Technical Field

The invention relates to a pipe section for use in a string of pipe to be deployed into a subsurface well. The invention further discloses various methods for use of the pipe section, such as method for connecting two or more pipe sections, a method for integrating a sand screen to the pipe section and a method for integrating a perforating gun to the pipe section.

This includes

- Combining materials of various properties to achieve a composite material suitable for downhole deployment and applications

- Method for integrating cables and control line into composite pipe and connections.

- Method for tracking and unique identity individual sections of fiber composite pipe using RFID.

The pipe section may be used in several further configurations in the pipe string, including

- Connecting two or multiple sections of (carbon fiber) composite pipe into a string of pipe and deployed into a subsurface well

- Method for manufacture sand screen from composite material.

- Method for packer with feed through.

Background Art

A composite material that includes carbon fiber is becoming an attractive alternative material to high alloy steel for use in fabrication of pipe and for completion equipment that is to be deployed in subsurface wells. fiber composite is especially becoming an attractive material because of: the low weight and high strength the positive development in cost compared to steel alloys the manufacturing process lends itself to integrating completion equipment into a fiber composite pipe the manufacturing process lends itself to integrating cables and control line to fiber composite pipe. it is corrosion resistant methods for deployment into a well is possible.

Carbon or other fiber composite material can on the other hand be a challenging material due to several factors: the mechanical strength is dependent on the orientation of the fibers.

The design of suitable pipe connections is less developed than then for alloy steel

Figure 1a discloses a typical prior art pipe string 100 that is deployed into a well in two parts 101 , 102. The configuration comprises a lower completion with screen 103 and an open hole packer 104 that is suspended to the casing with a packer 108. The second string 102 have a tube extension into the lower completion and a dual flow path, inside and outside the tube extension 106. There are no control line at this depth. The second string is suspended from the top of the well with a tubing hanger 107 and secured to the casing with a feed through packer 110. The feed though packer 110 allow a hydraulic or fluid line 105 to extend from the surface to control two valves placed below the feedthrough packer 108.

In this configuration the well design is limited to control of two reservoir zones Z1 , Z2 that flow in the completion from inside and outside the tube extension.

The conventional method of constructing the well is to drill the bore hole in sections of the well and to stabilize that last drilled section with steel casing and cement before drilling the next section, one size smaller than previous section. The final hole-section is drilled through the reservoir to the total depth (TD) of the well. The reservoir hole section is commonly left open, without any casing. Once the drill bit has reached TD, drilling fluid is pumped down the drill string and back to surface until the hole is free of drill solids. Then new fluid is pumped into the well pushing the dirty drilling fluid out. The new fluid (screen fluid) is designed to not plug screen. For long horizontal wells, this hole cleaning and fluid displacement is time consuming and expensive.

The lower half of the production tubing is pushed in place with heavy drill pipe and secured in the well with a packer set deep in the deepest casing 108. The horizontal reservoir section is not drilled longer that it is possible to push in place this lower completion string. This length is a well design constraint. Control lines and flow control valves are not usually part of lower completion as the risk for damage during installation is too great. Now the top part of the completion string can be installed and secured in place with the tubing hanger at the top end and another packer nearer the bottom end. The second packer can be set by pressurizing the top completion string against the closed valve below the packer (110). To accommodate zone flow control and pressure monitoring, an inner pipe extends from top completion and deep inside the lower completion. With this configuration, it is difficult to control more than two zones.

To produce from (or injected into the well) the drilling fluid filter-cake left on borehole wall is removed by clean-up flow or by chemical treatment.

LIS20130098602 describes a production tubing for oil wells comprising a plurality of cylindrical elements of composite material. The elements are joined together by male/female connections. Steel connections are detailed but mixing composite material with steel adds complexity to the design.

The male/female connection requires fabrication of an end piece made into the female or male design. This connection parts are exposed to damage from final manufacture and to installation at well site (under transport).

WO1 988009898 further describes a connection for tubular equipment made of composite material, where each end of the tube has a fitted glued inner sleeve a and a glued outer sleeve. The presently filed patent application addresses the challenges of the prior art publication and exploits the benefits of composite material. This is performed in a series of synergetic inventions.

Summary of invention

A pipe section for use in a string of pipe to be deployed into a subsurface well. The invention being distinctive in that the pipe section comprises a core made of a composite material, a carbon fiber layer arranged surrounding the core to form a composite laminate, and an outermost and/or innermost layer of a composite material arranged on the surface of the composite laminate for protection of the composite laminate.

The invention further relates to a method for connecting two or more pipe sections according to any of the preceding claims, into a string of pipes that is deployed into a subsurface well, wherein each first section of pipe has an upset ring secured to a first end of the respective first pipe section, wherein the method comprises the steps of a) lowering a first pipe section until the upset ring aids in handling of pipe sections and prevents the pipe string from falling into the well by the shoulder of a rotary table, b) slipping a coupling sleeve over the pipe end, c) placing an elastomer ring inside the coupling sleeve, d) lowering a second pipe section into the coupling sleeve to mate with the first pipe end of the pipe section installed in the rotary table, e) allowing the elastomer ring to compress between the respective pipe end sections of the connected pipe sections, f) applying an adhesive material between the coupling sleeve and the pipe sections to permanently securing the pipe sections to each other.

The invention further relates to a method for integrating a sand screen to a pipe section, to be deployed in a pipe string in a subsurface well, wherein the method comprises the steps of a) cutting a through hole in the pipe section, b) arranging an inflow control device above the through hole c) arranging an end ring around the pipe section a distance away from the inflow control device, d) arranging one or more mesh layers around the periphery of the pipe section in the area between the inflow control device and the end ring, arranging a load bearing pipe box on the outside of the features of steps b)-d). This provides a rotation of the sand screen from the composite materials, while at the same time the sand control mesh layers are protected by the external load bearing pipe.

Embodiments of the pipe section and methods are set out in the accompanying dependent claims.

The invention also describes a pipe system for connection of two or more pipe sections into a string of pipe and deployed into a subsurface well. Each pipe section is made of a composite material and having an upset ring secured to an end of the respective pipe section allowing the pipe section to be suspended from a rig rotary table, the system further comprises a coupling sleeve adapted to be slipped at least partly over the pipe section at the end having the upset ring for connection with a further pipe section.

The coupling sleeve comprises at least one fluid port arranged at the outside periphery of the coupling sleeve for connecting the pipe sections firmly together.

The coupling sleeve is made of a composite material or a composite compatible resin.

The coupling sleeve may have a tapered shape to reduce the pipe stress at the connection point.

The pipe system comprises an elastomer ring adapted to be arranged between pipe section end in two connected pipe sections to prevent mortar material from the pipes to enter the interior of the pipe string.

Each pipe section may have an integrated cable, such as electrical power cable or a control line. The cable or control line of cable may be embedded into the pipe section or laid in an intention arranged longitudinally at the surface of the pipe section.

The upset ring may have a square edge.

Use of a pipe section according to any of the claim, as a section in a string of pipe to be deployed into a subsurface well

Brief description of drawings

Figure 1 a shows a typical prior art completion of a subsea well pipe string,

Figure 2a-8b shows the steps of connecting two composite pipe sections together into a string of pipe for deployment into a subsurface well,

Figure 2a shows a section of a composite pipe,

Figure 2b shows the cross-section of the composite pipe section including control line electrical cable,

Figure 3a shows the section of the composite pipe with the upset ring attached,

Figure 3b shows the section of the composite pipe lowered into the well and resting on the rotary table,

Figure 4 shows the composite material coupling sleeve arranged over the pipe,

Figure 5 shows a connection elastomer ring arranged inside the coupling sleeve,

Figure 6 shows the second pipe section lowered vertically over the rig rotary table and slipped into the coupling sleeve,

Figure 7 shows the section pipe section lowered towards the first pipe section,

Figure 8a shows the introduction of a material mortar through fluid ports in the sleeve to permanently secure two adjacent pipe sections together,

Figure 8b shows a rig elevator system for suspending a second pipe section to be lowered onto the pipe string,

Figure 9a-9b shows a second embodiment of the composite pipe section with an indentation for receiving an electrical cable/control line,

Figure 9c-9e shows an embodiment of the method for connecting two composite pipe sections with integrated control line or electrical cable, together into a string for deployment into a subsurface well,

Figure 9f -9k shows a further embodiment of the method for connection two composite pipe section together into a string for deployment into a subsurface well, where the cable or control line is a continuous cable or control line,

Figure 10a-16 shows steps of integrating a sand control filter with a section of composite pipe,

Figure 10a shows the manufacture of a composite pipe on a cylindrical molding,

Figure 10b shows a through hole in the composite pipe,

Figure 11 shows an inflow control device (ICD) ring that is mounted on the outside of the composite pipe section and a solid end ring arranged a distance apart from the ICD ring,

Figure 12 shows a drainage mesh layer that is wrapped on the outside of the inner sleeve between the ICD ring and the end ring,

Figure 13 shows a sand filter mesh layer that is wrapped on the outside of the drainage mesh layer and secured to the ICD ring and end ring,

Figure 14 shows a distribution mesh layer wrapped on the outside of the sand filter mesh layer,

Figure 15 shows a load bearing pipe box arranged outside of the mesh layer encapsulating the layers of mesh, ICD and the inner sleeve,

Figure 16 shows the removal of the cylindrical molding,

Figure 17-19 shows the sequential steps for integrating a perforating gun to the composite pipe for use in a subsurface well,

Figure 17 shows the manufacture of a composite pipe on a cylindrical molding,

Figure 20-22 shows a pipe section according to the invention with a packer and a control line and/or an electronic cable arranged within the pipe section,

Figure 1 b shows an embodiment of a completion of a subsea well string with pipe section and pipe section configurations according to the present invention. Detailed description of the invention

In general, the pipe section 3 according to the invention described is made of composite material.

A pipe section 3, 40 according to the invention is further illustrated in figure 2a and 2b. The pipe section may be a pipe section without electrical cable or control line, referred to as 3. The pipe section may also have one or more control line or electrical cables 42 embedded in the pipe section (figure 2b) or laid in an indentation 41 in the surface of the pipe section (figure 9a). Both the pipe sections with control line or electrical cable are referred to by reference number 40.

The pipe section 3, 40 disclosed in figure 2a having end sections 3a, 3b. The pipe end section 3a, 3b having a uniform outer and inner diameter. In the manufacturing process it is not possible to obtain a perfectly uniform outer and inner diameter. However, the outer and inner diameter of the pipe end sections 3a, 3b are as consistent and uniform as the manufacturing process allows.

In conventional pipe sections of alloy steel used in downhole well application, the mechanical properties are uniform throughout the cross-sectional area. The external mechanical properties of the alloy steel pipes are favorable for downhole deployment and applications. The steel material is rugged, impact resistant, sufficiently ductile, and does fray if subjected to abrasion.

Furthermore, you can use penetrating dies to grip the pipe.

The above properties may however not always be the case for a pipe section 3 made of composite material. The material chosen for strength in a composite pipe section 3, 40 for instance carbon fiber is embedded into a plastic matrix material and designed and manufactured as a composite laminate 2a, 2b, 2c with each carefully assigned properties. As shown if figure 2b, the composite laminate may be formed by a middle space layer hereinafter called core 2b. The core may be made of thermoplastic material, such as polyethylene or polypropylene. On both sides of core 2b there may be arranged an outer and inner carbon or glass fiber layer 2a, 2c set in an epoxy type plastic. When the pipe section normally is used as casing to support the borehole, the properties of steel allow drilling through the casing with a rotating drilling string and packers that can be installed the packer slips anchoring into the casing inner diameter.

Composite pipes are recognized as strong due to fiber reinforcement 2a, 2c, but they may suffer from perception by end user. The composite laminate 2a, 2b, 2c may thus not be sufficient rugged, impact resistant, nor ductile for some parts of the downhole deployment and applications. The composite laminate 2a, 2b, 2c may also in same case fray when subjected to abrasion. Also, ones do not think to use penetrating dies on carbon epoxy pipe.

In the pipe section according to the invention, there is therefore arranged an outermost layer 3c and/or an innermost layer 3d of a further composite material such as thermoplastic to serve as a protective skin for the fiber reenforced composite pipe 3. Smaller diameter pipe may only need thus layer on the outside. The outermost layer and/ or the innermost layer 3c, 3d offers protection to the load bearing layers within the pipe.

The material used to build this protective outer skin layer and/or inner protective skin layer 3c, 3d can be of high-density polyethylene (HDPE), a cross-linked polyethylene (PEX) or polyethylene terephthalate to mention a few options.

It is important that the material used must be rugged, impact resistant, sufficiently ductile, and fray if subjected to abrasion. Furthermore, the material chosen may be suitable to penetrating dies to grip the pipe.

As an option, a high-density polyethylene (HDPE) pipe can be made using about 40 percent recycled HDPE resin that was originally used in a wide variety of applications for the outer and/or inner layer. Finding a second life for plastic could be key to reducing plastic pollution and increasing the supply of recycled HDPE resin for the pipe industry. The core layer can also be built from recycled material.

It is to be noted that the pipe section 3, 40 with such outermost and/or innermost layer may be used in all subsequent embodiment described below. In an embodiment of the pipe section there may be arranged one or more integrating control lines and/or one or more electrical cables. Figure 2b shows the embodiment with embedded electrical cable and/or control line. However, the pipe section with the shown layer of figure 2b is also applicable without a control line or electrical cable.

The conventional method for installing cables and control line in wells with steel alloy pipe and conventional sand screen is by securing the cables and control line on the outside of the pipe and securing it with clamps. Cables, control line and clamps are brought separately and installed at the installation site. The installation is on the outside of the pipe and secured with clamps. The known methods for providing the cable protection during deployment, involves manufacturing screen with a longitudinal groove in the external surface to offer mechanical protection to the cable during deployment into a subsurface well. This method is for instance known from NO325203.

The integration of the cables and/or control line 42 internal to the composite pipe section 40 has the following benefits:

- the cable or hydraulic control line can be built into the composite pipe so that it is completely embedded and is internal to the pipe wall. The inner and outer surface or the composite pipe will protect and secure the cable or hydraulic control line in place during deployment and life of service. The cable or hydraulic control line is protected by the composite pipe,

- the cable or hydraulic control line is connected at each composite pipe connection. The method of connecting is integrated with the method of connecting the composite pipe,

- the product of cable or hydraulic control line is integrated into the product of composite pipe at manufacturing, there is no added cable or hydraulic control line or clamps at the installation site.

The benefits of integrating cable and/or hydraulic control line are also applicable for the sand screen configuration, perforating gun configuration and the packer configuration that uses the pipe section 3 with integrated control line and/or electrical cable as it allows means of control from surface via the integrated control line and/or electrical cable.

The pipe section and integrating a cable and/or hydraulic control line into the composite pipe section 40 is illustrated in figure 2b and figure 9a and 9b.

The figure 9a shows the pipe section 40 with a longitudinal indentation 41 in the pipe section 40 to allow control lines and/or cables 42 to be placed continuously on the outside of the pipe section and still be protected by the pipe section.

The control line and/or electrical cable 42 may be performed in a longitudinal or in a spiral pattern. There may also embedded more than one cable and/or control lines in the pipe section 40.

The pipe composite ends 3a, 3b are further cut to provide a uniform circular end shape, suitable for connection with a further pipe section 3’ etc.

The cable and/or hydraulic control line may also be arranged in the same indentation 41 and prepared for mating with cable and/or control lines of nearby pipe sections 3’. This will be illustrated in figures 9f-9k.

In the following, there will be described pipe section configurations 50, 10, 20, 30, 70 where the composite pipe section 3, 40 according to the invention is used as a base.

The figure 3a-8 shows a method for connecting two or multiple sections of composite pipe section 3, such as carbon fiber into a string of pipe and deployed into a subsurface well.

As with conventional pipes of steel alloy, it is advantageous that a string of composite pipe sections also can be manufactured and transported to well site location as individual pipe sections 1 .

The benefits of this are among others that there will be more flexible manufacturing process with less pipe to discard with any manufacturing defect, the pipe section that are more easily transported to the well location the pipe sections of various properties can be assembled at the well site into a string that is spaced out according to the well design and subsurface formation properties.

For the benefits to be realized, the method of connecting sections of pipe must meet the following functional requirements: it must be cost effective and result in connections that have consistent performance properties, the connector has feature that allows lowering the connected string into the wellbore, the connector performance properties in tensile strength, compression strength and torsional strength that are near equal to that of the pipe, the connector yield performance properties related to containing fluid pressure that is consistent, predictable, and with performance rating that is near equal to that of the pipe.

The known present solutions meet the functional requirements by integrating a steel alloy connection to the composite pipe. However, this will compromise the corrosion resistance advantage compared to a solution made completely from composite.

For the simplicity of explanation, the description and figures 3a-8b refer to a first pipe section 3 and a further or second pipe section 3’. These pipe sections 3, 3’ are generally equal but are referred to by different names to illustrate the connection of a subsequent or adjacent pipe section 3’ to a pipe section 3 already arranged in the well.

Figure 3a shows a section of a first composite pipe 3 with a first pipe section end 3a and a second pipe section end 3b according to the invention.

Figure 3b shows an upset ring 8 arranged at the first pipe end section 3a. The upset ring 8 is arranged a suitable distance from the first pipe end section 3a as shown in the figure. The distance may be referred to as a connection distance d that is large enough to provide a secure connection between two pipe ends. The distance may for instance be 50 cm, but other distances are also possible. The distance d may be between that of the pipe diameter of as much as 10 times the pipe diameter, dependent on connection mechanical strength requirements. The upset ring 8 provides a localized increasing in the pipe diameter on the outside of the pipe section 3. The increase may be for instance between 1-2 cm in a radial distance out from the outer surface of the pipe section 3. This further provides a square edge 2a on the outside surface of the pipe section 3 along a circumferential periphery of the pipe section 3.

The upset ring 8 may be of any material, for instance composite, such as thermoset plastic. The upset ring may also be steel with magnetic characteristics for later identification of connection location.

The upset ring 8 may further be integrated to the pipe as part of the pipe manufacturing process as an integrated element to the pipe section 3. The upset ring 8 may also be a separate element that is attached to the pipe section 3 in the manufacturing process. In both cases, the pipe section 3 is shipped to the well site location with the upset ring 8 permanently secured.

Figure 4 shows the first pipe section 3 installed at a well site. A second pipe end section 3b is lowered into the well as shown in the figure. The upset ring 8 is resting on a rig rotary table 9. More specifically the upset ring 2 is resting on a shoulder of the rotary table 9. This prevents that pipe section 3 to fall into the well. The first pipe end section 3a is in this position facing upwardly above the well.

Figure 4 further shows a coupling sleeve 4. The coupling sleeve 4 is slipped over the pipe section 3 resting in the rig rotary table. The coupling sleeve 4 is made of a composite material, such as the pipe itself but with internal fiber orientation suited for mechanical load at connection points.

The coupling sleeve 4 is guided over the first pipe section end 3a and stops on the top of the upset ring 8. The length of the coupling sleeve 4 can be about twice the connection distance d.

The coupling sleeve 4 may further be equipped with at least one radial hole 5 with nipple. The nipple may also be referred to as grease nipple. The hole with nipple 5 serves as a fluid port 5 on the outside diameter of the coupling sleeve 4. There are preferably arranged a plurality of fluid ports 5 on the outside of the coupling sleeve 4. The fluid ports 5 are in this case preferably arranged evenly spaced on the outside diameter.

The coupling sleeve 4 may further have thinner wall thickness and smaller outer diameter towards the ends. This means that the coupling sleeve may be tapered at the ends (not shown). This provides a reduction in the stress concentrations in the pipe section at coupling sleeve end points.

Figure 5 shows further an elastomer ring 6 that is placed inside the coupling sleeve 4. The elastomer ring 6 is resting on the first pipe end section 3a of the first pipe section 3.

The figure further discloses that there may be arranged several fluid ports 5 around the diameter of the coupling sleeve 4.

Figure 6 and 7 shows a second pipe section 3’ lowered onto the first pipe section 3 to be connected to the first pipe section 3.

The second pipe end 3b’ of the second pipe section 3’ is resting on the elastomer ring 6 that is already in place on the first pipe section 3.

The pipe ends 3b’, 3a of the first and second pipe section 3, 3’ will then meet and compress the elastomer ring 6

The elastomer ring 6 prevents further material mortar to enter the inner diameter of the assembled pipe.

Figure 8a shows the further the permanent securing of the coupling sleeve 4 to the pipe sections 3, 3’. This is performed by applying connection material mortar, such as a synthetic polymer glue, a hot melt thermoplastic glue or two compound thermoplastic set resin into the at least one fluid port 5. The excess mortar material will exit the upper side of the coupling sleeve 4 and is cleaned off. The upper side is referred to the side of the coupling sleeve facing away from the upset ring 2 when installed between two pipe sections 3, 3’

The jointed string can be lifted by rig elevator system (fig. 8b),

The string is further lowered until the section pipe section rests by the upset ring on the shoulder of the rig rotary table 9. The process for attaching a further pipe section onto the lowered second pipe section is then repeated.

Figure 8b shows the how the second pipe section 3’ is suspended from a rig elevator system 60 by use of the upset ring 8’. The rig elevator system 60 comprises rig elevator 61 adapted to be positioned below the upset ring 8’ to suspend the pipe section 3’ as shown in the figure 8b. The rig elevator 61 is further suspended from the drilling top drive 63 through a pair of bails 62.

Further embodiments of a method for connecting two or a multiple sections of composite pipe sections 40 into a string of pipe and deployed into a subsurface well, is shown in the figure 9a-9k. Both embodiments described method where a pipe section with electronical cable or control is used.

Figure 9a and 9b shows thus respectively the pipe section 40 with control line and/or electrical cable 42 or groove 41 for use respectively in the methods shown in 9f-9k. The pipe section 40 with upset ring 8 is referred to by reference number 50.

The first method describes a method where the pipe sections 40, 40’ have embedded internal electrical cable or control line 42, 42’.

It is to be noted that the method follows the same steps as the method as described in figure 3b-8b with the additional step combining cable ends 42a, 42’ embedded in the respective pipe sections 40, 40’.

Figure 9c shows the connection of the cable ends 42a, 42b of the composites pipe sections 40, 40’. Both pipe sections 40, 40’ have respectively a twisted pair of electrical conducting cable built internal to the pipe section wall. Near the respective ends of the pipe sections, the ends 42a, 42a’ of the cables or control line 42, 42 are routed to the external pipe section surface and are exposed.

Figure 9d shows that the coupling sleeve 4 is lifted so that the cable or control lines 42a, 42a’ are exposed. The cable ends 42a, 42’ may then be jointed with conventional electrical cable connection equipment.

The coupling sleeve 4 may thereafter be lowered onto the connection. The coupling sleeve 4 provides room for the electrical cable to be on the outside of the pipe section 40, 40’ but inside the coupling sleeve 4.

The coupling sleeve is then secured be mortar material as described in relation to figure 8a.

The second method shown in figure 9f-k is also similar to the method described in fig 3a-8, but in this embodiment, there is a continuous control line and/or electrical cable external to the pipe section yet integrated in an intendant 41 of the pipe section 40.

The grove or intendant 41 in the pipe section 40 allows the control line and/or electrical cable to be installed in the pipe section 40 and remain flush while feed into the well from a spooling unit 64, 63, 62. The spooling unit 64, 63, 62 is shown in the figure 9f-9i as a feeder 64 for feeding the control line into the pipe string. In addition, there may be one or more sheaves 63, 62 to facilitate the feeding of the control line and/or electrical cable 61 .

For the pipe sections 40, 40’ with continuously arranged cables and control lines 61 , there must in addition be a longitudinal cut in the coupling sleeve to allow control lines and cables to pass to the inside. The groove or intendant 41 provides that the control line and/or electrical cable 61 remains flush with the pipe section 40.

As for the continuous cable or hydraulic control line, the coupling sleeve 4 may also be made up by multiple composite split rings that may be slipped over the pipe resting in the rig rotary table 9. The split in the coupling sleeve allows placement, despite the presence of the continuous cable or hydraulic control line. The first split ring 4a stops on the top of the upset ring 8. Each split ring is given a slight rotation to ‘close’ the grove in what becomes the coupling sleeve 4. The length of the coupling sleeve is about twice the connection distance. The composite material coupling sleeve 4 is equipped with evenly spaced radial hole with nipples (grease nipples) that serve as fluid ports 5 on the outside diameter. Each split ring 4a can have mating castellations to facilitate coming together as a ‘one piece’ coupling sleeve 4.

This is performed compensate for the weakening structural strength of the coupling sleeve. The final coupling sleeve is thus an aggregate of pieces with a non-continuous side cut and structural strength with the connection material mortar (composite resin) keeping all pieces together

The method is otherwise equal to the method described in figure 3b-8b. The pipe section 3, 40 may also be used to integrate a sand screen to the pipe section. The method for integrating a sand screen into the pipe section is shown in the figures 10a-16.

The conventional to method to manufacture sand screen from steel alloy is to build on steel alloy base pipe. The base pipe is covered with layers of metal mesh secured on the outside of the base pipe. The final outside layer is often a metal shroud that offers protection to the metal mesh. The base pipe is the load bearing component in the sand screen product. Use of steel alloy material allows securing the mesh and protective shroud onto the base pipe with welded end-rings.

However, there are several disadvantages with this, for instance

- the steel alloy grades that are sufficiently corrosion resistant to common wells fluid are cost prohibitive and carbon emission heavy in the manufacturing process from iron ore to final product,

- the sand screen product is heavy and therefore the drag from pushing the screen down to final depth in a long and highly deviated is a constraint to the well design,

- the risk of mechanical damage to the metal mesh providing the sand control when running in hole with the screen is not entirety mitigated with this design. Common practice is therefore to not rotated the completion string when running in hole, even when string rotation would help in deploying the screen to the desired depth in extended reach wells.

A sand screen from composite materials offers the follow benefits,

- the composite materials are cost efficient corrosion resistant to common wells fluid, especially at modest temperature and high CO2 concentrations. The manufacturing process from fibers and resin is less carbon intense than streel,

- the sand screen product is light and therefore the drag from pushing the screen down to final depth in a long and highly deviated is a lesser constraint to the well design,

- the risk of mechanical damage to the mesh layers providing the sand control can be mitigated and largely eliminated by composite screen design. Rotation when running in hole with the screen is possible and this reduced drag end extend the deployment reach,

- use of inflow control devices has come commonplace for long screen strings; this is also possible with composite screen.

Figure 10a discloses a pipe section 3, 40 that is built on a cylindrical molding 11 . An inner sleeve 3c of the pipe section 3, 40 is contacting the cylindrical molding 11. The pipe section 3, 40 is made of a composite material, such as carbon fiber reinforced thermoset plastic but can also be any other material that is resistant to well fluid such as high-density polyethylene (HDPE), a crosslinked polyethylene (PEX) or polyethylene terephthalate.

Figure 10b discloses a radial through-hole 12 in the pipe section 3, 40. The through-hole 12 is cut in the inner sleeve 3a and will be the port of an inflow control device 13.

Figure 11 shows an inflow control device (ICD) ring 13 that is mounted on the outside of the pipe section 3, 40. The inflow control device ring 13 is arranged so that it encloses the through hole 12 in the pipe section 3, 40.

A further end ring 15 is mounted on the outside of the pipe section 3, 40. The end ring 15 is arranged a distance from the ICD housing 13 as shown in the figure 11. The end ring 15 has the same outer diameter as the ICD housing 13. It is further made as a solid ring.

The sidewall of the inflow control device housing 13 facing the end ring has one or more openings 14. The one or more openings is arranged to provide a flow between the outside of the pipe section 3, 40 and the interior of the pipe section 3, 40.

The inflow control device housing 13 may preferably be of composite material. This may be of the same material as the pipe section 3, 40 or high-density polyethylene or Ultra-high-molecular-weight polyethylene.

Figure 12 further discloses a drainage mesh layer 16. The drainage mesh layer 16 is wrapped on the outside of the pipe section 3, 40. The drainage mesh layer 16 is more preferably arranged between the ICD housing 13 and the end ring 15 as shown in the figure. The drainage mesh layer 16 is arranged so that the flow in the drainage mesh is adapted to enter the ICD housing 13.

The drainage mesh layer 16 may also be of a composite material, such as polyamide threads, plastic rods or the conventional choice, alloy steel.

Figure 13 shows a sand filter mesh layer 17 that is wrapped on the outside of the drainage mesh layer 16. The filter mesh layer is further secured with a sealing bond to the outside diameter of the ICD housing 13 and the end ring 15. The sealing bond may be performed by a composite resin the is applied between the sand filter mesh layer 17 and respectively the ICD housing 13 and the end ring 15. The sand filter mesh layer 17 is further arranged so there may be a flow through the sand filter mesh layer to the drainage mesh layer 16 and further to the ICD housing 13.

The sand filter mesh layer 17 may also be of a composite material.

Figure 14 further discloses a distribution mesh layer 18 that is wrapped on the outside of the sand filter mesh layer 17. The distribution mesh layer 18 is further adapted to allow a flow to access the entire surface area of the sand filter layer 17.

The distribution mesh layer 18 may further be of a composite material.

Figure 15 further disclose a load bearing pipe box 19. The load bearing pipe box 19 is arranged outside of all the mesh layers 16, 17, 18 as shown in the figure. The load bearing pipe box is adapted to encapsulate the drainage mesh layer 16, the filter mesh layer 17, the distribution mesh layer 18, the ICD housing 13 and the pipe section part enclosed by the load bearing pipe box 19. The load bearing pipe box is made of a composite material. The composite material may for instance be carbon fiber reinforced thermoset plastic combined with high-density polyethylene (HDPE), a cross-linked polyethylene (PEX) or polyethylene terephthalate on the exterior.

As further shown in figure 15, the load bearing pipe box 19 has one or more pipe box openings 19a. The opening(s) allows a flow from the outside and inside of the screen assembly 10.

Figure 16 shows the last step of the assembly process of the screen. In this figure the cylindrical molding 11 has been removed. The ends of the pipe section may also be cut to be prepared for connection with a further pipe section 3.

The load bearing pipe box provides a strengthening to the pipe section with sand screen. It further provides a possibility to rotate the pipe section with sand screen when deployed into the well

A further integration with control line and electrical cabling in the composite pipe 3, 40 as illustrated above in figure 9a makes it possible and practical to have an electric controlled valve within the ICD housing 13. This is not possible with a conventional sand screen integration as the control line then have to be arranged outside of the pipe section.

The figure 17-19 discloses an embodiment of the sequential steps for integrating a perforating gun to the composite pipe for use in an oil well.

Perforating the formation with explosive shaped charges to establish flow path between formation and well is an establish well construction technique. The known method is to deploy the shaped explosive charges into a tube (referred to as a perforating gun). The tube is then lowered into the well (on cable, coil tubing or drill pipe). Once the perforating gun is at depth, the gun is detonated the used gun is removed (pulled out of the well or dropped to the bottom of the well. Perforating is used in ‘cased hole’ with steel pipe and cement lining the borehole wall. The casing keeps the wellbore stable so the perforating gun can be removed, and production pipe put in place. Perforating is seldom or never used in open hole.

One problem with perforating is removing the used perforating gun. The common method to remove the used perforating gun is to keep the well full of weighted fluid and plug off the new perforations if needed. The well is then stable, and the perforation can be pulled out of the well (shoot and pull). Production pipe and sand screen is installed in the well and the flow potential of the perforations restored as best possible by means of fluid treatment.

One well completion method commonly used in Gulf of Mexico is known as ‘frack-packing’. This method is well suited when 1 ) cased hole is needed to stabilize he wellbore, 2) sand control with sand screen alone is not possible and gravel needs to be placed outside the sand screen 3) the perforated interval needs treatment to restore productivity and hydraulic fracturing is the preferred method. Within the field of frack-packing there is prior art on placing the perforating gun adjacent to screen and leaving the used gun the wellbore such that it can be positioned away so that is does not impede on the placement of gravel, the hydraulic fracturing, or the well production Ref US 6,286,598 B1 . There is also prior art on building the perforating gun within the sand screen so that it can be left in place and not impede on the placement of gravel, the hydraulic fracturing, or the well production Ref US 6,962,203 B2.

The invention described here is to be applied for stable wellbore that does not need to be lined with casing to later have pipe and screen deployed. For these types of wells, having external perforating gun installed below or above a sand screen provides opportunity detonate the external perforating gun and aid production from, or injection into a formation. The timing of the detonation of the external perforating gun can be after well fluid from the drilling phase and the deployment phase is removed from the well so that maximum benefit from clean perforations into the formation is enjoyed.

Figure 17 discloses a pipe section 3 that is built on the cylindrical molding 11 similar as illustrated in figure 9. The inner sleeve 3c of the pipe section 3 is contacting the cylindrical molding 11 . The pipe section will further serve as the inner sleeve of a perforating gun.

The pipe section 3 is made of a composite material as described above.

A further method applicable for pipe section 3 is a packer as shown in figure 20- 22, where figure 20 shows the pipe section 3.

Packers 50 are controlling the flow and pressure within a wellbore. These are installed on the string of pipe as indicated in figure 1 b.

Conventional packers are built on a mandrel from alloy steel tube material. External on this mandrel is a cone and slip mechanism that anchors the packer to the casing and an annular packing element that seal against the casing inner wall.

In addition, there is a cylinder mechanism that provides the force needed to drive the slips into the casing and compress the packer element. The complication is the control line that needs to be routed under the packer mechanism. This is traditionally done by drilling a long longitudinal hole in the cross-sectional area or the mandrel or via an alternative inner diameter of the packer. Both solutions add cost and complications to the packer design. Furthermore, the control needs to be ported to the outside of the packer mandrel at each end of the packer so no to interfere with a conventional threaded pipe connection. This introduces pinch points there the control line and/or electrical cable can suffer damage at installation and leak paths where the packer can lose pressure integrity.

A composite pipe section 3 according to the invention may be utilized as the mandrel of the packer

The control lines and electric cables are cost effectively built into the wall section of the composite mandrel, as shown in figure 21 .

The control lines and electric cables are built into the wall section of the composite mandrel, as shown in figure 21 , where these serves the well construction.

With composite material it is cost effectively to build cables into the material. Contrast to steel pipe where cable pass way is done with advanced machining including longitudinal gun drilling.

The packer with control lines can be made up to the completion string with type 1 composite connections.

The packer is built on the composite pipe section 3 utilizing known methods and design principles. The composite mandrel can have an outer layer that is thick walled and of a material that allows machining the profiles needed to fit on conventional cone and slips, conventional packing element, conventional cylinder housing and ratchet body lock mechanism. Ultra-high-density polyethylene could be such a material. Alternatively, an alloy steel pipe section can be slipped over and bounded to the composite packer mandrel and conventional construction methods applied.

The same methodology applies to hydraulic control or electric controlled downhole valves (referred to as flow control vales within smart completions), use conventional methods to build the valve on a composite material with the control integrated into the compost material tube. The pipe section 3 with packer is illustrated in figure 22.

Method for one trip deployment of the production pipe string with the assembled pipe section configuration from the tubing hanger to end of the reservoir section according to the invention is shown in figure 1 b.

The figure illustrates for instance two pipe sections 3, 3’, a packer arranged on a pipe section 50, a screen arranged on a pipe section 10, an external perforating gun arranged on a pipe section 20, a pipe section with a control line and/or an electrical cable 41 .

The drilling of the bore hole is done by conventional methods. Cleaning the borehole free from drill solids is still an important step. Replacing the drilling fluid with screen fluid is now an optional step.

The composite completion string is run into the well. Because the composite string is light and stiff it can be installed without the weight of the drill pipe and therefore the lower and upper completion is one continuous string. If there are issues getting it to TD it can be rotated down with torque applied at surface. The control lines are integrated with-in the string, and this allows to string to be lowered into the well with flow control valve and the screens closed. The closed string prevents drilling fluid ingress and prevents screen to be plugged from the drilling fluid. Therefor the displacement to screen fluid is an optional step. The completion string is secured in place at the top with the tubing hanger and the bottom part of the last casing with the packer. The packer is set with tubing pressure applied against closed valves in the screen section.

To produce from (or injected into the well) the drilling fluid filter-cake left on borehole wall is removed by clean-up flow or by chemical treatment. With the aid of the surface-controlled flow control valves, this clean -up can be done section by section. Once clean-up is completed to best efforts, the external perforating gun can be detonated to expose more and new formation to flow.

A further method that is applicable for all the pipe section 3, 40 and the pipe section configurations 50, 10, 20, 70 described above is the tracking and unique identification of individual fiber composite pipe sections 3, 40.

One emerging technology within inventory management is radio-frequency identification (RFID). The use of RFID for inventory management requires a scanner that uses radio waves to communicate with the RFID tag.

The RFID tag itself contains a microchip that allows the reader to read data and write data to the tag for real-time updating in place. Each tag is usually wrapped in a material like plastic or paper for protection and can be affixed to a variety of surfaces for tracking.

In the present application this tag will be built into each composite pipe section 3, 40.

Most tags used for inventory tracking are passive RFID tags, meaning they contain no battery and are powered by the waves from the readers. Active tags are powered. The latter type is more expensive and is used for long-range tracking of machineries such as trucks and railway cars. Both type of tags may be used with composite pipe section and pipe section configurations according to the invention.

Using RFID tags offers benefits beyond the inventory management process. Detailed information from manufacturing process including data about source of raw material can be built into each item of compost material. The benefit is quality control, ability to recall product on learning about material or manufacture defects, effective learning about what combination raw material and manufacture process that resulted into better or inferior products in service. Because composite material lends itself to manufacturing in small lot size, the number of variations within each type of products will be large. There will be variation in manufacturing method, technical and material selection, variation from lot to lot of same raw material. There will be results from quality and assurance testing during manufacturing.

The conventional method of tracking with product serial numbers and paper documentation may simply be overwhelmed.

Ongoing costs for an RFID system include tags, licensing fees, and maintenance. One of the benefits of operating a passive RFID system over the long term is the low cost of tags. An active RFID tag generally cost about 100 times as much as a passive tag. This is due the requirement of local power source and more involved housing design.