A New Approach to the Sand Control Problem A Multi-Layer, Wire-Wrapped Sand Screen
Authors: Spurlock J.W. , Demski D.B. 
Published: December 2007

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Single-layer, wire-wrapped sand screens have been used to control unconsolidated oil-bearing sands since the early 1900's. Although the first screens were somewhat primitive in design, the sane fundamental theories of their sand-restraining ability still apply today.. Gravel-packed screens and liners are considered very reliable but have limitations in that they are relatively expensive (primarily in rig time) to install and sometimes hinder subsequent workover operations on a well. This aspect of the gravel-packed screen has led to the development of a multi-layer, wire-wrapped sand screen which offers a new approach to the old problem of control of unconsolidated sand in both oil and gas wells.

The function of the multiple wraps of variously spaced wire is to bridge the larger sand grains at the outer layer of the screen, intermediate size grains in the successive layers, and the smaller size grains in the innermost layer. Thus, a selectively sorted gravel pack of formation sand is simulated in the screen. Gauge spacing of the wire is such that minute particles of silt and clay can migrate through the screen during installation and when production is initiated, thereby eliminating a major source of restriction experienced with conventional, single-wire-wrapped screens.

The multi-layer screen does not require a gravel pack but can be used with one if it is deemed advisable for added protection from highly abrasive particles in the well fluids produced at high velocities. It is applicable produced at high velocities. It is applicable for multiple completions and has been installed and tested in 33 wells onshore and 26 wells offshore with an overall success ratio of 80 percent. Completions with the screen have been percent. Completions with the screen have been made in high capacity gas wells and in oil wells produced by flowing, pumping and on gas-lift. produced by flowing, pumping and on gas-lift. The screen can be fabricated for any length interval and any size casing. It can be used for multiple completions without gravel packing and offers simplified mechanical packing and offers simplified mechanical possibilities for multi-zone completions. possibilities for multi-zone completions.