Patent Publication Number: US-2017362922-A1

Title: Filter Media 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. 62/350,514, titled “Filter Media For Sand Control Screen Assemblies” and filed on Jun. 15, 2016, and to U.S. Provisional Patent Application Ser. No. 62/403,979, titled “Filter Media 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 filter media 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. 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 filter media 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 base pipe having openings through a thickness of the pipe, a filter medium disposed about the base pipe, and a radial extension extending from the filter medium&#39;s inner surface and/or outer surface. The radial extension generally ensures substantially uniform radial spacing relative to the filter medium&#39;s inner and/or outer surface. In example embodiments, the radial extension may be a wire assembly and/or comprise metal sheet strips. 
     In another example embodiment, a sand control screen assembly includes a perforated base pipe, a filter medium disposed about the base pipe, and an offset means for providing a radial spacing relative to the filter medium&#39;s inner surface and/or outer surface. In example embodiments, the radial extension may be a wire assembly and/or comprise metal sheet strips. 
     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 perspective view of a section of a sand control screen assembly, according to an embodiment of the present invention. 
         FIG. 3B  is a side cross-sectional view of the sand control screen assembly section of  FIG. 3A , according to an embodiment of the present invention. 
         FIG. 3C  is a top view of the sand control screen assembly section, according to an embodiment of the present invention. 
         FIG. 3D  is a bottom view of the sand control screen assembly section, 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”, “upper”, “lower”, “inner”, “outer”, “top”, “bottom”, 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 a generally woven, wire-wrapped, or 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 alternative embodiments, the shroud  220  may be a wire-wrapped jacket, a slotted screen jacket, or a stamped jacket. 
       FIGS. 3A-3D  illustrate an exemplary embodiment of a section  300  of a sand control screen assembly for use in a wellbore. The sand control screen assembly of  FIGS. 3A-3D  may replace 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. 
     Referring to  FIGS. 3A-3D , the sand control screen assembly section  300  includes a perforated base pipe  305  having openings  325 , a filter medium  315 , and a perforated protective shroud  320  having openings  345 . In certain other embodiments, a drainage layer (not shown) may be included between the base pipe  305  and the filter medium  315 . For instance, when a mesh filter medium is utilized, a drainage layer may be included. In cases where a wire-wrapped or slotted liner is utilized, a drainage layer may be excluded. Generally, fluid flows in a direction from the shroud  320  towards the base pipe  305 . 
     In certain exemplary embodiments, the filter medium  315  may include an offset D 1  provided by a radial extension  350 . The radial extension  350  protrudes radially outwards from a central axis of a sand control screen assembly, and provides offset D 1  between the shroud  320  and the filter medium  315 . The offset D 1  can be in the range of from about 0.05 to about 1.0 inch. In certain embodiments, the radial extension  350  is provided by a wire or wire assembly. In certain other embodiments, the radial extension  350  can be oriented helically, longitudinally, or circumferentially on the weave tube. In other embodiments, the radial extension  350  is provided by metal sheet strips, either in sections or for the entire length of the tube. The radial extension  350  may be coupled to the filter medium  315  in any suitable manner known to one having ordinary skill in the art, such as welding or diffusion bonding. Once the sand control screen assembly is constructed, the offset D 1  allows for dispersion of fluid flow and therefore a decay of velocities approaching the filter medium  315 . The lower approach velocity results in a lower erosion rate over conventional filter media utilized. In addition, in certain embodiments, the offset D 1  may also provide some structural support for the shroud  300 . 
     In certain exemplary embodiments, the filter medium  315  may also include an offset D 2  provided by a radial extension  360 . The radial extension  360  protrudes radially inwards towards a central axis of a sand control screen assembly, and provides offset D 2  between the base pipe  305  (or a drainage layer, if one is included) and the filter medium  315 . The offset D 2  can be in the range of from about 0.05 to about 1.0 inch. In certain embodiments, the radial extension  360  is provided by a wire or wire assembly. In certain other embodiments, the radial extension  360  can be oriented helically, longitudinally, or circumferentially on the weave tube. In other embodiments, the radial extension  360  is provided by metal sheet strips, either in sections or for the entire length of the tube. The radial extension  360  may be coupled to the filter medium  315  in any suitable manner known to one having ordinary skill in the art, such as welding or diffusion bonding. Once the sand control screen assembly is constructed, the offset D 2  allows for increased drainage and thus lower erosion by reducing the flow concentration towards the base pipe perforation holes that have a limited opening ratio. 
     In addition, while the present figures illustrate radial extensions  350 ,  360  having a elliptical cross-sectional profile, one having ordinary skill in the art will recognize that in alternative embodiments, the radial extensions can have any profile shape configuration, such as triangular, rectangular, circular, oval, square, quatrefoil, curvilinear triangular, trapezoidal, pentagon, hexagon, other polygons, asymmetrical, and the like. In certain exemplary embodiments, the radial extensions  350 ,  360  line up in pairs when the filter medium  315  is assembled. In certain other embodiments, the radial extensions  350 ,  360  may be offset from one another when the filter medium  315  is assembled. One having ordinary skill in the art will also recognize that the radial extensions  350 ,  360  can vary in size, number, frequency, arrangement, and the like, from application to application. 
     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.