Sand control screen having a micro-perforated filtration layer

Abstract

A sand control screen (40) includes a perforated base pipe (42) and a filter layer (50) that has micro-perforations (52) therein. The filter layer (50) is attached to the base pipe (42) along the entire length of the filter layer (50). Channels (46) are formed between the base pipe (42) and the filter layer (50) to allow fluid to flow therebetween. The sand control screen (40) is formed by micro-perforating a length of material, such as sheet metal, to form the filter layer (50), creating channels (46) that will allow fluids to flow between the base pipe (42) and filter layer (50), wrapping the filter layer (50) around the base pipe (42), attaching the filter layer (50) to the base pipe (42) along the length of the filter layer (50) and creating a seam between the two edges of the filter layer (50).

Description

TECHNICAL FIELD OF THE INVENTION[0001]This invention relates, in general, to a sand control device used during the production of oil, gas or water and a manufacturing process related to the same and, in particular, to a sand control screen having a micro-perforated filtration layer.BACKGROUND OF THE INVENTION[0002]Without limiting the scope of the present invention, its background will be described with reference to producing fluid from a subterranean formation, as an example.[0003]After drilling each of the sections of a subterranean wellbore, individual lengths of relatively large diameter metal tubulars are typically secured together to form a casing string that is positioned within each section of the wellbore and cemented in place. This casing string is used to increase the integrity of the wellbore by preventing the wall of the hole from collapsing and to prevent movement of fluids from one formation to another formation.[0004]Once the process of drilling and installing casing...

AI Technical Summary

Benefits of technology

[0010]The present invention disclosed herein comprises a sand control screen having a micro-perforated filter layer for filtering particles out of fluid produced from a wellbore and a method for manufacturing the same. The sand screen of the present invention allows for precise, reliably reproducible and infinitely variable opening size, shape, density and pattern in the micro-perforated filter layer, thereby providing the desired sand control function. In addition, the sand control screen of the present invention is robust, easy to clean and simple to manufacture.

[0011]The sand control screen having a micro-perforated filter layer of the present invention includes a base pipe having a plurality of openings that allow fluid flow therethrough and a filter layer having a plurality of micro-perforations. The filter layer wraps around the base pipe and is attached thereto. A drainage layer such as channels, wire wrap or wire mesh between the base pipe and filter layer allows production fluid to flow between the filter layer and the base pipe.

Problems solved by technology

Production of these materials causes numerous problems in the operation of oil, gas or water wells.

These problems include plugging of formations, tubing and flow lines, as well as erosion of tubing, downhole equipment and surface equipment.

These problems lead to poor productivity, high maintenance costs and unacceptable well downtime.

It has been found, however, that existing sand screens continue to have a number of drawbacks.

For example, variations in the gauge of the wire or improper manufacture can result in inconsistencies in the opening size.

Larger gauges of wire become increasingly difficult to bend, while smaller gauges are more easily damaged in the processes of manufacture and installation or during production.

Additionally, screens that use multiple filter layers are, by their nature, difficult or impossible to clean.

Still further, the attachment of the wire wrap screen or wire mesh screen to the base pipe is an ongoing cause of concern.

A failure of any portion of the weld results in an uncontrolled opening and a loss of sand control.

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