GB2500109A

GB2500109A - Fluid deformable chamber with progressive deformation characteristics

Info

Publication number: GB2500109A
Application number: GB201303728A
Authority: GB
Inventors: Stephen Edmund Bruce; Stephen Kent; Dominic Patrick Joseph Mccann; David Alan Noblett; David Grant; Ewan Colin Smith
Original assignee: Darcy Technologies Ltd
Current assignee: Darcy Technologies Ltd
Priority date: 2013-03-01
Filing date: 2013-03-01
Publication date: 2013-09-11
Anticipated expiration: 2033-03-01
Also published as: GB2500109B; GB201303728D0

Abstract

Downhole apparatus comprising a fluid pressure deformable chamber 14 for location on a base member, the chamber having a body having a first portion of a first length, width and depth, a second portion having at least one of a second depth and width less than the first portion, and a transition portion coupling the first and second portions and configured to provide for a progression between deformation characteristics of the first and second portions. The second portion may be adapted to secure the chamber on the base member. A plurality of chambers may be provided around the base member.

Description

1

DOWNHOLE APPARATUS

FIEL& OF THE INVENTION

This invention relates to downhole apparatus and in particular, but not 5 exclusively, to flow control apparatus such as sand screens and associated apparatus and methods.

BACKGROUND OF THE INVENTION

WO 2009/001069 and WO 2009/001073, the disclosures of which are 10 Incorporated heroin in their entirety, describe arrangements for supporting borehole walls and for applying predetermined stresses to borehole walls. Inflatable chambers are mounted on a base pipe such that inflation of the chambers increases the diameter of the assembly. The chambers may support a sand control element

15 SUMMARY OF THE INVENTION

There is described a downhole apparatus comprising:

a tubular body;

first and second ports in a wall of the body, and a fluid pressure-responsive valve arrangement having a locked first 20 configuration associated with a first pressure in which the first port is open and the second port is closed, an unlocked second configuration associated with a second pressure higher than the first pressure in which the first port is open and the second port is closed, and a third configuration associated with a third pressure lower than the second pressure in which the second port is open.

25 There is also described a flow control method comprising;

applying a first pressure to a fluid pressure-responsive valve arrangement controlling the configuration of first and second ports in a wail of a tubular body, whereby the valve arrangement maintains a locked first configuration in which the first port is open and the second port is closed;

30 applying a second pressure higher than the first pressure whereby the valve arrangement assumes an unlocked second configuration in which the first port is open and the second port is closed, and applying a third pressure lower than the second pressure whereby the valve arrangement assumes a third configuration in which the second port is open, 35 The valve arrangement configuration may change in any appropriate sequence, for example the first configuration being followed by the second configuration which 1s then followed by the third configuration. Alternatively, the third

2

configuration may be followed by the second configuration which is then the first configuration.

The locked first configuration may be an initial configuration for the valve arrangement. Thus, for example, the apparatus may be run into a bore in the first 5 configuration.

The first port may bo closed in the third configuration.

The first port may include a check valve which closes the first port in the absence of a positive pressure differential across the valve.

The vaive arrangement may include a valve member which closes the second 10 port in the first and second configurations, The vaive member may close the first port in the third configuration. The valve member may take any appropriate form, and may be a sieeve. The vaive member may be biased towards a position to open the second port.

The valve arrangement may be locked In the first configuration by a lock 15 arrangement which may comprise a reieasable retaining member, such as a shear pin. The retaining member may retain a valve member in a first configuration relative to the body.

The valve arrangement may include more than one lock arrangement, for example eiements of the valve arrangement may be locked in position when the 20 valve arrangement is in the third configuration.

The valve arrangement may define a differential piston. One piston face may be exposed to an internal pipe pressure and a second piston face may be exposed to an external pressure, for example annulus pressure. Accordingly, a positive pressure differential between the pipe and the annulus wiil result in a fluid pressure 25 force acting on the piston.

The piston may be accommodated in a chamber with a port providing fluid communication with an external pressure. The port may dimensioned or otherwise configured to induce a pressure drop in fluid passing through the port.

A pressure relief arrangement may be associated with the piston, whereby if 30 the external pressure exceeds the internal pipe pressure, that is a negative pressure differential between the pipe and the annulus, the external pressure may be thus avoiding inadvertent or reverse activators of the piston. The <

may be relieved via a check valve or bleed vaive which allows higher external pressure to bleed across from the external side of the piston to the internal side of 35 the piston. The valve may be dimensioned or otherwise configured to induce a pressure drop in fluid passing through the valve. The form of the valve and the number of valves provided may be selected as appropriate, in one <

3

port extends through the piston and accommodates a bail urged into sealing engagement with a seat by a spring. Of course, those of skill in the art will recognise that such a pressure relief arrangement may have utility in other forms of downhole apparatus, particularly those that utilise differential pistons, in accommodating 5 reverse pressure differentials which might otherwise have an adverse effect on the operation of a pressure actuated tool

The first port may provide fluid communication with a first tool or device, for example a fiuid-deformable device, such as a chamber mounted on the body. The fluid-deformabie device may support a sand screen, such that the apparatus may be 10 utilised to facilitate fluid pressure activation of a sand screen, in one embodiment the first port provides communication between the interior of the body and a chamber which extends axially along the exterior of the body.

The second port may provide fluid communication between the interior of the tubular body and the exterior of the tubular body and be configured to, for example, 15 permit flow of production fluid from a formation into the body, or to permit the passage of fluid, such as injection, fracking or treatment fluid, from the body and into the formation. In some embodiments the second port may be utiilsed for passage of a fluid from the tubuiar body into the formation, and at some other time for passage of a fluid from the formation into the tubular body. The second port may be 20 configured with an inflow control device (ICD) and thus the apparatus may be utilised to facilitate fluid pressure activation of an ICD.

in one embodiment the second port comprises an ICD in the form of an insert, for example an insert of erosion resistant material such as tungsten carbide. A disc or other member may be provided with an insert and the disc may be adapted to be 25 located in a second port. The form of the insert may be selected to provide a predetermined pressure drop in fluid flowing through the port. In some discs a blank insert may be provided, preventing How through the second ports.

One or more vaive arrangements may be incorporated in a completion and provided one or more second ports provided with ICDs. Thus, based on surveys or 30 other well profiling information, an operator may configure the ICDs to provide a desired flow profile from the surrounding formations and into the well.

The apparatus may include two or more valve arrangements and associated first and second ports. Each vaive arrangement may be associated with a respective tool or device, for example each apparatus may be associated with a respective bore 35 wall-supporting apparatus, packer, hanger, or sand screen. The vaive arrangements and associated tools or devices may be axialiy spaced along the tubular body. Alternatively, or in addition, valve arrangements and associated tools or devices may

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be clrcumferentiaily spaced around the tubular body. Thus, multiple valve arrangements may be activated simultaneously,

The valve arrangement may be arranged in a fourth configuration with the second port closed. The valve arrangement may be adapted for mechanical 5 actuation to the fourth configuration. Thus, for example, in the fourth configuration the apparatus may prevent flow of production or other fluid from a formation info a completion, or prevent flow of fluid from a completion or other body into a formation.

The apparatus may comprise fluid deformahie members or chambers mounted on a base pipe, which members may be adapted to be activated by fluid 10 passing through the first port, The activated members may provide support for filter media, and may be utilised to locate filter media, such as a sand screen, in contact with a bore wail, or to increase the diameter described by filter media. The activated members may b© adapted to provide support for a bore wall, or to load or compress material between the members and a bore wall, with or without provision of filter 15 media, thus providing the beneficial effects as described in W02009/001089 and W02009/001073. A check valve or the like may be associated with the first port, for retaining fluid in the fluid deformable members. Alternatively, or in addition, relief valves or the like may be associated with the fluid deformable members, the valves being configured to release pressure from the members to avoid over-Inflation. 20 Furthermore, the apparatus may be configured to permit deflation or de-activation of the members, for example by provision of appropriate valves, thus facilitating removal or retrieval of an apparatus from a bore, although In most cases if is likely that the apparatus will be Intended for permanent installation.

There is described a tubular body forming part of a completion including one 25 or more sand screens, each screen incorporating an apparatus. The first, ports may communicate with fluid deformable members or chambers mounted on a base pip©, the chambers supporting a filter member. The screens may be run into a drilled hole to the desired depth with the valve arrangement in the locked configuration. A first pressure is then applied to the Inside of the completion and fluid may pass through 30 the first ports to simultaneously and at least partially inflate the chambers, increasing the diameter of the screens to locate the filter members against the surrounding bore wall or casing, The pressure applied is then increased to a higher second pressure and the valve arrangement assumes the unlocked second configuration. This may be achieved by provision of a valve member in the form of a sleeve and which 35 incorporates a differential piston, the valve member being initially locked in position by a shear pin. The higher second pressure may shear the pin and move the sleeve a small distance, against the action of a spring, maintaining the first port open and

the second port closed. The pressure may then be further increased to fully Inflate and activate the chambers; the pressure necessary to cause the pins to shear may be less than the pressure necessary to fully activate the chambers. Maintaining the pressure at this elevated level for a period of time ensures that all the pins shear and 5 all of the screens are fully activated against the borehole. The activated screens may thus be compliant with the wall of the weilbore, that is the screens will tend to follow and maintain contact with the weilbore surface, even if the surface is non-cylindrical or otherwise irregular. Pressure is then bled off from the completion, check valves associated with the first ports locking the elevated pressure inside the chambers and 10 maintaining to sleeves fully activated. As pressure continues to be bled off, the sleeves are moved by the springs to assume the third configuration in which the first ports are closed and the second ports are open. An additional barrier may be provided to close the first ports, for example a shuttle vaive may be provided between the first ports and the valve sleeve and may be positioned to close the first 15 ports. Production fluid may then flow from the formation, through the filter member and the second ports and Into the completion, and then to surface. In other embodiments the apparatus may be used to control the flow of fluid in the opposite direction, for example the flow of injection, tracking or treatment fluid into the formation.

20 Thus the screens may be fully activated by modulation of the pressure applied to the inside of the completion. If desired, the entire completion or a section of completion may be pressurised to simultaneously activate all of the screens or a number of screens provided in the pressurised section, which in the great majority of cases will be achievable without provision of specialist equipment or expertise. 25 Furthermore, no intervention is required, increasing the speed and reliability of the operation. Alternatively, screens may be activated individually or in groups, for example by utilising an appropriate tool or device to isolate individual screens or groups of screens. This allows different activation pressures to be utilised for selected screens and for selected locations in the well.

30 The completion will typically be intended to be a permanent installation.

However, the completion may be configured to be retrievable or removable, typically by permitting deflation and deactivation of the chambers.

Where the apparatus comprises fluid deformabie members or chambers mounted on a base pipe which have been activated by fluid passing through the first 35 port, the activated apparatus may provide a structure with improved crush and collapse resistance.

6

There is described downhole apparatus in the form of a fluid pressure deformabie chamber for location on a base member, the chamber having a body-having a first portion of a first length, width and depth, a second portion having at least one of a second depth and width less than the first portion, and a transition 5 portion coupling the first and second portions and configured to provide for a progression between deformation characteristics of the first and second portions.

The second portion may be utilised to locate or secure the chamber on the base member.

The second portion may form an end of the chamber, and a second portion 10 and an associated transition portion may be provided at one or both ends of the chamber. On filling the chamber with fluid the depth of the chamber may increase. The pressure of fluid utilised to deform the chamber may be selected based on a number of criteria. For example, a pressure of between i .4 and 5,5 MPa (200 and 800 psi) may he used to fully activate the chamber, but of course other ranges of 15 pressure may be effective.

A plurality of chambers may be provided around a base member. The chambers may extend axially of the base member and be arranged side-by-side to provide substantially complete circumferential coverage of the base member. The chambers may support a member or device, for example a filter member, such as a 20 sand screen.

The chamber may have a wall formed to match the profile of an associated base member. Typically, the chamber will have an arcuate Inner wall where the chamber is intended to be mounted externally of a cylindrical base member. As the chamber is filled with fluid an outer wall moves radially outwards, increasing the 25 depth of the chamber and the diameter of the assembly. The chamber may have an arcuate outer wall intended to match the surface of a surrounding bore wall.

The chamber may Include an activation port to provide for passage of chamber-deforming fluid. The port may be provided at any appropriate location on the chamber. The port may be provided In the second portion, at an end of the 30 chamber, which may form a spigot. The activation port may be located on a main axis of the chamber. The associated spigot may have, initially at least, the same depth as the body.

The first width and depth may be substantially constant along the length of the body,

35 A fluid port may be provided at the other end of the chamber. Alternatively,

the other end of the chamber may be closed or sealed and may serve primarily to locate the end of the chamber relative to the base member, A port at the chamber

end may be open to, for example, facilitate filling of the chamber during fabrication or assembly to remove air from the chamber, to accommodate a pressure relief valve, or to provide for communication with another chamber, for example a chamber on an adjacent device, which device may be a sand screen.

5 Edges of the transition portion may feature an Inner radius and an outer radius. The inner radius reduces stresses in the transition portion as the chamber is deformed. The outer radius also reduces stresses in the transition portion as the chamber is deformed. Additionally, the outer radius reduces length and width shrinkage of the chamber as the chamber is deformed. The outer radius also 10 reduces the potential for damaging a filter member extending over the chamber and tends to provide a smoother profile in the deformed chamber,

The transition portion may be configured to cooperate with a chamber block defining a fluid passage. The chamber block may be configured to maintain Its form while the chamber is deformed. The block may define a female port configured to ,15 receive the transition portion. The transition portion may be bonded to the block, for example by welding, to provide a pressure-tight seal between the chamber and the block. The block may be configured to be secured to a base member. The chamber may be bonded to the block prior fo the block being secured to the base member. Accordingly, the transition portion and block may be, for example, welded around the 20 complete periphery to ensure pressure Integrity before the assembly is mounted on the base member. The block may include an inlet port in an inner wall. The inlet port may include a check valve. The inlet port may be configured to communicate with the first port.

There is described a method of connecting a fluid pressure-deformable 25 chamber having an activation port at an end of the chamber to a base member, the method comprising forming a sealed connection between the activation port and a chamber block and then mounting the chamber block on the base member.

The block may take any appropriate form and may be relatively rigid with respect to the chamber such that the block substantially maintains Its form when the 30 chamber is deformed. The block may include a valve.

The activation port may be provided in a transition portion as described above.

There is described a support layer for location between a downhole filter member and an associated base member, the support layer comprising a sheet of 35 material, the sheet being apertured and formed fo provide a fluid path,

This permits the support layer fo function as a drainage layer.

The support layer may be formed of a curved sheet.

8

The support layer may feature surface protrusions to space the sheet from an adjacent member. Alternatively, or in addition, the layer may have an undulating form, for example the layer may be corrugated or otherwise define peaks and troughs, or the layer may be formed of overlapping members, or multiple layers may 5 be provided and adjacent layers overlapped.

The support layer may be utilised in a sand screen as used in the production of hydrocarbons from subterranean formations.

The support layer may comprise a plurality of members.

The support layer may be formed of any suitable material. The layer may 1.0 comprise a solid sheet, for example solid steel plate, although other materials may be utilised,

The apertures may take any appropriate form, pattern, shape or size. For example, rows of openings may be punched or pressed from the sheet. In use the apertures may allow passage of oil or gas.

15 The apertures may be of a consistent form over the support layer.

Alternatively, the form of the apertures may be varied to control the passage of fluid through the layer, and In particular to equalise flow through the layer over the length of the layer. For example, the number or dimensions of apertures may Increase or decrease along the length of the layer depending of the distance between the 20 apertures and a valve or flow port in the base support. Typically, apertures spaced further from the flow port will provide a larger flow area to compensate for the pressure drop that will occur as the fluid flows from the apertures to the flow port.

If the support layer Is provided with protrusions these may take any appropriate form, pattern, shape, size or depth. The protrusions may lift or space the 25 support layer from the base member, allowing oil or gas to flow beneath between the layer and the base member. The protrusions may b© arranged to allow fluid to flow one or both of axially and circumferentially.

The protrusions may be formed by embossing a pattern in the sheet of materia! to create protrusions on the inner surface.

30 The support layer may be formed to match the profile or form of one or both of the filter member and base member. The support layer may be provided in combination with fluid pressure-deformabie base members or activation chambers,, and a support layer member may be configured fo provide a bridge between adjacent activation chambers, to ensure support for the filter member, particularly as the 35 chambers are activated and gaps open up between the chambers, and to provide radial support for the surrounding well bore wail. The support layer may also assist in maintaining the circular form of the screen as the screen is activated. The

9

activation chambers may have surfaces formed to provide a fluid pathway along the surface of the support member.

There is described a retainer for a sand screen filter member comprising a clamp member configurable fo clamp at least an end portion of a fiiter member 5 against a clamp body configured for securing fo a base member.

There is described a method of retaining a filter member en a sand screen, the method comprising:

locating the filter member around a base member; and clamping at least end portions of the fiiter member against the base member, 10 The filter member may be in the form of a weave, The filter member may he wrapped around the base member.

The clamp member may comprise an axially translatable retainer having a clamping surface configured to cooperate with an opposing clamping surface on the clamp body, whereby a portion of the filter member may be secured between the 15 surfaces. The clamping surfaces may define tapers,

The clamp member may be a clamp ring and may be threaded or otherwise securabie to the clamp body. Where a threaded clamp ring is provided, relative rotation of the clamp ring and clamp body may induce axial movement of the clamp ring on the clamp body,

20 The clamp body may be integral with the base member. Alternatively, the clamp body may be separate from the base member, and may float at least axially relative to ihe base member. This arrangement facilitates in accommodating axial shrinkage of the filter member if the fiiter member is to be subject to expansion.

The clamp body may be recessed beyond the clamp body clamping surface 25 to accommodate an end of the filter member. If necessary or desirable, the filter member may be spot weided In the recess during assembly to retain the filter member in place before the clamp member is fixed to the clamp body.

There is also described asand screen incorporating the retainer, and fo a method of assembling a sand screen.

30 Fiiter media, which may be In the form of a weave, is wrapped around a base member having a clamp body secured at each and. The weave may be held in place, fo facilitate assembly, using ratchet straps, spot welds, or the like. Spot welds may be provided along the length of the weave and the weave may be welded to the base member or to a support or drainage layer between the base member and the 35 filter member. The ends of the weave are tightly wrapped around recesses in the clamp bodies, Clamp or retainer rings are then screwed onto the clamp bodies. The

10

weave is trapped between tapers on the clamp ring and the clamp body, thus securing the weave in place around the base member.

There ss described a method of restricting flow between zones in a well, the method comprising; providing a layer of deformabie material on a sand screen; and 5 activating the sand screen such that the deformabie material contacts and seals against the wall of the well.

The deformabie material may be provided en a portion of the sand screen, for example at one or both ends of a sand screen.

The deformabie materia! may be arranged on the sand screen such that fluid 10 may pass beneath the materia!, for exampie through or beneath the sand screen.

The wail of the well may be lined, for exampie with casing or liner, or may be unlined.

The deformabie material may be an elastomer, and may be a sweilahte material activated by water, oil, or some other material.

15 There is described a method of increasing the strength of a base member comprising mounting chambers on the base member and inflating the chambers.

The member may take any appropriate form, and may be a hollow or solid member, for example a pipe or a beam.

The chambers may be arranged around a surface of the member and may 20 extend axially of the member. The chambers may be provided on an outer surface of the base member, or on an Inner surface of the base member.

The member may be restrained or contained within a bore or other surrounding wail. An external point load applied to a chamber, and which tends fo deform the chamber wall, will tend fo Increase the interna! fluid pressure in the 25 chamber and result in the load being spread aiong the length of the chamber.

Further, when a load is applied on one side of the member, the chambers on the other side of the member may be compressed between the member and the bore wall and radially distribute the reaction force over the opposite surface of the member. For tubuiar members, such as downhole structures, the provision of the 30 chambers wlil thus enhance the collapse resistance of the members.

There Is described a method of creating a crush-resistant structure, the method comprising;

locating a base pipe in a bore; and inflating chambers located between the base pipe and the bore with fluid, 35 thereby providing a structure having an elevated crush resistance.

The structure may be compliant with the bore, that is an outer surface of the structure substantial follows the bore wall.

structure may comprise a sand screen.

The structure may be located in a swelling formation or a formation with geo-mochanlcal movement.

There is described a shroud for a sand control apparatus, the shroud having 5 elongate slots and the shroud being configured to be located on a sand control apparatus with the slots inclined to the longitudinal axis of the apparatus.

The shroud may be provided in combination with a sand control apparatus, for example a sand screen. The shroud may be positioned on the exterior of the apparatus, adjacent a sand control element. The sand control apparatus may be 10 radially expandable, that is at least a portion of the apparatus may be activated to

The slots may be inclined at any appropriate angle, for example at 15 degrees to the longitudinal axis.

The inclination of the slots fends to increase the force or |

15 extend or activate the shroud, Thus, the shroud may be utilised to control the activation of the apparatus. For exampie, where the activation is obtained by inflating pressure deformabie chambers beneath the sand control element, the shroud may serve to control the pressure necessary to initiate activation. The inclination of the slots may also serve to reduce the friction between the shroud and the sand control 20 element as the sand screen activates.

There is described a method of controlling the activation of a sand screen having a shroud surrounding a sand control element, the method comprising selecting the activation characteristics of the shroud such that the shroud controls the radial force at which activation of the sand screen is initiated.

25 This has particular utility in sand screens which utilise fluid pressure to activate the screens. By selecting the shroud characteristics an operator may select the pressure which initiates activation. Thus, increases in pressure induced during other operations not intended to activate the screen lower pressures will not induce premature activation of the

30

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:

35 Figure 1 is a schematic illustration of part of a completion including three sand screens;

Figure 2 is a part cut-away view of part of one of the screens of Figure 1;

12

Figure 3 corresponds to Figure 2 but shows the screen in an activated configuration;

Figures 4, 5, 6 and 7 are sectional views of a vaive arrangement of one of the screens of Figure 1, showing the valve arrangement in first, second, third and fourth 5 configurations, respectively;

Figures 4a and 4b are views of an iCD insert assembly;

Figure 4c is a schematic of a check vaive;

Figures 8 and 9 are views of ends of activation chambers of one of the sand screens of Figure 1;

10 Figures 10 and 11 are views of activation chambers and chamber blocks of one of the sand screens of Figure 1;

Figures 12a and 12b are views of elements of a drainage layer of one of the sand screens of Figure 1;

Figure 13 is a sectional view of a clamp arrangement of one of the sand 15 screens of Figure 1;

Figure 14 is a plan view of a sheet to be formed into a sand screen shroud;

Figure 15 is en enlarged view of a portion of the sheet of Figure 14;

Figures 18 and 1? are views of a sand screen; and

Figures 18, 19, 20 and 21 are schematic sectional views of structures.

20

DETAILED DESCRIPTION OF THE DRAWINGS

Reference is first made to Figure 1 of the drawings, which is a schematic illustration of part of a well bore completion Including three sand screens 10. Of course the completion will include many other elements and devices not shown in the 25 drawing, such as a she© on the leading end of the completion, packers for zonal isolation, hangers, valves and the like. Typically a completion will incorporate more than three screens, the number of screens being selected as appropriate.

As will be described in further detail below, the screens 10 are run into the hole In a refracted or smaller diameter configuration and subsequently activated fo 30 assume a larger diameter configuration, In which the outer surface of the screens engages the bore wail, whether this be formed by casing, liner, or an uniined bore section.

Figure 2 of the drawings illustrates a part cutaway view of part of one of the screens of Figure 1, showing the screen 10 in an initial configuration. The screen 10 35 comprises a base pipe 12 providing mounting for six activation chambers 14 which extend axially along the outer surface of the base pipe 12, The chambers 14 are arranged side-by-side around the base pipe 12 and, as will be described, may be

inflated or deformed by filing the chambers 14 with high pressure fluid such that the chambers 14 assume an activated configuration as illustrated in Figure 3 of the drawings.

A drainage layer Is located externally of the chambers 14, the layer 5 comprising six strips 18 of apertured steel sheet Like the chambers 14, the strips 18 are arranged side-by-side and extend axially along the screen 10, but are circumferentially offset relative to the chambers 14, as illustrated in the drawings,

such that when the chambers 14 are extended the strips 18 bridge the gaps 20 formed between the chambers 14, Further detail relating to the drainage layer will 10 be provided below.

The drainage layer supports a filter media in the form of a weave 22, the weave form being selected such that the aperture size of the weave 22 does not vary as the weave 22 is extended to accommodate the deformation of the activation chambers 14. The weave 22 may comprise a single iength of material wrapped 15 around the drainage layer with the longitudinal edges overlapping, or may comprise two or more lengths or strips of material. A protective shroud 24 is provided over the weave 22,

Reference is now also made fo Figures 4, 5, 8 and 7 of the drawings, which are sectional view of a valve arrangement 30 of one of the screens 10 of Figure 1, 20 showing the valve arrangement in first, second, third and fourth configurations respectively. In use, a valve arrangement 30 will be provided at the lower end of each screen 10 between the lower end of the activation chambers 14 and a stub acme connection 32 and a premium connection (not shown) at the end of the screen 10, It will be noted that Figures 4, 5, 8 and 7 omit the drainage layer 18, weave 22 25 and shroud 24,

The valve arrangement 30 comprises a body 34 comprising a number of interconnected cylindrical portions 34a, 34b which also form the lower end of the screen body. As will be described, the valve arrangement 30 also includes a number of generally cylindrical Internal parts which are configurable fo control passage of fluid 30 through first and second ports 38, 38 in the body portion 34a, The first ports 38 provide communication with the activation chambers 14 via respective chamber blocks 40 which each incorporate a check valve 42 including a bail 44. The ball 44 may be formed of any suitable material, for example FIFE, ceramic, steal, rubber, brass or aluminium. The second ports 38 also extend through the body portion 34a 35 and, when open, allow production fluid to flow from the exterior of the screen 10 into the base pipe 12, and subsequently to surface.

14

The second ports 38 may be dimensioned or otherwise configured to provide a predetermined pressure drop in production fluid flowing into the base pipe, Thus, over the length of the completion the operator may configure the second ports fo provide a desired flow profile faking account of iocai formation conditions, in one 5 embodiment each second port 38 is provided with an inflow control device (ICD) assembly in the form of a disc 39 for location in the port 38, the disc having a central flow port accommodating an appropriately sized tungsten carbide insert 41, as illustrated in Figures 4a and 4b of the drawings (the skilled person will note that the ports 38 as illustrated in the figures are non-circular, and thus ICDs in the form of 10 discs 39 are intended for use in combination with an alternative embodiment featuring circular second ports). The insert 41 is selected fo provide the desired flow area or pressure drop and is pressed Info the disc 39, which is then screwed into the port 38 from the outside of the body portion 34a, the disc outer face being provided with a screw thread configured to engage with a corresponding screw thread 15 provided on the port 38. The disc 39 is also provided with an G~ring seal, if appropriate, some ports 38 of a valve arrangement 30 may be fitted with a disc including a blank Insert, preventing flow through selected ports.

The vaive arrangement 30 includes a primary vaive sleeve 48, A central part of the sleeve 48 defines production ports 48 which, when the valve arrangement 30 20 is in the third configuration, are aligned with the second ports 38, In the first configuration, as Illustrated in Figure 4, the production ports 48 are offset from the second ports 38, and isolated from the exterior of the vaive sleeve 48 by seals 50, 51, A further seal 52 also serves to Isolate the second port 38. The lower part of the valve sleeve 48 defines an internal profile 55 for engaging an intervention tool, as will 25 be described. The upper end of the sleeve 48 includes collet fingers 49 which have outer profiles for engaging with locating recesses 45 formed in the inner diameter of the body 34. The collet fingers 49 also define profiles 43 which allow for mechanical engagement with an intervention tool If required, as will be described.

A secondary valve or shuttle sleeve 47 is located externally of the primary 30 vaive sleeve 46 and carries external seals 54 for isolation of the first port 36 when the valve arrangement Is in the third and fourth configurations, as illustrated In Figures 8 and 7. The sleeves 46, 47 are initially fixed together by shear pins 59, in the first and second configurations the shuttle sleeve 47 is located downwards and clear of the first ports 38, and activation ports 86 in the primary vaive sleeve 48, which may 35 include a filter member 57, are aligned with the first ports 36, providing for fluid communication between the inferior of the screen 10 and the activation chambers 14,

15

A valve actuating sleeve 58 is also located within the body 34 and features an external shoulder BO which provides a seaiing contact with the body portion 34b. Shear pins 82 initially lock the sleeve 58 relative to the sfeeve body against the action of a compression spring 83 contained in a chamber 87 between the sleeve 58 and 5 the body portion 34b, Whiie the upper face of the shoulder 60 is exposed to internal or pipe pressure, the lower face of the shoulder 80 is exposed to external or annulus pressure via a port 61 in the sleeve body, such that the shoulder 80 acts as a differential piston.

To prevent accidental unlocking of the sleeve 58 due to reverse differential 10 pressure, for example an rise in annulus pressure relative to Internal pressure, check valves 65 (one shown) extend through the shoulder 80, allowing fluid to bleed from the chamber between the sleeve 58 and the body portion 34b and into the valve, thus relieving any excess reverse pressure. A schematic of a check valve 85 is shown in Figure 4c of the drawings, Accordingly if, for example, during installation or retrieval 15 of the completion, fluid is being circulated down through the completion and up the surrounding annulus, there may be circumstances in which the annulus pressure (P1} rises above the internal pressure (P3). In this situation, fluid from the annulus may bleed through the port 81 and into the spring chamber 87, undergoing a pressure drop fo a lower pressure (P2) in the process. This reduces the pressure 20 differential across the shoulder 60. However, if sufficient, the remaining pressure differential between the chamber 87 and the interior of the completion may then lift the check valve ball 89 off its seat 71, against the action of a spring 73, allowing the fluid to bleed from the chamber 87 and into the completion. Thus, an operator may employ relatively high circulation rates, safe in the knowledge that a higher pressure 25 in the annulus will not result in premature shearing of the pins 82, and premature release of the sleeves 58, 48, 47, The number and configuration of check valves 65 may be selected as appropriate to the completion configuration and anticipated operating conditions,

An upper end of the sleeve 58 extends externally of the lower end of the 30 primary valve sleeve 48, and abuts the lower end of the shuttle sleeve 47.

As noted above, in the first configuration the activation ports 58 are aligned with the first ports 38, while the second ports 38 are closed due to the misalignment between the ports 38 and the production ports 48; the screens 10 are run in hole in this configuration. A positive pressure differential between the inferior of the screens 35 10 and the chambers 14 will open the check valve 42 and allow fluid to flow from the interior of the completion into the activation chambers 14, via the chamber blocks 40, Thus, in use, when the completion is pressurised up to a first pressure, the chambers

16

14 will undergo an initial degree of inflation or deformation with the valve arrangement 30 in this first configuration. The pip© pressure may be held at this first pressure for a period fo provide an Initial degree of inflation of the chambers 14, Of course, rather than pressurising the entire completion, an operator may run a wash 5 pipe or the like inside the completion to communicate pressure from surface to the screens 10.

After a predetermined interval the internal pipe pressure may be increased to a higher second level to bring the differential pressure experienced across the shoulder 80 to a level sufficient ievel to shear the pins 62, as illustrated in Figure 5. 10 This pressure differential causes the check valve balls 69 fo seat, ensuring the check valves 65 remain closed. This results in a small downward movement of the sleeve 58, against th© action of the spring 63, until the lower end of the sleeve 58 engages a stop 84, However, this movement is not transferred fo the primary valve sleeve 48, or the shuttle sleeve 47, Thus, the first port 36 remains open while the higher 15 second pressure fully inflates and activates the chambers 14.

After a further predetermined interval, following which the operator may be confident that all of the screens 10 have been fully activated, pressure may be bled off from the completion, allowing the spring 63 to move the sleeve 68 upwards relative to the body 34, as illustrated in Figure 8. After an initial degree of 20 movement, this movement of the sieeve 58 is also translated to the valve sleeves 46, 47, moving the sleeves 46, 47 upwards to close the first ports 36 and open the second ports 38, In particular aligning the ports 38 with the production ports 48 in the sleeve 48. This requires the collet fingers 49 to be dislodged from the lower recess 45a and moved fo engage with the upper recess 45b. Furthermore, alignment of the 25 ports 38, 48 is ensured by the provision of timing pins 31, which prevent relative rotation of the body portfon 34a and sleeves 46. 47,

In this third valve configuration high pressure fluid is locked in the inflated chambers 14 by the check valves 42 and the shuttle sleeve 47, while production fluid may flow into the screen through the aligned ports 38, 48,

30 If any of the valve sleeves 46, 47 do not move to the third configuration when pressure is bled off, and intervention fool may be employed fo engage the collet profile 43 and mechanically shift the sleeves 46, 47 upwards. In addition, if at any point in the future an operator wishes to shut off production from a particular screen 10, a mechanical intervention tool may be run info the bore fo engage the sleeve 35 profile 55. The primary valve sieeve 46 may thus be pushed downwards, dislodging the collet fingers 49 from the upper recess 45b to the lower recess 45a, such that the ports 38, 48 are moved out of alignment, as illustrated in Figure 7 of the drawings.

However, a split ring 66 located hi a recess 88 in the body portion 34a engages with an external shoulder 70 on the upper end of the actuating sleeve 58 preventing downward movement of the sleeve 58 and also locking the shuttle sleeve 47 in the port-closing position; if sufficient force is applied by the Intervention tool the 5 connecting shear pins 59 between the sleeves 48, 47 will fail, allowing relative movement of the sleeves 48s 47, such that the first port 38 remains isolated.

Reference is now made fo figures 8, 9, 10 and 11 of the drawings, which illustrate details of the activation chambers 14 and the chamber blocks 40. in particular, Figure 8 shows the lower end of an activation chamber 14, while Figure 9 10 shows the upper end of an activation chamber 14, The activation chambers 14 are elongate and have a width W and depth D. in one embodiment, the chambers 14 are formed by folding a long narrow sheet of metal in a series of steps to provide the desire profile, the meeting edges then being joined by a suitable method, for example being laser or high frequency welded. However, both ends of the chambers are cut 15 away to provide a narrow fab or spigot 72. The cut metal edges which define the lower spigot 72a are welded to leave an opening for passage of fluid, while the upper spigot 72b is welded closed. Thus, the opening 74 on the lower spigot 72a is of a width w, iess than the chamber width VV. Also, the edges defining the transition from the fuil width chamber to the spigots 72 are radlused, in particular being formed with 20 an outer radius 78 and an inner radius 78. On inflation or deformation of the chambers 14, the outer radius 76 reduces the stresses at the end of the chambers 14, reduces the shrinkage in length during activation, reduces the potential for damaging the weave 22, and smoothes out the end profile of the deformed chamber 14. The inner radius 78 reduces stresses in the transition area during activation, 25 The open spigot 72a allows for fluid communication between the activation chamber 14 and the interior of the completion, via the chamber block 40 which includes an opening 80 an an end face fo receive the spigot 72a. The spigot 72a and chamber block 40 are assembled while separated from the screen body, and the components are then bonded together around the complete perimeter of the opening 30 80 to provide pressure Integrity, the bond 82 being perhaps most cleariy visible in Figure 11 of the drawings, The bond 82 may be provided by any suitable method, typically welding, for example TIG, laser or robotic welding,

Within the chamber block 40 there is a drilled hole 84 (Figure 7} which extends fo intercept a radial recess 85 which accommodates the check valve 42. 35 The closed spigot 72b is restrained by an alternative clamp body (not shown).

The upper end of the chambers 14 may be fixed fo the respective upper clamp body or be mounted fo permit a degree of axial movement, for example to allow for axial

18

shrinkage of the chamber 14 on inflation. in other embodiments the spigot 72b may be provided with a relief vaive to protect against ovsr-pressurlsation of the chambers 14, or may provide fluid communication with other activating chambers in the same or an adjacent assembiy.

5 The chamber blocks 40 are retained In place on the screen body 34a by clamps 88 (Figure 7) which are bolted to the body 34a and engage with shoulders 90 formed on the edges of the biocks 40.

As noted above, drainage strips 18 are mounted externally of the mounted chambers 14, and parts of a drainage layer strip 18 are frustrated in Figure 12a and 10 12b of the drawings, in use, the drainage layer formed by the strips 18 lifts the weave 22 from the activating chambers 14, maximising inflow through and around the screen. The strips 18 are of solid steei plate provided with perforations 92 which allow oil or gas to flow through weave 22 and into the screen 10. The strips are produced by punching and embossing flat plate to provide the required pattern, 15 before roll forming to the required radius and then cutting to length. The perforations 92 may be any appropriate shape or size, and In the Illustrated embodiment each strip 18 includes four axial rows of round holes. As noted above, the strips 18 are also embossed to form protrusions on the inner surface of the strips 18, fo lift the drainage layer up from the activation chambers 14 to permit flow under the layer and 20 between the activating chambers 14 and the strips 18, Again, the embosses 94 may be any appropriate shape, size or depth, and in the Illustrated embodiment the embosses 94 are formed as four axial rows, axially and circumferentiaily offset from the perforations 92. The strips 18 are formed with an inner radius to match the outer radius of the activation chambers 14 fo ensure that the outer diameter of the screen 25 10 is minimised and that the drainage layer formed by the strips 18 provides optimum support across the activation chambers 14,

The ends of the strips 18 are tapered and are secured on the screen 10 by welding to shouiders 91 (Figure 7} provided on the chamber block clamps 88. The strip ends are aiso slotted fo facilitate deformation; the strip ends must bend end 30 extend to accommodate the activation of the chambers 14,

Following activation and deformation of the chambers 14 the drainage layer strips 18 provide support to the weave 22 as the gaps 20 (Figure 3) between [he activation chambers 14 increases. Aiso, the radiused strips 18 assist in maintaining a substantially circular shape during the activation process, in the absence of such 35 support, the screen would assume a hexagonal shape due to the weave 22 and the outer shroud 24 forming straight lines between each activation chamber outer diameter.

19

Reference is now also made to Figure 13 of the drawings, which illustrates a damp arrangement for use in securing the weave 22 in place on the screen 10. The Figure shows the body portion 34a which serves as a damp body and a retainer ring 98 which may be threaded fo the body 34a. The clamp body 34a defines a recess 5 100 upwards of the thread 97, and a tapering surface 98 leading down into the recess 100. The ring 96 includes a corresponding tapering surface 102 on its upper end, such that when the ring 96 is tightened on the body 34a the surfaces 98, 102 come together and damp a portion of the weave 22 therebetween.

During the fabrication process, the weave 22 is wrapped around the screen 10 body, over the drainage layer formed by the strips 18, with the upper and lower ends of the weave 22 positioned in the recesses 100 (a similar clamping arrangement is provided at the upper end of the screen).

The weave 22 may be held in place using rachet straps, spot welding or the like, and if desired the weave 22 may be spot welded in the recess 100, Spot welds 15 may also be provided along the length of the screen 10, to secure the weave 22 to the strips IS, The damping ring 96 is then screwed on to the clamp body 34a and the taper surfaces 98,102 damp and secure the weave 22. The shroud 24 is then located over the clamped weave 22,

Reference is now made to Figures 14 and 16 of the drawings, which illustrate 20 details of the apertured sheet or plate 23 utilised fo form the shroud 24.

Conventional shrouds are formed with elongate longitudinally extending overlapping slots, and on expansion of the sand screen the slots open to accommodate the increase in the circumference described by the shroud; the shroud is intended to provide a degree of protection for the weave but is intended to be readily extendable 25 such that the expansion of the weave is not restricted. The screen 10 may be provided with such a conventional shroud. However, the shroud 24 features 30 mm long slots 25 which are inclined at 15 degrees along the plate length, This results in a shroud 24 which will require greater pressure to expand, thus providing greater control of the activation pressure required to initiate expansion of the screen 10. The 30 angled slots 25 also result In less friction between the outer surface of the weave 22 and the Inner surface of the shroud 24 as the slots 25 open and the weave 22 slides underneath the shroud 24,

For most applications it is envisaged that the shroud 24 will form the outer surface of the screen. However, in some embodiments a portion of the screen may 35 he covered with an elastomer, as illustrated In Figures 18 and 17 of the drawings. In this embodiment a neoprene elastomer coating 104 has been wrapped around a portion of the screen outside diameter. Once such a screen has been activated, the

20

rubber coating 104 will be pushed out against the surrounding casing or formation and wili provide a restriction or baffSe to the fiow of production fluids between zones; the coating 104 may provide a low pressure seal or a restriction to flow of fluid past the screen, but may permit fluid to flow beneath the coating 104 and into or along the 5 screen. Of course in other embodiments different qualities of material may be utilised fo provide a higher pressure seal.

Reference is now made to Figures 18, 19, 20 and 21 of the drawings which are schematic sectional view of structures. In the screens described above, and as illustrated in Figure 18, activation chambers 14 are arranged around a circular base 10 pipe 12, Testing has demonstrated that the provision of inflated activation chambers 14 on the outside diameter of the base pipe 12 contained within a bore creates a structure with significantly enhanced crush resistance when compared to a structure consisting essentially of a base pipe 12 alone. If is believed this is due, at least in part, to the cushioning effect of the activation chambers 14, compression of an 15 inflated activation chamber 14 by an externally applied mechanical load leading to an increase in internal fluid pressure which results in the load being spread along the length of the chamber 14 and radially around the screen. Also, when such a structure is subject to a high ioad on one side of the structure the pressure increases in the chambers on the other side of the structure: for example, if a high load Is 20 applied in the region of the chamber 14(8), an elevated pressure is measured in the opposite chamber 14(3), and to a lesser extent in adjacent chambers 14(4} and 14(2), Testing has further demonstrated that the chambers 14 tend fo absorb at least initial deformation of the structure, such that the internal diameter of the base pipe 12 remains substantially unobstructed. Also, the deformed chambers 14 tend fo recover. 25 typically by around 50%, when the applied force is reduced.

Testing also identified that the sand integrity of sand screens incorporating inflated chambers 14 as described herein when subject to crush or pinch loads was maintained at very high loading, as was the integrity of the chambers 14, In one test the pressure in the chambers 14 increased from an initial 1000 psi fo almost 1200 30 psis corresponding to a 1 inch deformation of a sand screen with an activated outer diameter of 814 inches. Thus, a sand screen will withstand significant crush loading, for example from a swelling or partially collapsing formation, and will accommodate a degree of deformation without adversely affecting the base pipe 12. Of course this effect is not limited to sand screen, and inflatable chambers may be mounted on an 35 impervious section of a completion intended to intersect a non-producing problem formation. Accordingly, an operator may be able fo utilise significantly lighter and less expensive base pipe 12, and may be able to drill and then maintain bores

21

through difficult formations, for example swelling formations which would otherwise be expected tc crush bore lining tubing located In the bores.

Figures 19, 20 and 21 illustrate that this principle may be employed to increase the collapse and crush resistance of other tubular forms, such as the 5 rectangular and triangular base pipes 108, 108 of Figures 19 and 20, and aiso in providing protection against internal ioads as illustrated In Figure 21

It will be apparent to those of skill in the art thai the above described embodiments are merely exemplary of the present Invention, and that various modifications and improvements may be made to these embodiments without 10 departing from the scope of the invention.

CLAUSES

1, Downhole apparatus comprising:

a tubuiar body;

15 first and second ports in a wall of the body, and a fluid pressure-responsive valve arrangement having a locked first configuration associated with a first pressure in which the first port is open and the second port is dosed, an unlocked second configuration associated with a second pressure higher than the first pressure In which the first pert is open and the second 20 port is ciosed, and a third configuration associated with a third pressure lower than the second pressure in which the second port is open and the first port is closed,

2, The apparatus of clause 1, wherein the locked first configuration is an initial configuration for the valve arrangement,

25

3, The apparatus of clause 1 or 2, wherein the first port includes a check vaive.

4, The apparatus of clause 3, wherein the check vaive is configured to permit flow in a first direction through the first port and fo restrict flow in an opposite second

30 direction,

5, The apparatus of any preceding clause, wherein the valve arrangement includes a vaive member which closes the second port in the first and second configurations.

35

6, The apparatus of clause 5, wherein the valve member closes the first port In the third configuration.

22

7, The apparatus of clause 5 or 6, wherein the valve member comprises a sleeve.

5 8. The apparatus of clause 5, 6 or 7, wherein the valve member is biased towards a position to open the second port,

9, The apparatus of any preceding clause, wherein the valve arrangement is iockable in the first configuration by a releasable retaining member.

10

10, The apparatus of clause 9, wherein the retaining member retains a valve member in a first configuration relative to the body.

11, The apparatus of any preceding clause, wherein the valve arrangement 15 includes more than one lock arrangement.

12, The apparatus of any preceding clause, wherein elements of the vaive arrangement, are locked in position when the vaive arrangement is in the third configuration.

20

13, The apparatus of any preceding clause, wherein the valve arrangement defines a differential piston configured for one piston face to be exposed to an internai pipe pressure and a second piston face to be exposed to an external pressure.

25

14, The apparatus of any preceding clause, wherein the first port provides fluid communication with a first fool or device,

15, The apparatus of clause 14, wherein the first device comprises a fluid-30 deformabie device.

18. The apparatus of clause 15, wherein the fiuid-deformabie device comprises a chamber mounted on the body,

35 17, The apparatus of clause 15 or 18, wherein the fluid-deformable device supports a sand screen, such that the apparatus may be utilised to facilitate fluid pressure activation of a sand screen.

23

18. The apparatus of any preceding clause, wherein the first port provides communication between the interior of the body and a chamber which extends axially along the exterior of the body,

5

19, The apparatus of any preceding clause, wherein the second port provides fluid communication between the interior of the tubular body and the exterior of the tubular body.

10 20. The apparatus of clause 19, wherein the second port is configurable to permit flow of production fluid from a formation into the body, or to permit flow of fluid from the body into a formation.

21, The apparatus of clause 20, wherein the second port is associated with an 15 inflow control device (ICD).

22. The apparatus of any preceding clause, comprising two or more valve arrangements and associated first and second ports.

20 23. The apparatus of clause 22, wherein each valve arrangement is associated with a respective tool or device.

24, The apparatus of clause 23, wherein each valve arrangement is associated independently with a respective bore wail-supporting apparatus, packer, hanger, or

25 sand screen,

25. The apparatus of clause 23 or 24, wherein the valve arrangements and associated tools or devices are axially spaced along the tubular body.

30 28. The apparatus of clause 23, 24 or 25, wherein valve arrangements and associated tools or devices are circumferential!;/ spaced around the tubular body,

27, The apparatus of any preceding clause, wherein the valve arrangement has a fourth configuration with the second port closed.

35

28, The apparatus of clause 27, wherein the valve arrangement is adapted for mechanical actuation fo the fourth configuration.

24

29. The apparatus of clause 27 or 28, wherein in the fourth configuration the apparatus is arranged to prevent flow of production fluid from a formation into a completion.

5

30. The apparatus of any preceding clause, comprising fluid deformabie chambers mounted on a base pipe, which chambers are adapted to be activated by fluid passing through the first port,

1(5 31, The apparatus of clause 30, wherein the activated chambers are arranged to provide support for filter media.

32. The apparatus of clause 31, wherein the activated members are arranged fo locate fiiter media in contact with a bore wall.

15

33. The apparatus of ciause 31 or 32, wherein the activated members are arranged to increase the diameter described by fiiter media.

34. The apparatus of any of ciauses 30 to 33, wherein the activated members are 20 adapted fo provide support for a bore wail

35. The apparatus of any of ciauses 30 to 34, wherein the activated members are adapted to load or compress material between the members and a bore wali.

25 36. A tubular body for forming part of a completion including one or more sand screens, each screen incorporating an apparatus in accordance with any one of the preceding clauses.

37. The body of ciause 36, wherein the first ports communicate with fluid

30 deformabie chambers mounted on a base pipe, the chambers supporting a fiiter member.

38, A flow controi method comprising:

applying a first pressure to a fluid pressure-responsive valve arrangement 35 controlling the configuration of first and second ports in a wall of a tubular body, whereby the vaive arrangement maintains a locked first configuration in which the first port is open and the second port is closed;

25

applying a second pressure higher than the first pressure whereby the valve arrangement assumes an unlocked second configuration in which the first port Is open and the second port is closed, and applying a third pressure lower than the second pressure whereby the valve 5 arrangement assumes a third configuration in which the second port is open.

39. The method of clause 38, wherein the first configuration is followed by the second configuration which is then followed by the third configuration.

10 40. The method of clause 38, wherein the third configuration is followed by the second configuration which is then followed by the first configuration,

41. The method of any of clauses 38 to 40, wherein the locked first configuration is an initial configuration for the valve arrangement.

15

42. The method of any of clauses 38 to 41, comprising running the apparatus into a bore in the first configuration.

43. The method of any of ciauses 38 to 42s wherein the first post is closed in the 20 third configuration.

44. The method of any of clauses 38 fo 43, comprising closing the first port in the absence of a positive pressure differential across the valve.

25 45. The method of any of clauses 38 to 44, comprising closing the second port with a vaive member In the first and second configurations,

48, The method of any of clauses 38 to 45s cosrsprising closing the first port with a valve member in the third configuration.

30

47, The method of any of clauses 38 fo 48, comprising biasing a valve member towards a position to open the second port,

48. The method of any of clauses 38 to 47, comprising reieasably looking the 35 valve arrangement in the first configuration.

26

49, The method of any of clauses 38 fo 48, comprising locking elements of the valve arrangement in position when the vaive arrangement is in the third configuration.

5 50. Th© method of any of clauses 38 to 49, comprising communicating fluid through the first port to a first device.

51. The method of clause 50, comprising communicating fluid through the first port to a fluid-deformabie device.

1 A

i. v

52. The method of clause 51, comprising supporting a sand control element on the fluid-deformabie device and communicating fluid to the device to activate the element.

15 53. The method of any of clauses 38 fo 52, comprising flowing production fluid from a formation into the body through the second port, or flowing fluid from the body into a formation through the second port,

54. The method of any of clauses 38 to 53, comprising providing two or more 20 valve arrangements and associated first and second posts, each valve arrangement being associated with a respective too! or device, and activating the valve arrangements simultaneously.

55. The method of any of clauses 38 to 54, comprising configuring the valve 25 arrangement in a fourth configuration with the second port dosed.

58. The method of clause 55, comprising mechanically actuating the valve arrangement fo the fourth configuration.

30 57. The method of any of clauses 38 to 58, comprising activating fluid deformabie chambers mounted on a base pipe with fluid passing through the first port.

58. The method of clause 57. comprising supporting filter media on the activated chambers.

35

59, The method of ciause 58, comprising activating the chambers to locate the filter media adjacent a bore wall.

97

80, The method of clause 58 or 59, comprising activating the chambers to increase the diameter described by the filter media,

5 61. The method of any of ciauses 57 to 80, comprising activating the chambers to provide support for a bore wail,

62, The method of any of clauses 57 to 61., comprising activating the chambers to load or compress material between the members and a bore wall,

10

83. The method of any of ciauses 38 to 62, comprising providing one or more vaive arrangements on a tubular body forming part of a completion including one or more sand screens, each sand screen associated with a respective valve arrangement, the first ports communicating with fluid deformabie chambers mounted .15 on a base pipe, and the chambers supporting a fiiter member,

64, The method of clause 63, comprising running the screens into a drilied hole to a desired depth with the vaive arrangement m the first locked configuration,

20 85. The method of ciause 84, comprising applying a first pressure to the inside of the completion and passing fluid through the first ports fo simultaneously and at least partially inflate the chambers, increasing the diameter of the screens fo locate the fiiter members against a surrounding bore waii or casing.

25 66, The method of ciause 65, comprising Increasing the pressure applied to a higher second pressure and such that the vaive arrangement assumes the second configuration.

87, The method of ciause 86, comprising providing a valve member in the form of 30 a sleeve and which incorporates a differential piston, the valve member being initially looked in position by a shear pin, the higher second pressure shearing the pin and moving the sleeve a smaii distance, against the action of a spring, maintaining the first port open and the second port closed.

35 68, The method of clause 67, comprising further increasing the pressure to fully inflate and activate the chambers.

28

69. The method of clause 88, wherein the pressure necessary to shear the pins is 50 - 70% less than the pressure necessary to fuliy activate the chambers.

70. The method of clause 68 or 89, comprising maintaining the pressure at the 5 further increased pressure for a peried ef time sufficient to ensure that ail the pins shear and all of the screens are fuliy activated against a surrounding borehole or casing wall,

71. The method of clause 88, 89 or 70, comprising bleeding pressure off from the 10 completion, whereby check valves associated with the first ports lock the elevated pressure inside the chambers and maintain the to sleeves fully activated,

72. The method of ciause 71 comprising bleeding further pressure, moving the sleeves to the third configuration to close the first ports and open the second ports,

15

73. The method of ciause 72, further comprising locating an additional barrier to close the first ports.

74. The method of ciause 73, wherein the additional barrier is a shuttle valve 20 provided between the first ports and the valve sleeve, and positioning the shuttle valve fo close the first ports,

75. The method of any of clauses 72 to 74, comprising flowing production fluid from the formation, through the second ports and into the completion, and then to

25 surface, or flowing fluid from the completion, through the second ports and into the formation.

78, The method of any of clauses @3 to 75, comprising pressurising the completion to simultaneously activate a plurality of screens provided in the 30 pressurised section.

77. The method of any of clauses 83 fo 78, comprising activating at least one selected screen by Isolating and pressurising said at least one selected screen.

35 78. Downhole apparatus comprising a fluid pressure deformabie chamber for location on a base member, the chamber having a body having a first portion of a first length, width and depth, a second portion having at least one of a second depth

29

and width less than the first portion, and a transition portion coupling the first and second portions and configured to provide for a progression between deformation characteristics of the first and second portions,

5 79, The apparatus of clause 78, wherein the second portion is adapted fo locate or secure the chamber on the base member.

80, The apparatus of clause 78 or 79, wherein the second portion forms an end of the chamber.

5. V.'

81, The apparatus of ciause 78, 79 or 80, wherein the chamber is configured such that on filling the chamber with fluid the depth of the chamber increases.

82, The apparatus of any of clauses 78 fo 81, wherein a plurality of chambers is 15 provided around a base member.

83, The apparatus of clause 83, wherein the chambers extend axially of the base member and are arranged side-by-side to provide substantially complete circumferential coverage of the base member.

20

84, The apparatus of any of ciauses 78 to 83, wherein the chamber supports a member or device.

85, The apparatus of clause 84, wherein the chamber supports a filter member.

25

88. The apparatus of any of clauses 78 to 85, wherein the chamber has a wall formed fo match the profile of an associated base member.

87. The apparatus of any of clauses 78 to 88, wherein the chamber has an 30 arcuate inner wall where the chamber is intended to be mounted externally of a cylindrical base member,

88. The apparatus of any of clauses 78 fo 87< wherein as the chamber is filled with fluid an outer wall moves radially outwards, Increasing the depth of the chamber

35 and the diameter of the assembly.

30

89. The apparatus of any of clauses 78 to 88, wherein the chamber has an arcuate outer wall

90. The apparatus of any of clauses 78 to 89, wherein the chamber Includes an 5 activation port to provide for passage of chamber-deforming fluid.

91. The apparatus of clause 90, wherein the port is provided in the second portion, at an end of the chamber.

10 92. The apparatus of ciause 90 or 91, wherein the activation port is located on a main axis of the chamber.

93. The apparatus of clause 91 or 92, wherein a fluid port is provided at the other end of the chamber.

15

94. The apparatus of clause 91 or 92, wherein the other end of the chamber is closed,

95. The apparatus of any of ciauses 78 to 94, wherein edges of the transition

29 portion feature an inner radius and an outer radius,

96. The apparatus of any of clauses 78 to 95, where the transition portion is configured to cooperate with a chamber block defining a fluid passage,

25 97. The apparatus of clause 98, wherein the chamber block is configured to maintain lis form while the chamber is deformed.

98, The apparatus of ciause 96 or 97, wherein the chamber block defines a female port configured fo receive the transition portion.

30

99, The apparatus of clause 98, 97 or 98, wherein the transition portion is bonded to the block.

100, The apparatus of any of clauses 98 to 99, wherein the block is configured fo 35 he secured fo a base member.

31

101, The apparatus of clause 100, wherein the chamber is adapted to be bonded fo the block prior to the block being secured to the base member.

102. The apparatus of clause 101, wherein the transition portion and biook are 5 adapted to be bonded around the complete periphery to ensure pressure Integrity before the assembly is mounted on the base member.

103. The apparatus of any of clauses 98 to 102, wherein the block includes an inlet port in an inner wail.

10

104, The apparatus of clause 103, wherein the Inlet port includes a check valve.

108, The apparatus of clause 103 or 104, wherein the inlet port is configured to communicate with the first port of the apparatus of any of clauses 1 to 37.

15

108. The apparatus of any of clauses 78 to 105, wherein the first width and depth are substantially constant along the length of the body.

107, A method of connecting a fluid pressure-deformabie chamber having an 20 activation port at an end of the chamber to a base member comprising forming a sealed connection between the activation port and a chamber block and then mounting the chamber block on the base member.

108, The method of clause 107, wherein the block is configured to substantially 25 maintain its form when the chamber is deformed,

109, The method of clause 107 or 108, wherein the assembled elements form part of a sand screen.

30 110. The method of any of clauses 107 to 109, comprising providing a check valve in the block,

111. The method of any of clauses 107 fo 110, wherein the fluid pressure deformabie chamber has a body having a first portion of a first length, width and 35 depth, a second portion having at least one of a second depth and width less than the first portion, and a transition portion coupling the first and second portions and

32

configured to provide for a progression between deformation characteristics of the first and second portions,

112, A support member for location between a downhole filter member and an

5 associated base member, the support member comprising a sheet of material, the sheet being apertured and formed to provide a fluid path.

113, The support member of ciause 112, wherein the member is substantially rigid.

10 114. The support member of clause 112 or 113, wherein [he member is formed of a curved sheet.

115. The support member of any of clauses 112 to 114, wherein the member features surface protrusions adapted to space the sheet from an adjacent member.

15

116. The support member of any of clauses 112 to 115, wherein the member has an undulating form,

117. The support member of clause 118, wherein the member is corrugated.

20

118. The support member of any of clauses 112 to 117, wherein the member comprises a soiid sheet,

119. The support member of clause 118, wherein the member comprises solid 25 steel plate.

120. The support member of any of clauses 112 to 119, wherein the apertures are of a consistent form over the support member.

30 121. The support member of any of clauses 112 to 119, wherein the form of the apertures is varied over the support member to control the passage of fluid through the member,

122. The support member of clause 121. wherein the form of the apertures is 35 configured to equalise flow through the member over the length of the member.

33

123. The support member of clause 121 or 122, wherein at least one of the number and dimensions of apertures changes along the length of the member depending on the distance between the apertures and a valve or flow part in the base member.

5

124. The support member of clause 123, wherein apertures spaced further from the flow port are configured to provide a iarger flow area to compensate for the pressure drop that will occur as the fluid flow from the apertures to the flow port,

10 125. The support member of any of clauses 112 fo 124, wherein the support member is provided with protrusions configured to space the support member from the base member.

126. The support member of clause 125, wherein the protrusions are formed by 15 embossing a pattern in the sheet of material fo create protrusions on the inner surface.

127. A sand screen incorporating a plurality of support members as defined in any of clauses to 112 to 126.

20

128. The sand screen of clause 127, wherein the support members are configured fo provide support for a fiiter member.

129. The sand screen of clause 127 or 128, wherein the support members are 25 formed to match the profile of one or both of a filter member and the base member.

130. The sand screen of clause 127, 128 or 129, further comprising fluid pressure-deformabie activation chambers, wherein the support members are configured to provide bridges between adjacent activation chambers.

30

131. The sand screen of any of clauses 127 fo 130, wherein the support members are configured to provide radial support for a surrounding well bore wall.

132. The sand screen of any of clauses 127 to 131, wherein the support members 35 assist in maintaining the circular form of the screen as the screen is activated.

34

133, A drainage layer for a sand screen comprising a plurality of support members in accordance with any of clauses 112 to 128,

134, A retainer for a sand screen filter member comprising a clamp member

5 configurable to clamp at least an end portion of a fiiter member against a clamp body configured for securing to a base member.

135, The retainer of clause 134, wherein the clamp member comprises an axially translatable retainer having a clamping surface configured to cooperate with an

10 opposing clamping surface on the clamp body, whereby a portion of the filter member may be secured between the surfaces,

138. The retainer of clause 135, wherein the clamping surfaces define tapers,

15 137. The retainer of clause 135 or 138, wherein the clamp body is recessed beyond the clamp body clamping surface to accommodate an end of the filter member.

138. The retainer of any of clauses 134 fo 137, wherein the clamp member is a 20 clamp ring and is threaded to the clamp body, whereby relative rotation of the clamp ring and clamp body induces axial movement of the damp ring on the clamp body,

139. The retainer of any of ciauses 134 fo 138, wherein the clamp body is integral with the base member.

25

140. The retainer of any of clauses 134 to 139, wherein the ciamp body is separate from the base member, and is adapted to float at ieast axially relative to the base member.

30 141. A sand screen incorporating the retainer of any of clauses 134 fo 140 in combination with a filter member.

142. The sand screen of clause 141, wherein the filter member comprises a weave.

35

143. The sand screen of clause 141 or 142, wherein the filter member is wrapped around the base member.

35

144, The sand screen of any of clauses 141 to 143, comprising filter media wrapped around a base member having a damp body secured at each and,

5 145. A method of retaining a filter member on a sand screen, the method comprising:

locating the filter member around a base member; and clamping at least end portions of the filter member against the base member,

10 148, The method of clause 145, comprising wrapping the filter member around the base member.

147, The method of clause 145 or 148, comprising axially translating a retainer having a clamping surface towards an opposing clamping surface and securing a

15 portion of the filter member between the surfaces.

148, The method of clause 147, comprising accommodating an end of the filter member is a recess beyond the clamping surfaces,

20 149, The method of clause 148, comprising spot welding the fiiter member In the recess during assembly fo retain the filter member in place before the clamping the fiiter member against the base member,

150, A method of restricting flow between zones in a well, the method comprising: 25 providing a layer of deformabie material on a sand screen; and activating the sand screen such that the deformabie material contacts and seals against the wall of the well.

151 The method of clause 150, wherein the deformabie material is provided on a 30 portion of the sand screen.

152, The method of ciause 150 or 151, wherein the deformabie material is provided at at least one end of the sand screen.

35 153, The method of ciause 150, 151 or 152, wherein the deformabie material is arranged on the sand screen such that fluid may pass beneath the material.

36

154, The method of any of clauses 150 to 153, wherein the wall of the well is lined,

155, The method of any of clauses 150 to 153, wherein the wall of the well is uniined,

5

158. The method of any of clauses 150 to 155, wherein the deformabie material is an elastomer,

157, The method of any of clause 150 to 156, wherein the deformabie material is 10 swellable,

158. A method of increasing the strength of a base member comprising moynting chambers on the base member and inflating the chambers,

15 159. The method of clause 158, wherein the base member is hollow,

160, The method of ciause 158 or 159, comprising arranging the chambers around an external surface of the base member.

20 161. The method of clause 158, 159 or 180, comprising arranging the chambers around an internal surface of the base member,

182, The method of ciause 158, 159 ,150, or 181., comprising arranging the chambers to extend axially of the base member,

25

163, The method of any of ciauses 158 to 162, wherein the base member is contained within a bore.

184, A method of creating a crush-resistant structure, the method comprising; 30 locating a base pipe in a bore; and

Inflating chambers located between the base pipe and the bore with fluid, thereby providing a structure having an elevated crush resistance.

185, The method of clause 164, wherein the structure 1s compliant with the bore

35

165. The method of clause 184 or 185, wherein the structure comprises a sand screen.

^7

166. The method of clause 164, 185 or 188, wherein the structure is located in a swelling formation or a formation with geo-mechanical movement.

5 157. A shroud for a sand confroi apparatus, the shroud having elongate slots and the shroud being configured to be located on a sand control apparatus with the slots inclined to the longitudinal axis of the apparatus,

188, Sand confroi apparatus comprising the shroud of clause 167, the shroud 10 being positioned on the exterior of the apparatus, adjacent a sand control element,

189. A method of controlling the activation of a sand screen having a shroud surrounding a sand control element, the method comprising selecting the activation characteristics of the shroud such that the shroud controls the radial force at which i 5 activation of the sand screen is initiated.

170. The method of clause 169, comprising utilising fluid pressure fo activate the screen,

20 171. The method of clause 189 or 170, comprising providing the shroud with elongate slots and locating the shroud on a sand screen with the slots inclined to the longitudinal axis of the screen.

25

30

35

38

5

Claims

10

1. Downhole apparatus comprising a fluid pressure deformabie chamber for location on a base member, th© chamber having a body having a first portion of a first length, width and depth, a second portion having at least one of a second depth and width less than the first portion, and a transition portion coupling the first and

15 second portions and configured to provide for a progression between deformation characteristics of the first and second portions.

20

3. The apparatus of claim 1 or 2, wherein the second portion forms an end of the chamber.

4. The apparatus of claim 1, 2 or 3, wherein the chamber is configured such 25 that on filling the chamber with fluid the depth of fhe chamber increases,

5. The apparatus of any of claims 1 fo 4, wherein a plurality of chambers is provided around a base member,

30 8. The apparatus of ciaim 5, wherein fhe chambers extend axially of the base member and are arranged side-by-side to provide substantially complete circumferential coverage of the base member.

7. The apparatus of any of claims 1 to 6, wherein the chamber supports a 35 member or device,

8. The apparatus of claim 7, wherein fhe chamber supports a filter member.

39

9, The apparatus of any of claims 1 fo 8, wherein the chamber has a wail formed fo match the profile of an associated base member.

5 10. Th® apparatus of any of claims 1 to 9S wherein the chamber has an arcuate inner wali where the chamber is intended to be mounted externally of a cylindrical base member,

11. The apparatus of any of claims 1 to 10, wherein as fhe chamber is filled 10 with fluid an outer wali moves radially outwards, increasing fhe depth of the chamber and th© diameter of the assembly.

12. The apparatus of any of claims 1 to 11 wherein the chamber has an arcuate outer wall.

15

13. The apparatus of any of claims 1 to 12, wherein the chamber includes an activation port to provide for passage of chamber-deforming fluid.

14. The apparatus of claim 13, wherein the port is provided in the second 20 portion, at an end of the chamber.

15. The apparatus of claim 13 or 14, wherein fhe activation port is located on a main axis of fhe chamber.

25 16. The apparatus of claim 14 or 15, wherein a fluid port is provided at the other end of the chamber.

17. The apparatus of claim 14 or 15, wherein fhe other end of the chamber is closed,

30

18. The apparatus of any of claims 1 to 17, wherein edges of the transition portion feature an inner radius and an outer radius.

19. The apparatus of any of claims 1 fo 18, where fhe transition portion is 35 configured to cooperate with a chamber block defining a fluid passage.

40

20, The apparatus of claim 19, wherein fhe chamber block is configured fo maintain its form while th© chamber is deformed,

21, The apparatus of ciaim 19 or 20, wherein fhe chamber block defines a 5 female port configured to receive the transition portion,

22, The apparatus of claim 19, 20 or 21, wherein fhe transition portion is bonded fo the block.

10 23, The apparatus of any of claims 19 to 22, wherein fhe block is configured to be secured fo a base member,

24, The apparatus of ciaim 23, wherein the chamber is adapted to be bonded to the block prior to the block being secured fo the base member,

15

25. The apparatus of claim 24, wherein the transition portion and block are adapted to be bonded around fhe complete periphery to ensure pressure integrity before fhe assembly is mounted on the base member,

20 26, The apparatus of any of claims 19 to 25: wherein the block includes an inlet port in an inner wall.

27. The apparatus of claim 28, wherein the inlet port includes a check vaive.

25 28. The apparatus of claim 26 or 27, wherein fhe Inlet port is configured fo communicate with the first port of the downhole apparatus comprising:

a tubular body;

first and second ports in a wall of the body, and a fluid pressure-responsive vaive arrangement having a locked first 30 configuration associated with a first pressure In which the first port is open and the second post is closed, an unlocked second configuration associated with a second pressure higher than the first pressure in which the first port is open and fhe second port Is closed, and a third configuration associated with a third pressure lower than the second pressure In which the second port is open and the first port is closed,

35

29. The apparatus of any of claims 1 to 28, wherein the first width and depth are substantially constant along fhe length of the body.

41

Amended claims have been filed as follows;-CLAIMS

1. Downhole apparatus comprising a fluid pressure deformabie chamber for location on a base member, the chamber having a body having a first portion of a 5 first length, width and depth, a second portion having at least one of a second depth and width less than the first portion, and a transition portion coupling the first and second portions and configured to provide for a progression between deformation characteristics of the first and second portions.

10 2. The apparatus of claim 1, wherein the second portion is adapted to locate or secure the chamber on the base member.

15

4. The apparatus of claim 1, 2 or 3, wherein the chamber is configured such CO that on filling the chamber with fluid the depth of the chamber increases.

CO 5. The apparatus of any of claims 1 to 4, wherein a plurality of chambers is o

CD O

20 provided around a base member.

6. The apparatus of claim 5, wherein the chambers extend axially of the base member and are arranged side-by-side to provide substantially complete circumferential coverage of the base member.

25

30

7. The apparatus of any of claims 1 to 6, wherein the chamber supports a member or device.

8. The apparatus of claim 7, wherein the chamber supports a filter member.

9. The apparatus of any of claims 1 to 8, wherein the chamber has a wall formed to match the profile of an associated base member.

10. The apparatus of any of claims 1 to 9, wherein the chamber has an

35 arcuate inner wall where the chamber is intended to be mounted externally of a cylindrical base member.

42

11. The apparatus of any of claims 1 to 10, wherein as the chamber is filled with fluid an outer wall moves radially outwards, increasing the depth of the chamber and the diameter of the assembly.

5 12. The apparatus of any of claims 1 to 11, wherein the chamber has an arcuate outer wall.

10

14. The apparatus of claim 13, wherein the port is provided in the second portion, at an end of the chamber.

15. The apparatus of claim 13 or 14, wherein the activation port is located on 15 a main axis of the chamber.

CO 16. The apparatus of claim 14 or 15, wherein a fluid port is provided at the

1 other end of the chamber.

oo

20 17. The apparatus of claim 14 or 15, wherein the other end of the chamber is

CD closed.

o

19. The apparatus of any of claims 1 to 18, where the transition portion is configured to cooperate with a chamber block defining a fluid passage.

25

20. The apparatus of claim 19, wherein the chamber block is configured to 30 maintain its form while the chamber is deformed.

21. The apparatus of claim 19 or 20, wherein the chamber block defines a female port configured to receive the transition portion.

35 22. The apparatus of claim 19, 20 or 21, wherein the transition portion is bonded to the block.

43

23. The apparatus of any of claims 19 to 22, wherein the block is configured to be secured to a base member.

24. The apparatus of claim 23, wherein the chamber is adapted to be bonded 5 to the block prior to the block being secured to the base member.

25. The apparatus of claim 24, wherein the transition portion and block are adapted to be bonded around the complete periphery to ensure pressure integrity before the assembly is mounted on the base member.

10

26. The apparatus of any of claims 19 to 25, wherein the block includes an inlet port in an inner wall.

27. The apparatus of claim 26, wherein the inlet port includes a check valve.

28. The apparatus of claim 26 or 27, wherein the inlet port is configured to communicate with the first port of the downhole apparatus comprising:

a tubular body;

first and second ports in a wall of the body, and a fluid pressure-responsive valve arrangement having a locked first configuration associated with a first pressure in which the first port is open and the second port is closed, an unlocked second configuration associated with a second pressure higher than the first pressure in which the first port is open and the second port is closed, and a third configuration associated with a third pressure lower than the second pressure in which the second port is open and the first port is closed.

29. The apparatus of any of claims 1 to 28, wherein the first width and depth are substantially constant along the length of the body.

30

15

CO CO

o

CD O

20

25

35