 . The method according to  claim 1 , wherein the deforming step further comprises radially retracting the second tubular structure, thereby increasing a flow area of the flowpath.  
     
     
         4 . The method according to  claim 1 , wherein the deforming step further comprises sealingly engaging the second tubular structure with the first tubular structure.  
     
     
         5 . The method according to  claim 4 , wherein the deforming step further comprises radially extending the second tubular structure.  
     
     
         6 . The method according to  claim 5 , wherein the extending step comprises contacting the first tubular structure with an outer sealing material of the second tubular structure.  
     
     
         7 . The method according to  claim 6 , wherein the contacting step comprises decreasing a flow area disposed between adjacent portions of the sealing material.  
     
     
         8 . The method according to  claim 1 , wherein the deforming step comprises increasing a flow area of the flowpath disposed between portions of a sealing material of the second tubular structure.  
     
     
         9 . The method according to  claim 1 , wherein the deforming step comprises changing a flow area of the flowpath disposed externally on the second tubular structure.  
     
     
         10 . The method according to  claim 9 , wherein in the changing step, a width of a longitudinal channel in fluid communication with an opening formed through a second sidewall of the second tubular structure is changed.  
     
     
         11 . The method according to  claim 9 , wherein in the changing step, a depth of a longitudinal channel in fluid communication with an opening formed through a second sidewall of the second tubular structure is changed.  
     
     
         12 . The method according to  claim 9 , wherein the flowpath includes at least one restriction of the flow area, and wherein the changing step further comprises changing a resistance to fluid flow through the restriction.  
     
     
         13 . The method according to  claim 12 , wherein the restriction is formed externally on the second tubular structure.  
     
     
         14 . The method according to  claim 12 , wherein the restriction is formed between portions of sealing material on the second tubular structure.  
     
     
         15 . The method according to  claim 12 , wherein the restriction is formed in a channel formed externally on the second tubular structure.  
     
     
         16 . The method according to  claim 1 , wherein the first tubular structure comprises a well screen, and wherein the deforming step further comprises sealingly engaging the second tubular structure at opposite ends of the well screen.  
     
     
         17 . The method according to  claim 1 , wherein the deforming step further comprises outwardly extending the second tubular structure.  
     
     
         18 . The method according to  claim 17 , wherein the extending step further comprises compressing a member within the second tubular structure.  
     
     
         19 . The method according to  claim 17 , wherein the extending step further comprises displacing a swaging tool in the second tubular structure.  
     
     
         20 . The method according to  claim 17 , wherein the extending step further comprises inflating a membrane within the second tubular structure.  
     
     
         21 . The method according to  claim 20 , wherein the first tubular structure includes a well screen, and wherein the inflating step further comprises sealingly engaging portions of the second tubular structure with opposite ends of the well screen, thereby constraining fluid flow through the well screen to also flow through the second tubular structure.  
     
     
         22 . The method according to  claim 17 , wherein the extending step further comprises extending only selected portions of the second tubular structure.  
     
     
         23 . The method according to  claim 22 , wherein in the extending step, the selected portions are configured so that they are less resistant to extension thereof than unselected portions of the second tubular structure.  
     
     
         24 . The method according to  claim 1 , wherein the deforming step further comprises altering a flow area disposed radially between the second tubular structure and the first tubular structure.  
     
     
         25 . The method according to  claim 24 , wherein in the deforming step, the flow area is disposed axially between an opening formed through a sidewall of the second tubular structure and an inflow area of the first tubular structure.  
     
     
         26 . The method according to  claim 1 , wherein the second tubular structure includes a flow control device disposed between external seals, and wherein the extending step further comprises extending the seals into contact with the first tubular structure.  
     
     
         27 . The method according to  claim 1 , wherein the flowpath is a tortuous path formed on the second tubular structure, and wherein the deforming step further comprises engaging the tortuous path with the first tubular structure.  
     
     
         28 . The method according to  claim 1 , further comprising the steps of positioning a sensor within the second tubular structure after the deforming step and sensing a parameter of fluid flowing through the flowpath.  
     
     
         29 . A method of controlling fluid flow through multiple well screens of a screen assembly positioned in a wellbore, the method comprising the steps of: 
 positioning a tubular structure within the screen assembly; and    deforming the tubular structure, thereby altering at least one flowpath for flow of fluid through at least one of the well screens.    
     
     
         30 . The method according to  claim 29 , wherein the deforming step further comprises altering multiple flowpaths for flow of fluid through corresponding respective ones of the well screens.  
     
     
         31 . The method according to  claim 29 , wherein the deforming step further comprises altering first and second flowpaths for flow of fluid through first and second well screens.  
     
     
         32 . The method according to  claim 31 , wherein in the altering step, the first flowpath is altered to restrict fluid flow therethrough differently from restriction to fluid flow through the second flowpath.  
     
     
         33 . The method according to  claim 29 , further comprising the step of sealingly engaging the screen assembly with the wellbore between adjacent ones of the well screens.  
     
     
         34 . The method according to  claim 29 , wherein in the positioning step the tubular structure is in a radially contracted configuration, and in the deforming step the tubular structure is deformed to a radially enlarged configuration thereof.  
     
     
         35 . The method according to  claim 29 , wherein the deforming step further comprises radially retracting the tubular structure, thereby increasing a flow area of the flowpath.  
     
     
         36 . The method according to  claim 29 , wherein the deforming step further comprises sealingly engaging the tubular structure with the screen assembly.  
     
     
         37 . The method according to  claim 36 , wherein the deforming step further comprises radially extending the tubular structure.  
     
     
         38 . The method according to  claim 37 , wherein the extending step comprises contacting the screen assembly with an outer sealing material of the tubular structure.  
     
     
         39 . The method according to  claim 38 , wherein the contacting step comprises decreasing a flow area disposed between adjacent portions of the sealing material.  
     
     
         40 . The method according to  claim 29 , wherein the deforming step comprises increasing a flow area of the flowpath disposed between portions of a sealing material of the tubular structure.  
     
     
         41 . The method according to  claim 29 , wherein the deforming step comprises changing a flow area of the flowpath disposed externally on the tubular structure.  
     
     
         42 . The method according to  claim 41 , wherein in the changing step, a width of a longitudinal channel in fluid communication with an opening formed through a sidewall of the tubular structure is changed.  
     
     
         43 . The method according to  claim 41 , wherein in the changing step, a depth of a longitudinal channel in fluid communication with an opening formed through a sidewall of the tubular structure is changed.  
     
     
         44 . The method according to  claim 41 , wherein the flowpath includes at least one restriction of the flow area, and wherein the changing step further comprises changing a resistance to fluid flow through the restriction.  
     
     
         45 . The method according to  claim 44 , wherein the restriction is formed externally on the tubular structure.  
     
     
         46 . The method according to  claim 44 , wherein the restriction is formed between portions of sealing material on the tubular structure.  
     
     
         47 . The method according to  claim 44 , wherein the restriction is formed in a channel formed externally on the tubular structure.  
     
     
         48 . The method according to  claim 29 , wherein the deforming step further comprises sealingly engaging the tubular structure with the screen assembly straddling at least one of the well screens.  
     
     
         49 . The method according to  claim 29 , wherein the deforming step further comprises outwardly extending the tubular structure.  
     
     
         50 . The method according to  claim 49 , wherein the extending step further comprises displacing a swaging tool in the tubular structure.  
     
     
         51 . The method according to  claim 49 , wherein the extending step further comprises compressing a member within the tubular structure.  
     
     
         52 . The method according to  claim 49 , wherein the extending step further comprises inflating a membrane within the tubular structure.  
     
     
         53 . The method according to  claim 52 , wherein the extending step further comprises extending selected portions of the tubular structure.  
     
     
         54 . The method according to  claim 53 , wherein in the extending step, the selected portions are configured so that they are less resistant to extension thereof than unselected portions of the tubular structure.  
     
     
         55 . The method according to  claim 52 , wherein the inflating step further comprises sealingly engaging portions of the tubular structure straddling at least one of the well screens, thereby constraining fluid flow through the well screen to also flow through the tubular structure.  
     
     
         56 . The method according to  claim 29 , wherein the deforming step further comprises altering a flow area disposed radially between the tubular structure and the screen assembly.  
     
     
         57 . The method according to  claim 56 , wherein in the deforming step, the flow area is disposed axially between an opening formed through a sidewall of the tubular structure and an inflow area of the screen assembly.  
     
     
         58 . The method according to  claim 29 , wherein the tubular structure includes a flow control device disposed between external seals, and wherein the extending step further comprises extending the seals into contact with the screen assembly.  
     
     
         59 . The method according to  claim 29 , wherein the flowpath is a tortuous path formed on the tubular structure, and wherein the deforming step further comprises engaging the tortuous path with the screen assembly.  
     
     
         60 . The method according to  claim 29 , further comprising the steps of positioning a sensor within the tubular structure after the deforming step and sensing a parameter of fluid flowing through the flowpath.  
     
     
         61 . The method according to  claim 29 , further comprising the step of outwardly deforming the screen assembly, so that the well screens contact the wellbore.  
     
     
         62 . The method according to  claim 61 , wherein the step of outwardly deforming the screen assembly is performed prior to the step of positioning the tubular structure within the screen assembly.  
     
     
         63 . A system for controlling fluid flow in a wellbore, the system comprising: 
 a well screen in the wellbore; and    a tubular structure received in the well screen, the tubular structure being deformed after reception within the well screen, thereby altering a flowpath for flow of fluid through the well screen.    
     
     
         64 . The system according to  claim 63 , further comprising a sensor positioned within the tubular structure, the sensor sensing a parameter of fluid flowing through the flowpath.  
     
     
         65 . The system according to  claim 63 , wherein the flowpath is a tortuous path formed on the tubular structure, and wherein the tortuous path is engaged with the well screen.  
     
     
         66 . The system according to  claim 63 , wherein the tubular structure includes a flow control device disposed between external seals, the seals being sealingly engaged straddling the well screen.  
     
     
         67 . The system according to  claim 63 , wherein the deformed tubular structure alters a flow area disposed radially between the tubular structure and the well screen.  
     
     
         68 . The system according to  claim 67 , wherein the flow area is disposed axially between an opening formed through a sidewall of the tubular structure and an inflow area of the well screen.  
     
     
         69 . The system according to  claim 63 , wherein the tubular structure is deformed so that it is outwardly extended relative to a configuration of the tubular structure prior to its reception within the well screen.  
     
     
         70 . The system according to  claim 69 , wherein the tubular structure includes selected portions thereof which are less resistant to outward extension thereof than unselected portions of the tubular structure.  
     
     
         71 . The system according to  claim 70 , further comprising a membrane received within the tubular structure, the membrane being inflated and thereby outwardly extending the selected tubular structure portions greater than the unselected tubular structure portions.  
     
     
         72 . The system according to  claim 70 , wherein the selected tubular structure portions straddle the well screen.  
     
     
         73 . The system according to  claim 70 , wherein the selected portions are sealingly engaged straddling the well screen, thereby constraining fluid flow through the well screen to also flow through the tubular structure.  
     
     
         74 . The system according to  claim 63 , wherein a flow area disposed radially between the tubular structure and the well screen is altered by deformation of the tubular structure after reception within the well screen.  
     
     
         75 . The system according to  claim 63 , wherein the tubular structure includes at least one selected portion thereof which is less resistant to radial displacement than unselected portions of the tubular structure.  
     
     
         76 . The system according to  claim 75 , wherein the flowpath extends across the selected tubular structure portion.  
     
     
         77 . The system according to  claim 76 , wherein an area of the flowpath is decreased by radial extension of the selected tubular structure portion.  
     
     
         78 . The system according to  claim 76 , wherein an area of the flowpath is increased by radial retraction of the selected tubular structure portion.  
     
     
         79 . The system according to  claim 63 , wherein the flowpath is disposed externally on the tubular structure.  
     
     
         80 . The system according to  claim 63 , wherein the flowpath is disposed at least partially in an external sealing material of the tubular structure.  
     
     
         81 . The system according to  claim 80 , wherein the flowpath is disposed between portions of the sealing material.  
     
     
         82 . The system according to  claim 80 , wherein the flowpath is disposed at least partially in a channel formed in the sealing material, the channel being in fluid communication with an opening formed through a sidewall of the tubular structure.  
     
     
         83 . A tool for radially deforming a tubular structure within a subterranean well, the tool comprising: 
 a housing;    axially spaced apart seals carried externally on the housing; and    a pressure generating device configured for generating a pressure differential across a portion of the tubular structure when the seals are sealingly engaged with the tubular structure axially straddling the tubular structure portion.    
     
     
         84 . The tool according to  claim 83 , wherein the pressure generating device increases fluid pressure between the seals.  
     
     
         85 . The tool according to  claim 84 , wherein the pressure generating device includes a piston responsive to a first fluid pressure in an internal passage of the housing to generate a second fluid pressure between the seals, the second fluid pressure being greater than the first fluid pressure.  
     
     
         86 . The tool according to  claim 83 , wherein the pressure generating device decreases fluid pressure between the seals.  
     
     
         87 . The tool according to  claim 86 , wherein the pressure generating device includes a piston responsive to a first fluid pressure in an internal passage of the housing to generate a second fluid pressure between the seals, the second fluid pressure being less than the first fluid pressure.  
     
     
         88 . The tool according to  claim 83 , wherein the housing has an exterior and extends on opposite sides of the seals, and further comprising a bypass passage permitting fluid flow through the housing from the exterior of the housing on one opposite side of the seals to the exterior of the housing on the other opposite side of the seals when the seals are sealingly engaged with the tubular structure.  
     
     
         89 . The tool according to  claim 83 , further comprising a stop member carried externally on the housing, the stop member limiting radial deformation of the tubular structure when the pressure generating device generates the pressure differential across the tubular structure portion.  
     
     
         90 . The tool according to  claim 89 , wherein the stop member limits radially inward deformation of the tubular structure when the pressure generating device generates the pressure differential across the tubular structure portion.  
     
     
         91 . The tool according to  claim 89 , wherein the stop member is extended outwardly when the pressure generating device generates the pressure differential across the tubular structure portion.  
     
     
         92 . The tool according to  claim 91 , further comprising a piston carried externally on the housing, the piston displacing the stop member when the pressure generating device generates the pressure differential across the tubular structure portion.  
     
     
         93 . A tool for radially deforming a tubular structure within a subterranean well, the tool comprising: 
 a generally tubular mandrel having an internal fluid passage;    an annular member carried externally on the housing, the member extending radially outward when the member is axially compressed; and    a piston responsive to fluid pressure in the fluid passage to axially compress the member.    
     
     
         94 . The tool according to  claim 93 , wherein the tool has an exterior and extends on opposite sides of the member, and further comprising a bypass passage permitting fluid flow through the tool from the exterior of the tool on one opposite side of the member to the exterior of the tool on the other opposite side of the member.  
     
     
         95 . The tool according to  claim 93 , further comprising axially spaced apart external seals carried on a housing attached to the mandrel.  
     
     
         96 . The tool according to  claim 95 , wherein an opening formed through a sidewall of the housing between the seals is in fluid communication with the mandrel fluid passage.  
     
     
         97 . The tool according to  claim 96 , further comprising a check valve permitting fluid flow from the opening to the mandrel fluid passage, but preventing fluid flow from the mandrel fluid passage to the opening.  
     
     
         98 . The tool according to  claim 96 , further comprising a sensor, the sensor sensing a property of fluid flowing from the opening through the mandrel fluid passage.  
     
     
         99 . The tool according to  claim 98 , wherein the sensor is a flowmeter.  
     
     
         100 . A method of controlling fluid flow through a first tubular structure positioned in a well, the method comprising the steps of: 
 installing a line externally on a second tubular structure having a sealing material carried externally thereon, the line extending across the sealing material;    positioning the second tubular structure within the first tubular structure in the well; and    sealingly engaging the sealing material with the first tubular structure.    
     
     
         101 . The method according to claim  100 , wherein in the installing step, the line is installed in a channel formed externally on the sealing material.  
     
     
         102 . The method according to claim  100 , wherein in the sealingly engaging step, the line is sealingly engaged with the sealing material.  
     
     
         103 . The method according to claim  100 , wherein in the sealingly engaging step, the line is compressed between the sealing material and the first tubular structure.  
     
     
         104 . The method according to claim  100 , wherein in the installing step, the sealing material is part of a flow regulating portion of the second tubular structure, the sealing material having deformable flow channels formed thereon for adjusting a flow area therethrough.  
     
     
         105 . The method according to claim  104 , wherein the installing step further comprises installing the line in an external channel positioned between adjacent ones of the flow channels.  
     
     
         106 . The method according to claim  100 , wherein the installing step further comprises interconnecting the line with a sensor external to the second tubular structure, and further comprising the step of establishing communication via the line between a remote location and the sensor on opposite sides of the sealing material after the sealingly engaging step.