Patent Publication Number: US-10767449-B2

Title: Protective shrouds for sand control screen assemblies

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority under 35 U.S.C. § 119 to U.S. Provisional Patent Application Ser. No. 62/350,443, titled “Protective Shrouds For Sand Control Screen Assemblies” and filed on Jun. 15, 2016, and to U.S. Provisional Patent Application Ser. No. 62/403,922, titled “Protective Shrouds For Sand Control Screen Assemblies” and filed on Oct. 4, 2016, the entire contents of which are hereby incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present application relates generally to structures adapted for filtering particulates from a flowing fluid in a wellbore that traverse a subterranean hydrocarbon bearing formation, and in particular, to protective jackets or shrouds for sand control screen assemblies. 
     BACKGROUND 
     Sand exclusion screen assemblies are employed in wellbores during the production of hydrocarbon fluids from subterranean formations. Conventional sand screen assemblies include a perforated base pipe, a drainage layer, a filter medium, and a protective jacket or shroud. Such screen assemblies are designed to filter out particles, such as formation sand or placed gravel/proppant, while facilitating the passage of hydrocarbon fluids into the wellbore. One drawback in the deployment of such screen assemblies is the erosion of the filter medium by particle impingement contained in the fluids that pass the screen assemblies. The presence of particulate in the flow stream, coupled with the current designs and manufacturing methods of the screen assemblies, can cause erosion. For instance, current designs and manufacturing methods minimize the space, or offset, between the sand screen components for a number of reasons, which can increase erosion of the filter medium. For example, the offset between conventional shrouds and the filter medium is not controlled and the shrouds are susceptible to deformation and/or radial movement, which can cause the shroud to interface with the filter medium at various locations away from the welds at the ends of the base pipe. Since conventional shrouds may have perforated holes, these holes cause a flow concentration that localizes and increases the erosion of the filter medium resulting from an inadequate amount of flow dispersion due to the interface between the shroud and the filter medium. When the filter medium becomes eroded, then particles are produced from the well, which is highly undesirable. Production of these particles can cause excessive erosion of production tubulars, downhole equipment and surface equipment, and lead to high maintenance costs and undesirable downtime of wells. 
     Accordingly, a need has arisen for a sand control screen assembly that is capable of filtering fines out of a production stream from a subterranean hydrocarbon bearing formation and that does not readily suffer from erosion. 
     SUMMARY 
     The present application is generally related to protective jackets or shrouds for sand control screen assemblies for filtering particulates from a flowing fluid in a wellbore that traverses a subterranean hydrocarbon bearing formation. 
     In an example embodiment, a sand control screen assembly includes a filter medium for particle control and/or particle filtration, a protective shroud or jacket disposed about the filter medium, and a radial extension. The radial extension provides substantially uniform radial spacing relative to the jacket&#39;s inner surface. Generally, the sand control screen assembly also includes a base pipe and a drainage layer. The drainage layer is positioned about the base pipe, and the filter medium is positioned about the drainage layer. In certain instances where a drainage layer is not utilized, the filter medium is positioned about the base pipe. 
     In another example embodiment, a sand control screen assembly includes a filter medium for particle control and/or particle filtration, a perforated shroud disposed about the filter medium, and an offset means for ensuring substantially uniform radial spacing relative to the jacket&#39;s inner surface. Generally, the sand control screen assembly also includes a base pipe and a drainage layer. The drainage layer is positioned about the base pipe, and the filter medium is positioned about the drainage layer. In certain instances where a drainage layer is not utilized, the filter medium is positioned about the base pipe. 
     In yet another example embodiment, a method of manufacturing a jacket for a sand control screen assembly includes (a) providing a single sheet of metal, (b) forming at least one protrusion on the metal sheet adjacent to a junction where the metal sheet is assembled to form the jacket, and (c) assembling the metal sheet to form the jacket, wherein upon assembly, the at least one protrusion faces an interior of the jacket. Generally, the sand control screen assembly also includes a filter medium. The jacket is positioned about the filter medium, and the protrusion(s) provide a substantially uniform radial spacing between the filter medium and the jacket. 
     These and other aspects, objects, features, and embodiments will be apparent from the following description and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a schematic illustration of a wellbore environment including a pair of sand control screen assemblies, according to an embodiment of the present invention. 
         FIG. 2A  is a top perspective view of a sand control screen assembly, according to an embodiment of the present invention. 
         FIG. 2B  is a partial cut away view of the sand control screen assembly of  FIG. 2A , according to an embodiment of the present invention. 
         FIG. 2C  is an exploded view of the sand control screen assembly of  FIG. 2A , according to an embodiment of the present invention. 
         FIG. 2D  is a side cross-sectional view of the sand control screen assembly of  FIG. 2A , according to an embodiment of the present invention. 
         FIG. 3A  is a side view of a shroud for a sand control screen assembly, showing the interior of the shroud, according to an embodiment of the present invention. 
         FIG. 3B  is a perspective view of the shroud of  FIG. 3A , according to an embodiment of the present invention. 
         FIG. 3C  is a side view of the shroud of  FIG. 3A , according to an embodiment of the present invention. 
         FIG. 3D  is a side cross-sectional view of the shroud of  FIG. 3A , taken along section A-A, according to an embodiment of the present invention. 
         FIG. 4A  is a side view of another shroud for a sand control screen assembly, showing the interior of the shroud, according to an embodiment of the present invention. 
         FIG. 4B  is a perspective view of the shroud of  FIG. 4A , according to an embodiment of the present invention. 
         FIG. 4C  is a side cross-sectional view of the shroud of  FIG. 4A , taken along section B-B, according to an embodiment of the present invention. 
         FIG. 5A  is a side view of yet another shroud for a sand control screen assembly, showing the interior of the shroud, according to an embodiment of the present invention. 
         FIG. 5B  is a perspective view of the shroud of  FIG. 5A , according to an embodiment of the present invention. 
         FIG. 5C  is a side cross-sectional view of the shroud of  FIG. 5A , taken along section C-C, according to an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     The present application provides sand control screen assemblies that are more resistant to erosion than conventional sand control screen assemblies. By limiting erosion loss, it is not required to reduce the rate of oil and gas production, which is common in instances of sand screen erosion. 
     The invention may be better understood by reading the following description of non-limitative, exemplary embodiments with reference to the attached drawings, wherein like parts of each of the figures are identified by the same reference characters. In the following description of the representative embodiments of the invention, directional terms, such as “above”, “below”, “top”, “bottom”, “inner”, “outer”, “upper”, “lower”, etc., are used for convenience in referring to the accompanying drawings. In general, “above”, “upper”, “upward” and similar terms refer to a direction toward the earth&#39;s surface along a wellbore, and “below”, “lower”, “downward” and similar terms refer to a direction away from the earth&#39;s surface along the wellbore towards the bottom of well. 
     Referring to  FIG. 1 , illustrated is a wellbore system  100  that may employ the principles of the present disclosure, according to one or more embodiments of the disclosure. As depicted, the wellbore system  100  includes a wellbore  105  having production intervals  110 ,  115 , having sand control screen assemblies  120 ,  125 , respectively, positioned therein. The wellbore  105  extends through various formations  130 ,  135  in the earth strata. A casing  140  is supported within wellbore  105  by cement  145 . A production or completion string  150  includes various tools, such as sand control screen assembly  120  that is positioned within production interval  110  between packers  160 ,  165 . In addition, the production or completion string  150  includes a sand control screen assembly  125  that is positioned within production interval  115  between packers  170 ,  175 . The sand control screen assemblies  120 ,  125  serve the primary functions of filtering particulate matter out of the production fluid stream and may also include flow control capabilities or other additional functionality. One or more control lines  180  may extend from a ground surface within annulus  185  and pass through sand control screen assemblies  120 ,  125  to provide instructions, carry power, signals and data, and transport operating fluid, such as hydraulic fluid, to sensors, actuators and the like associated with sand control screen assemblies  120 ,  125  and other tools or components positioned downhole. Sensors (not shown) operably associated with production or completion string  150  may be used to provide valuable information to the operator via control line  180  during the production phase of the well, such as fluid temperature, pressure, velocity, constituent composition and the like, such that the operator can enhance the production operations. 
     Even though  FIG. 1  depicts sand control screen assemblies  120 ,  125  in a cased hole environment, one skilled in the art will recognize that the sand control screen assemblies of the present invention are equally well suited for use in open hole environments. Also, even though  FIG. 1  depicts a vertical completion, one skilled in the art will recognize that the sand control screen assemblies of the present invention are equally well suited for use in well having other directional configurations including horizontal wells, deviated wells, multilateral wells, and the like. 
       FIGS. 2A-2D  illustrate an exemplary embodiment of a sand control screen assembly  200  for use in wellbore  105  ( FIG. 1 ). Along with the other sand control screen assemblies described in the present application, the sand control screen assembly  200  may replace one or more of the screen assemblies  120 ,  125  described in  FIG. 1  and may otherwise be used in the exemplary wellbore system  100  depicted therein. 
     The screen assembly  200  generally includes a perforated base pipe  205 , a drainage layer  210 , a filter medium  215 , and a protective jacket or shroud  220 . Generally, during hydrocarbon production, fluid from the subterranean formation flows in a direction from the formation, through the shroud  220 , and towards a central axis Ac of the base pipe  205 . The base pipe  205  provides structural support to the assembly  200 , and also provides flow communication via openings  225  with the production or completion string  150  ( FIG. 1 ) in the wellbore  105 . The drainage layer  210  occasionally is a slotted screen and includes a plurality of ribs  235  that are substantially symmetrically disposed or positioned about the central axis Ac of the base pipe  205 . In certain embodiments, the slotted screen is made up of wrapped wires. The drainage layer  210  is placed around the surface of the base pipe  205  and typically distributes inflow to the base pipe  205 . In certain embodiments, the drainage layer  210 , composed of the slotted screen and the plurality of ribs  235 , can be replaced by other porous structures such as metal meshes. The filter medium  215  that surrounds the drainage layer  210  is utilized for particle control and/or particle filtration of a predetermined size. The filter medium  215  is generally woven, wire-wrapped, or a slotted liner. The shroud  220  surrounds the filter medium  215  and provides protection to the assembly  200  during installation. In certain exemplary embodiments, the shroud  220  is a perforated jacket. In certain other embodiments, the shroud  220  may be a slotted screen jacket or a stamped jacket. The shroud  220  is a generally cylindrical-shaped tube  240  having one or more openings  245  that extend from an outer wall  240   a  of the tube  240  to an inner wall  240   b  of the tube  240 . Fluid from the subterranean formation generally flows in a direction from the outer wall  240   a  towards the inner wall  240   b  through openings  245 . An offset means is provided between the shroud  220  and the filter medium  215 , as described further with the exemplary embodiments below. 
       FIGS. 3A-3D  illustrate an exemplary embodiment of a shroud  300  for a sand control screen assembly for use in a wellbore. Along with the other shrouds described in the present application, the shroud  300  may replace the shroud  220  of the sand control screen assembly  200  described in  FIGS. 2A-D  and may otherwise be used in the exemplary wellbore system  100  ( FIG. 1 ) depicted therein. 
     The shroud  300  is a generally cylindrical-shaped tube  340  having one or more openings  345  that extend from an outer wall  340   a  of the tube  340  to an inner wall  340   b  of the tube  340 , whereby fluid can pass through the openings  345 . In certain exemplary embodiments, the shroud  300  includes an offset D 1  provided by a radial extension  350 . The radial extension  350  protrudes radially inwards towards a central axis Ac, and provides offset D 1  between the shroud  300  and a filter medium (not shown). The offset D 1  can be in the range of from about 0.05 to about 1.0 inch. In certain embodiments, the shroud  300  may be manufactured from a single sheet of metal with a bend of about 90 degrees at the edges to allow for a predetermined length protruding radially inward when the tube  340  is assembled. Generally, the bends at the edges can be in a range of from about 60 to about 120 degrees inwards to form the offset D 1 . Once the tube  340  is constructed, the controlled offset D 1  allows for dispersion of fluid flow and therefore a decay of velocities approaching the filter medium. The lower approach velocity results in a lower erosion rate over conventional shrouds utilized. In addition, in certain embodiments, the offset D 1  may also provide some structural support to the shroud  300 . 
       FIGS. 4A-4C  illustrate an exemplary embodiment of a shroud  400  for a sand control screen assembly for use in a wellbore. Along with the other shrouds described in the present application, the shroud  400  may replace the shroud  220  of the sand control screen assembly  200  described in  FIGS. 2A-D  and may otherwise be used in the exemplary wellbore system  100  ( FIG. 1 ) depicted therein. The shroud  400  is the same as that described above with regard to shroud  300 , except as specifically stated below. For the sake of brevity, the similarities will not be repeated hereinbelow. 
     Referring now to  FIG. 4A-4C , the shroud  400  includes an offset dl provided by a wire  450  that is coupled to a metal sheet that is welded to form tube  440  of the shroud  400 . The wire  450  protrudes radially inwards towards central axis Ac, and has a dimension that provides an offset dl between the shroud  400  and a filter medium (not shown). In certain exemplary embodiments, the wire has a circular cross section and the diameter/offset dl can be in the range of from about 0.05 to about 1.0 inch. The wire  450  may be coupled to the tube  440  in any suitable manner known to one having ordinary skill in the art, such as helical or longitudinal welding. 
       FIGS. 5A-5C  illustrate an exemplary embodiment of a shroud  500  for a sand control screen assembly for use in a wellbore. Along with the other shrouds described in the present application, the shroud  500  may replace the shroud  220  of the sand control screen assembly  200  described in  FIGS. 2A-D  and may otherwise be used in the exemplary wellbore system  100  ( FIG. 1 ) depicted therein. The shroud  500  is the same as that described above with regard to shroud  300 , except as specifically stated below. For the sake of brevity, the similarities will not be repeated hereinbelow. 
     Referring now to  FIG. 5A-5C , the shroud  500  includes an offset  51  provided by dimples or protrusions  550  that are formed adjacent to or near the junctions where a metal sheet is welded to form tube  540  of the shroud  500 . In certain alternative embodiments, the protrusions  550  are formed at a position away from the junctions. The protrusions  550  protrude radially inwards towards central axis Ac, and provide an offset  51  between the shroud  500  and a filter medium (not shown). In certain exemplary embodiments, the offset Si can be in the range of from about 0.05 to about 1.0 inch. The protrusions  550  may be formed in the metal sheet forming the tube  540  in any suitable manner known to one having ordinary skill in the art, such as stamping. In addition, while the present figures illustrate rectangular protrusions  550 , one having ordinary skill in the art will recognize that in alternative embodiments, the protrusions can have any profile shape configuration, such as triangular, circular, elliptical, oval, square, quatrefoil, curvilinear triangular, trapezoidal, pentagon, hexagon, other polygons, asymmetrical, and the like. In certain exemplary embodiments, the protrusions  550  line up in pairs when the tube  540  is assembled, as shown in  FIG. 5B . In certain other embodiments, the protrusions  550  may be offset from one another when the tube  540  is assembled. 
     In certain exemplary embodiments, methods of the present invention include methods of manufacturing a jacket for a sand control screen assembly. A single sheet of metal includes at least one protrusion adjacent to a junction where the metal sheet is assembled to form the jacket. The jacket is then assembled from the metal sheet such that the at least one protrusion extends towards the interior of the jacket. In certain embodiments, the protrusion may be a wire assembly, such as wire  450  ( FIGS. 4A-4C ). In certain other embodiments, the protrusion is formed by a bend at an edge of the metal sheet, as described with respect to  FIGS. 3A-3D . In yet other embodiments, the protrusions are dimples, such as protrusions  550  ( FIGS. 5A-5C ). 
     Although embodiments described herein are made with reference to example embodiments, it should be appreciated by those skilled in the art that various modifications are well within the scope and spirit of this disclosure. Those skilled in the art will appreciate that the example embodiments described herein are not limited to any specifically discussed application and that the embodiments described herein are illustrative and not restrictive. From the description of the example embodiments, equivalents of the elements shown therein will suggest themselves to those skilled in the art, and ways of constructing other embodiments using the present disclosure will suggest themselves to practitioners of the art. Therefore, the scope of the example embodiments is not limited herein.