Downhole systems and methods for removing particulate matter from produced fluids

Abstract

The current invention provides methods and systems for producing fluids, substantially free of particulate matter, from subterranean formation. The current invention is particular suitable for use in uncased boreholes penetrating unconsolidated subterranean formations.

What is claimed is:  
     
         1 . A downhole system for removing particulate matter from fluids produced from a subterranean formation comprising: 
 an expandable screen, in the expanded state, located within a borehole penetrating at least a portion of the subterranean formation;    a substantially solid permeable composition binding the screen to the walls of the borehole.    
     
     
         2 . The system of  claim 1 , wherein the permeable composition has a permeability rating between about 0.1 darcies and about 400 darcies.  
     
     
         3 . The system of  claim 1 , wherein the permeable composition has a permeability rating between about 0.1 and about 100 darcies.  
     
     
         4 . The system of  claim 1 , wherein the permeable composition is selected from the group consisting of permeable cement, resin-coated particulate and mixtures thereof.  
     
     
         5 . The system of  claim 1 , wherein the permeable composition comprises from about 10 to about 90% by weight permeable cement and from about 10 to about 90% by weight resin-coated particulate.  
     
     
         6 . A downhole system for removing particulate matter from fluids produced from a subterranean formation comprising: 
 a perforated casing located within a borehole penetrating at least a portion of the subterranean formation;    an expandable screen located within the perforated casing; and,    a substantially solid permeable composition located within the perforations of the perforated casing.    
     
     
         7 . The system of  claim 6 , wherein the permeable composition has a permeability between about 0.1 darcies and about 400 darcies.  
     
     
         8 . The system of  claim 6 , wherein the permeable composition has a permeability rating between about 0.1 and about 100 darcies.  
     
     
         9 . The system of  claim 6 , wherein the permeable composition is selected from the group consisting of permeable cement, resin-coated particulate and mixtures thereof.  
     
     
         10 . The system of  claim 6 , wherein the permeable composition comprises from about 10 to about 90% by weight permeable cement and from about 10 to about 90% by weight resin-coated particulate.  
     
     
         11 . A method for producing fluid from a subterranean formation comprising the steps of: 
 a) extending a borehole from the earth's surface into at least a portion of the subterranean formation;    b) placing a casing within the borehole;    c) perforating the casing;    d) placing a curable composition in the resulting perforations;    e) allowing the curable medium to cure thereby forming a permeable composition; and,    f) producing fluid from the subterranean formation through the permeable composition.    
     
     
         12 . The method of  claim 11 , wherein the curable composition has a permeability rating between about 0.1 and 400 darcies when cured and is selected from the group consisting of permeable cement, resin-coated particulate and mixtures thereof.  
     
     
         13 . The method of  claim 11 , wherein the curable composition has a permeability rating between about 0.1 and 100.0 darcies when cured.  
     
     
         14 . The method of  claim 11 , including the step of selecting a curable composition having a permeability rating when cured between about 10 to about 20 times greater than the permeability rating of the subterranean formation.  
     
     
         15 . The method of  claim 11 , further comprising placing an expandable well screen within the casing in the region of the perforations and expanding the expandable well screen.  
     
     
         16 . The method of  claim 11 , wherein the curable composition is selected from the group consisting of permeable cement, resin-coated particulate and mixtures thereof.  
     
     
         17 . A method for producing fluid from a subterranean formation comprising the steps of: 
 a) extending a borehole from the earth's surface into at least a portion of the subterranean formation;    b) placing a casing within the borehole;    c) perforating the casing;    d) placing a curable composition within the borehole;    e) placing an expandable well screen in the curable composition;    f) expanding the expandable screen;    g) allowing the curable composition to cure thereby forming a permeable composition; and,    h) producing fluid from the subterranean formation.    
     
     
         18 . The method of  claim 17 , wherein the curable composition has a permeability rating between about 0.1 and 400.0 darcies when cured.  
     
     
         19 . The method of  claim 17 , wherein the curable composition has a permeability rating between about 0.1 and 100.0 darcies when cured.  
     
     
         20 . The method of  claim 17 , wherein the curable composition is selected from the group consisting of permeable cement, resin-coated particulate and mixtures thereof.  
     
     
         21 . The method of  claim 17 , wherein the expandable screen is encased within the curable composition following expansion.  
     
     
         22 . The method of  claim 17 , including the step of selecting a curable composition having a permeability rating when cured between about 10 to about 20 times greater than the permeability rating of the subterranean formation.  
     
     
         23 . A method for producing fluid from a subterranean formation comprising the steps of: 
 a) extending a borehole from the earth's surface into at least a portion of the subterranean formation;    b) placing a casing within the borehole;    c) perforating the casing;    d) placing a curable composition within the resulting perforations;    e) placing an expandable well screen in the portion of the borehole adjacent to the perforations;    f) expanding the expandable screen;    g) allowing the curable composition to cure thereby forming a permeable composition; and,    h) producing fluid from the subterranean formation.    
     
     
         24 . The method of  claim 23 , wherein the curable composition has a permeability rating between about 0.1 and 400.0 darcies when cured.  
     
     
         25 . The method of  claim 23 , wherein the curable composition has a permeability rating between about 0.1 and 100.0 darcies when cured.  
     
     
         26  The method of  claim 23 , wherein the curable composition is selected from the group consisting of permeable cement, resin-coated particulate and mixtures thereof.  
     
     
         27 . The method of  claim 23 , wherein the expandable screen is encased within the curable composition following expansion.  
     
     
         28 . The method of  claim 23 , including the step of selecting a curable composition having a permeability rating when cured between about 10 to about 20 times greater than the permeability rating of the subterranean formation.  
     
     
         29 . A method for producing fluid from a subterranean formation comprising the steps of: 
 a) extending a borehole from the earth's surface into at least a portion of the subterranean formation;    b) placing an expandable well screen in the borehole;    c) placing a curable composition within the borehole;    d) expanding the expandable screen;    e) allowing the curable composition to cure thereby forming a permeable composition; and,    f) producing fluid from the subterranean formation.    
     
     
         30 . The method of  claim 29 , wherein the curable composition has a permeability rating between about 0.1 and 400.0 darcies when cured.  
     
     
         31 . The method of  claim 29 , wherein the curable composition has a permeability rating between about 0.1 and 100.0 darcies when cured.  
     
     
         32 . The method of  claim 29 , wherein the curable composition is selected from the group consisting of permeable cement, resin-coated particulate and mixtures thereof.  
     
     
         32 . The method of  claim 29 , wherein the expandable screen is encased within the curable composition following expansion.  
     
     
         33 . The method of  claim 29 , including the step of selecting a curable composition having a permeability rating, when cured, between about 10 to about 20 times greater than the permeability rating of the subterranean formation.  
     
     
         34 . The method of  claim 29 , wherein the permeable composition of step c) further comprises a filter cake breaker.  
     
     
         35 . A method for producing fluid from a subterranean formation comprising the steps of: 
 a) extending a borehole from the earth's surface into at least a portion of the subterranean formation;    b) placing a curable composition within the portion of the borehole penetrating the subterranean formation;    c) placing an expandable well screen in the permeable composition;    d) expanding the expandable screen;    e) permitting the permeable composition to cure thereby forming a permeable composition; and,    f) producing fluid from the subterranean formation.    
     
     
         36 . The method of  claim 35 , wherein the curable composition has a permeability rating between about 0.1 and 400.0 darcies when cured.  
     
     
         37 . The method of  claim 35 , wherein the curable composition has a permeability rating between about 0.1 and 100.0 darcies when cured.  
     
     
         38 . The method of  claim 35 , wherein the curable composition is selected from the group consisting of permeable cement, resin-coated particulate and mixtures thereof.  
     
     
         39 . The method of  claim 35 , wherein the expandable screen is encased within the curable composition following expansion.  
     
     
         40 . The method of  claim 35 , including the step of selecting a curable composition having a permeability rating when cured between about 10 to about 20 times greater than the permeability rating of the subterranean formation.  
     
     
         41 . The method of  claim 35 , wherein the permeable composition of step b) further comprises a filter cake breaker.