Screens and screen assemblies having overlapping layers

Abstract

There is provided a screen comprising a support layer and a filter layer that overlap so as to reduce an overall thickness of the screen. The support layer can include a plurality of support elements and the filter layer can include one or more filter elements. The support elements can be embedded in the filter elements, or vice versa, such that the support layer and the filter layer overlap by at least 5%. In some embodiments, the support elements can be entirely embedded in the filter elements or the filter elements can be entirely embedded in the support elements. The filter layer can define a filter area that has a flow through area that is at least 1 % of the total surface area of the screen, or in some cases, between 4% and 20% of the total surface area of the screen.

Description

SCREENS AND SCREEN ASSEMBLIES HAVING OVERLAPPING LAYERSTECHNICAL FIELD

[0001] The technical field generally relates to screens and screen assemblies, for example, for use in applications requiring a relatively small thickness of the screen without compromising strength. In particular, the technical field relates to a screen for use in downhole components including, but not limited to, downhole valve assemblies, sand screens, and flow control regulators.BACKGROUND

[0002] Recovery of fluids from subterranean formations following hydraulic fracturing can be complicated by the presence of particulate matter, most notably sand, within the fluids. Production of sand along with target petrochemical fluids can lead to plugging and erosion of wellbore infrastructure, potentially impacting profitability due to increased maintenance costs accompanied by reduced production. Various strategies have been developed for controlling sand production and can be grouped into those strategies that allow sand into the wellbore and those that restrict access into the wellbore. A common strategy for restricting access is the inclusion of screens that prevent particles of a defined size from entering the wellbore with production fluids.

[0003] Known screens are multilayered, including two or more distinct layers of material, including a filter layer, which dictates the gauge, and a support layer for maintaining structural integrity. For example, wire wrap screens include a perforated base pipe or support structure layer, one or more ribs extending along the length of the support structure, and a wire wrapped over the ribs. These screens have three distinct layers that do not overlap or extend radially through each other. Moreover, the support structure and rib wires on conventional wire wrap screens significantly reduce the overall-cross sectional opening area of the screen and require the flow to traverse axially before exiting through a perforation in the base pipe, which can reduce the flow-through capacity of the screen.

[0004] Figure 2A shows a perspective axial cut out view of a typical wire wrapped screen design comprising a perforated base pipe 16 overlayed with longitudinal ribs 15, with wires 17 wrapped radially over the longitudinal ribs 15 along the axial length of thescreen. The distinct layers, shown schematically in cross section in FIG. 2B, do not overlap, they are stacked on top of each other. The wrapped wires form the filter layer 12 on the exterior or input side of the screen, the filter layer 12 followed by the support layer 14. For wire wrapped screens the support layer comprises two layers. A first support layer formed by the longitudinal ribs 15, is followed up by the second support layer comprising the perforated base pipe 16. Fluid contacting the screen on the input side follows a flow path, F, and passes between adjacent wires into space between longitudinal ribs, and either passes directly through a perforation or moves axially to the nearest perforation (see arrow in FIG. 2A and 2B) and into the wellbore string passage 7.

[0005] Another example of known screens are screens that have been described for use in valve assemblies as, or part of, a sliding sleeve, such as that described in U.S. Patent No. 11 ,87,025. The screen described is formed by machining threads on the inner surface of a tubular filter element to create an inverted V edge within the interior of the filter element. Longitudinal slots machined into the outer surface and transverse to the interior threads, at a depth necessary to intersect the most radial tip of the V edge, provides access through the filter element. Fluid enters the longitudinal slots before passing through the V edge. The outer section provides the support and the depth of the V -edge acts as the filter layer. While the screen is formed from a single tubular, the resulting layers, like those with the wire wrapped screen, do not overlap. Where the support layer stops, the filter layer, by the presence of the V edge, starts.

[0006] In cemented wells, the screen sleeve needs to be shrouded during install to prevent accumulation of cement within the filter layer. The shroud may be provided as another sliding sleeve that is internally concentric relative to the screen sleeve, and during install the screen sleeve is situated within a narrow annulus between the shroud and the housing of the valve assembly. The screen sleeve must therefore comprise a thickness that is compatible with the narrow annulus. As such, improving the pressure rating of a screen sleeve using known multilayer designs is limited due to dimensions of the annulus.

[0007] Over time, sand can accumulate on the input side of the screen creating additional stress on the screen. Commercial screens are generally rated according to the minimum pressure that a screen can withstand before failure as the ability of the screen to maintain structural integrity, even in low pressure environments, is crucial as a failingscreen due to collapse may result in closure of the well. Increasing the rating using conventional screen design requires a thicker, stronger, support layer, which ultimately increases the thickness of the screen. A thicker screen will result in one or both of a reduced internal diameter or increased external diameter of the wellbore string in screened sections. Reduced internal diameter reduces flow rates and may restrict use of some downhole tools and an increase in external diameter may result in snagging during well completion or prevent the wellbore string from fitting within the wellbore.

[0008] Therefore, a need exists for improving downhole screen designs that provide flexibility in balancing structural integrity and screening without significantly impacting the overall thickness of the screen.SUMMARY

[0009] According to one aspect, there is provided a screen for screening fluids containing a particulate, wherein the screen comprises an input side and a discharge side, the screen comprising: a screen thickness spanning from the input side to the discharge side; a filter layer comprising a gauge and a filter layer thickness; a support layer for providing structural support and comprising a support layer thickness; and a plurality of size-restricted flow paths having at least one inlet and at least one outlet and extending through both the filter layer and the support layer and configured to provide fluid communication from the input side to the discharge side; wherein at least a fraction of the thickness of each of the support layer and the filter layer are embedded within each other such that the screen thickness is less than the sum of the support layer thickness and the filter layer thickness; and wherein the gauge represents the smallest dimension in the plurality of size-restricted flow paths passing through the filter layer.

[0010] In some embodiments, the filter layer comprises a filter layer input side and a filter layer discharge side; and the support layer comprises a support layer input side and a support layer discharge side; wherein the input side of the screen is formed by the filter layer input side, the support layer input side, or a combination of the filter layer input side and the support layer side.

[0011] In some embodiments, the input side is formed by the filter layer input side.

[0012] In some embodiments, the input side is formed by the support layer input side.

[0013] In some embodiments, the filter layer thickness is essentially the same as the support layer thickness.

[0014] In some embodiments, the filter layer thickness is not the same as the support layer thickness.

[0015] In some embodiments, 5% to 100% of the thickness of the support layer is embedded within at least a fraction of the thickness of the filter layer.

[0016] In some embodiments, 50% to 100% of the thickness of the support layer is embedded within at least a fraction of the thickness of the filter layer.

[0017] In some embodiments, 5% to 100% of the thickness of the filter layer is embedded within at least a fraction of the thickness of the support layer.

[0018] In some embodiments, 50% to 100% of the thickness of the filter layer is embedded within at least a fraction of the thickness of the support layer.

[0019] In some embodiments, the thickness of the support layer is completely embedded with the filter layer.

[0020] In some embodiments, the thickness of the filter layer is completely embedded with the support layer.

[0021] In some embodiments, the gauge is from 0.006 inches to 0.05 inches.

[0022] In some embodiments, the pressure rating of the screen is from about 1 PSI to about 20,000 PSI.

[0023] In some embodiments, the pressure rating of the screen is from about 100 PSI to about 15,000 PSI.

[0024] In some embodiments, a total cross-sectional flow area of each of the one or more inlets is substantially equal to or less than a total cross-sectional flow area of each of the one or more outlets.

[0025] In some embodiments, wherein a total cross-sectional flow area of each of the one or more outlets is substantially equal to or less than a total cross-sectional flow area of each of the one or more inlets.

[0026] In some embodiments, wherein the one or more inlets comprise a total cross- sectional flow area that is from about 1% to about 90% a total surface area of the screen.

[0027] In some embodiments, the filter layer comprises a sheet comprising a plurality of holes that contribute to the shape of the plurality of flow paths.

[0028] According to one broad aspect, there is provided a screen for screening fluids containing a particulate, wherein the screen comprises an input side and a discharge side and is configured to provide fluid communication therebetween, the screen comprising: a support layer comprising a plurality of support elements extending in a first direction; and a filter layer comprising a plurality of filter elements extending in a second direction; wherein the first direction is transverse to the second direction such that the plurality of support elements and the plurality of filter elements define a plurality of flow paths each having at least one inlet and at least one outlet, wherein the plurality of flowpaths are configured to provide the fluid communication; and wherein the plurality of support elements are embedded in the plurality of filter elements.

[0029] In some embodiments, the plurality of support elements are embedded in the plurality of filter elements, such that at least a portion of a height of the plurality of support elements is contained within a thickness of the plurality of filter elements.

[0030] In some embodiments, an entirety of the thickness of the plurality of support elements is embedded in the height of the plurality of filter elements, such that a height of the screen is equal to the height of the plurality of filter elements.

[0031] In some embodiments, the at least a portion of the height of the plurality of support elements is at least 5% of the height of the plurality of filter elements.

[0032] In some embodiments, the at least a portion of the height of the plurality of support elements is at least 50% of the height of the plurality of filter elements.

[0033] In some embodiments, the at least a portion of the height of the plurality of support elements is at least 80% of the height of the plurality of filter elements.

[0034] In some embodiments, the height of the plurality of support elements is equal to or less than the height of the plurality of filter elements.

[0035] In some embodiments, at least 5% of the height of the plurality of filter elements is contained in the height of the plurality of support elements.

[0036] In some embodiments, at least 50% of the height of the plurality of filter elements is contained in the height of the plurality of support elements.

[0037] In some embodiments, at least 80% of the height of the plurality of filter elements is contained in the height of the plurality of support elements.

[0038] In some embodiments, each of the plurality of support elements comprise opposing side walls extending in the first direction, a base facing the discharge side, and an input surface facing the input side; and wherein each of the plurality of filter elements have longitudinal sides extending in the second direction, a base facing the input side, and an outlet surface facing the discharge side.

[0039] In some embodiments, the thickness of the screen is equal to or less than a length of the longitudinal sides of the plurality of filter elements.

[0040] In some embodiments, each of the inlets are defined by the longitudinal sides of adjacent ones of the plurality of filter elements; and wherein each of the outlets are defined by the longitudinal sides of the adjacent ones of the plurality of filter elements and the opposing side walls of adjacent ones of the plurality of support elements.

[0041] In some embodiments, the base of each of the plurality of filter elements has a width in the first direction that is greater than a width of the outlet surface in the first direction.

[0042] In some embodiments, the base of each of the plurality of support elements has a length in the second direction that is greater than a length of the input surface in the second direction.

[0043] In some embodiments, the input surface of each of the plurality of support elements is a support apex.

[0044] In some embodiments, the support apex is curved.

[0045] In some embodiments, a total cross-sectional flow area of each of the inlets is substantially equal to or less than a total cross-sectional flow area of each of the outlets.

[0046] In some embodiments, a given one of the flow paths comprises a given one of the inlets and a plurality of the outlets.

[0047] In some embodiments, a total cross-sectional flow area of the given one of the inlets is substantially equal to or less than a total cross-sectional flow area of each of the plurality of outlets.

[0048] In some embodiments, the screen comprises a cylindrical barrel having a longitudinal axis and the first direction is a circumferential direction and the second direction is an axial direction relative to the longitudinal axis.

[0049] In some embodiments, the screen comprises a cylindrical barrel having a longitudinal axis and the second direction is a circumferential direction and the first direction is an axial direction relative to the longitudinal axis.

[0050] In some embodiments, the screen comprises a cylindrical barrel having a longitudinal axis and a given one of the first direction and the second direction is provided at an angle relative to the longitudinal axis and an opposing one of the first direction and the second direction is substantially perpendicular to the given one of the first direction and the second direction.

[0051] In some embodiments, a cross-sectional shape of the plurality of support elements is one of: a semioval, a semicircle, a circle, a triangle, a square, a rectangle, a trapezoid, a discorectangle, a semi-discorectangle, a parallelogram, a polygonal, or an irregular polygonal.

[0052] In some embodiments, the cross-sectional shape of the plurality of support elements is the semioval.

[0053] In some embodiments, a cross-sectional shape of the plurality of filter elements is one of: a semioval, a semicircle, a circle, a triangle, a square, a rectangle, a trapezoid, a discorectangle, a semi-discorectangle, a parallelogram, a polygonal, or an irregular polygonal.

[0054] In some embodiments, the cross-sectional shape of the plurality of filter elements is the triangle.

[0055] According to another aspect, there is provided a screen assembly for use in a subterranean wellbore, the screen assembly comprising: a cylindrical barrel having a longitudinal axis and comprising a frame having opposing flanges and defining an internal flow passage; and a screen extending between the opposing flanges and having an input side comprising inlets and a discharge side comprising outlets, wherein the discharge side faces the internal flow passage, the screen comprising flow paths defined through the cylindrical barrel enabling fluid communication between the input side and the discharge side, the screen comprising: a support layer comprising a plurality of support elements; and a filter layer comprising at least one filter element; wherein the support layer is embedded in the filter layer such that at least a portion of a height of the plurality of support elements is contained within a height of the at least one filter element.

[0056] According to another aspect, there is provided a screen for screening fluids containing a particulate, wherein the screen comprises an input side and a discharge side and is configured to provide fluid communication therebetween, the screen comprising: a support layer comprising a plurality of support elements extending in a first direction and comprising a base facing the discharge side and an input surface facing the input side; a filter layer comprising a plurality of filter elements extending in a second direction and comprising a base facing the input side and an outlet surface facing the discharge side; and a plurality of flow paths each having at least one inlet and at least one outlet, wherein the plurality of flow paths are configured to provide the fluid communication; and wherein the plurality of support elements are embedded in the plurality of filter elements.

[0057] In some embodiments, the outlet surfaces of adjacent ones of the plurality of support elements and the base facing the discharge side of adjacent ones of the plurality of filter elements form the at least one outlet.

[0058] In some embodiments, the input surfaces of adjacent ones of the plurality of filter elements form the at least one inlet.

[0059] According to another aspect, there is provided a screen for screening fluids containing a particulate, the screen comprising a plurality of flow paths having at least one inlet and at least one outlet; wherein a thickness of the screen is equal to or less than 8 mm and wherein a width of the at least one inlet is between about 0.015 mm and about 0.051 mm.

[0060] In some embodiments, the width of the at least one inlet is about 0.025 mm.

[0061] In some embodiments, a ratio of inlet to outlet cross-sectional area is between1 :1 and 1 :3.

[0062] According to another aspect, there is provided a flow control apparatus comprising: a housing including a housing passage and a flow communicator for effecting flow communication between an environment external to the housing and the housing passage; a flow controller for controlling flow communication via the flow communicator between the housing passage and the external environment, the flow controller comprising: an outer barrel comprising a screen assembly; and an inner barrel comprising a shroud-defining counterpart; wherein the screen assembly comprises a single layer screen comprising a plurality of flow paths defined by a support layer comprising a plurality of support elements and a filter layer comprising at least one filter element extending transversely to the plurality of support elements, wherein each of the plurality of flow paths have at least one inlet defined by the filter layer and at least one outlet; wherein the outer barrel and the inner barrel are selectively movable such that the flow control apparatus is configured to move between a production configuration and a closed configuration.

[0063] In some embodiments, the at least one outlet is defined by adjacent ones of the plurality of support elements and / or the filter layer.

[0064] In some embodiments, the at least one inlet is further defined by the adjacent ones of the plurality of support elements.

[0065] In some embodiments, a thickness of the single layer screen is equal to a height of the plurality of filter elements.

[0066] According to another aspect, there is provided a process for recovering a subterranean fluid wherein the subterranean fluid passes though the screen as defined herein and is recovered to surface.

[0067] In some embodiments, the subterranean fluid comprises a hydrocarbon or water.

[0068] According to another aspect, there is provided a screen for screening fluids containing a particulate, the screen comprising a support layer and a filter layer defining flow paths having at least one inlet and at least one outlet, wherein at least 5% of the thickness of the support layer is embedded in the thickness of the filter layer.

[0069] In some embodiments, a width of the at least one inlet is between about 0.015 mm and about 0.051 mm.

[0070] In some embodiments, the width of the at least one inlet is about 0.025 mm.

[0071] In some embodiments, a ratio of inlet to outlet cross-sectional area is between1 :1 and 1 :5.

[0072] In some embodiments, the ratio of inlet to outlet cross-sectional area is 1:2.

[0073] In some embodiments, at least 50% of the support layer is embedded in the filter layer.

[0074] In some embodiments, at least 80% of the support layer is embedded in the filter layer.

[0075] In some embodiments, a thickness of the screen is equal to or less than 20 mm.

[0076] In some embodiments, a thickness of the screen is equal to or less than 8 mm.

[0077] In some embodiments, a thickness of the screen is equal to or less than 5 mm.

[0078] In some embodiments, the screen has a pressure rating of at least 100 PSI.

[0079] According to another aspect, there is provided a screen for screening fluids containing a particulate, the screen comprising a support layer and a filter layer, wherein the screen layer and the filter layer overlap.

[0080] In some embodiments, the filter layer defines a filter area comprising a plurality of inlets and wherein a flow through area of the plurality of inlets is between 1% and 90% of a total surface area of the filter.

[0081] In some embodiments, the filter layer defines a filter area comprising a plurality of inlets and wherein a flow through area of the plurality of inlets is between 2% and 50% of a total surface area of the filter.

[0082] In some embodiments, the filter layer defines a filter area comprising a plurality of inlets and wherein a flow through area of the plurality of inlets is between 4% and 20% of a total surface area of the filter.

[0083] According to another aspect, there is provided a screen for screening fluids containing a particulate, wherein the screen comprises an input side and a discharge side, the screen comprising: a screen thickness spanning from the input side to the discharge side; a filter layer comprising a gauge and a filter layer thickness; a support layer for providing structural support and comprising a support layer thickness; and a plurality of size-restricted flow paths having at least one inlet and at least one outlet and extending through both the filter layer and the support layer and configured to provide fluid communication from the input side to the discharge side; and wherein at least a fraction of the thickness of each of the support layer and the filter layer are embedded within each other such that the screen thickness is less than the sum of the support layer thickness and the filter layer thickness.BRIEF DESCRIPTION OF THE DRAWINGS

[0084] The attached figures illustrate various features, aspects and embodiments of the technology described herein.

[0085] FIG. 1 is a cross-sectional schematic of a completed well with stages having screens for restricting access;

[0086] FIG. 2A is a cut-out perspective view of a prior art wire-wrapped screen;

[0087] FIG. 2B is a cross-sectional schematic of the wire-wrapped screen of FIG. 2A showing three (3) non-overlapping layers;

[0088] FIG. 3 is a cross-sectional schematic combining a filter layer with a support layer to form an overlapped screen according to one implementation;

[0089] FIGs. 4A-4D are cross-sectional schematics in various embodiments of overlapped screens, highlighting differences in overlap and positioning of layers relative to the input side and discharge side of an overlapped screen;

[0090] FIGs. 5A-C are enlarged cross-sectional, input side, and discharge side views of a screen according to another implementation;

[0091] FIGs. 6A-C are enlarged cross-sectional, input side, and discharge side views of a screen according to another implementation;

[0092] FIG. 7A is a perspective view of a screen assembly according to one implementation in a cylindrical arrangement;

[0093] FIG. 7B is a perspective enlarged view of the screen from the screen assembly of FIG. 7A showing the orientation of filter elements and support elements;

[0094] FIG. 7C is an input side view of the screen from the screen assembly of FIG. 7A;

[0095] FIG. 7D is a discharge side view of the screen from the screen assembly of FIG. 7A;

[0096] FIG. 8A is an axial cross-sectional view through the thickness of the cylindrical screen of the screen assembly of FIG. 7A;

[0097] FIG. 8B is an enlarged view of the axial cross-section of the cylindrical screen of FIG. 8A as indicated by the dashed circle;

[0098] FIG. 9A is a radial cross-sectional view of the cylindrical screen of the screen assembly of FIG. 7A;

[0099] FIG. 9B is an enlarged view of the radial cross-sectional of the cylindrical screen of FIG. 9A as indicated by the dashed circle;

[0100] FIG. 10 is a schematic, cross-sectional view of a flow control apparatus according to one implementation;

[0101] FIG. 11 is a schematic, cross-sectional view of a screen according to one implementation, and a shroud-defining counterpart for use in the flow control apparatus shown in FIG. 10;

[0102] FIGs. 12A, 12B, and 12C are schematic, cross-sectional views of the flow control apparatus shown in FIG. 10 in an open configuration, a closed configuration, and a production (screened) configuration, respectively;

[0103] FIG. 13 is an enlarged cross-sectional view of a portion of a screen assembly according to another implementation taken at a cutting plane line that extends in the axial direction of the screen;

[0104] FIG. 14 is an enlarged cross-sectional view of a portion of the screen assembly shown in FIG. 13 taken at a cutting plane line that extends in a direction that is perpendicular to the axial direction of the screen;

[0105] FIG. 15 is an enlarged cross-sectional view of a portion of a screen assembly according to another implementation taken at a cutting plane line that extends in the axial direction of the screen; and

[0106] FIG. 16 is an enlarged cross-sectional view of a portion of the screen assembly shown in FIG. 15 taken at a cutting plane line that extends in a direction that is perpendicular to the axial direction of the screen.DETAILED DESCRIPTION

[0107] As will be explained below in relation to various embodiments and embodiments, the present disclosure relates to screens and screen assemblies for screening reservoir fluids to mitigate ingress of particulate material into the wellbore string. It will be understood by the skilled person that the description herein of screen and screenassembly designs, including features, applications for use, and particular embodiments, are provided for the purpose of understanding the invention, and not for limiting of the claimed invention to that described. Furthermore, drawings depicting elements are not necessarily drawn to scale and should not be seen as limiting specifications for all aspects covered.

[0108] With specific reference to FIG. 1 , a completed well 1 typically includes a wellbore 2 extending essentially vertically down from a surface 3 before deviating from vertical into a relatively horizontal path within the subterranean formation 4. The subterranean formation may include one or more zones 6 (indicated by boxes). A wellbore string 5 inserted within the wellbore 2 comprises a wellbore string passage 7 and stages 8 where access is provided for movement of fluids between the subterranean formation 4 and the wellbore string passage 7. The stages 8 are ideally aligned with the zones 6 and can include perforations, or ports which may be regulated to allow, prevent, or control flow. Fractures 9 extending from the stages 8 are formed using hydraulic fracturing techniques known in the art. The annular region 10 between the wellbore string 5 and the wellbore 2 may include zonal isolation material (e.g. cement) or packers to prevent flow between zones via the annular region. For sand control purposes, flow of fluid from the subterranean formation 4 into the wellbore string passage 7 at one or more stages 8 may be size restricted by the inclusion of a screen 11. This includes, but is not limited to, wirewrapped screens and screen sleeves as part of a valve assembly or flow control apparatus.

[0109] Screen design contemplates the surface area which may be exposed to the fluid to be screened, the gauge or mesh size determining the size of particles to be restricted for access through the screen, the flow area, and the structural support required to withstand the pressures present within the subterranean formation where the screen is deployed. The surface area geometry can vary and may include, but is not limited to, cylindrically shaped, and flat screens having various 2D shapes (e.g. circular, square). While surface area geometry is an important consideration it is not the focus of this disclosure. The gauge, flow area, and structural support characteristics may be directly relevant for design of a screen having a predetermined pressure rating that can restrict particles with a defined size, without significantly increasing the thickness of the screen.

[0110] Screens having overlapping support and filter layers described herein are particularly useful for applications that would benefit from using a screen with a relatively small thickness. Screens comprise an input side where fluid first contacts the screen, a discharge side where screened fluids leave the screen and proceed to the wellbore string passage, and flow paths that extend from the input side to the discharge side. Fluid entering the screen at the input side travels through the flow paths, with particles present in the fluid that exceed the gauge precluded from proceeding past the filter layer. The flow paths span the thickness of the screen and pass through both the filter and support layers, which in known screens do not overlap. By overlapping, it is meant that the layers extend into each other, with at least a fraction of the height or thickness of a layer occupying the same plane of at least a fraction of the height or thickness of the other layer when viewed in a cross-section. In other words, the support layer and filter layer are at least partially embedded within the thickness of each other. For known screens, when the flow path in the filter layer ends, the flow path through the support layer starts, or vice versa. In the present invention, at least a fraction of the height or thickness of each of the filter and support layers overlaps or is embedded within one another, and the flow path can be through the support layer and the filter layer concurrently.

[0111] The present invention as described herein covers a screen with overlapping, or embedded, filter and support layers. FIG. 3 shows schematically in cross-section how a filter layer 20 can be combined with a support layer 30 so that the layers are overlapping. The filter layer comprises a plurality of size-restricted flow paths, the size restriction selected to correspond to the desired gauge. The support layer is designed to provide structural support consistent with a preferred pressure rating. Screens are oriented to have an input side, I, and a discharge side, D. The input side refers to the side of screen where fluid contacts and enters the screen, typically the reservoir side for screens employed downhole. The discharge side refers to the side of the screen where fluid leaves the screen and enters the wellbore string passage, or possibly another space within a wellbore or wellbore component. The screen thickness, Ts, is defined by the distance from the input side of the screen to the discharge side of the screen. Fluid enters the screen from the input side and follows the flow path F through the screen to the discharge side before exiting the screen. Particulate matter with a size greater than the predetermined gauge will be blocked from entering the flow path at the input side of the filter layer (see particles in FIG. 3 as an example), or along the path where the smallest dimension is present.

[0112] The support layer and the filter layer also have an input side and a discharge side, which refers to where fluid enters and leaves the layer in question. The filter layer thickness, TFL, is defined by the distance from the input side, IFL, to the discharge side, DFL, of the filter layer. The support layer thickness, TSL, is defined by the distance from the input side, lSi_, to the discharge side, DSL, of the support layer. Note that the input and discharge sides for the filter and support layers are only labelled in FIG. 3 but are present in all embodiments of the screen described herein. That the filter layer and support layer are embedded within each other means that Ts must be less than the sum of TFL and TSL.

[0113] When referring to sides, input side or discharge side, it is meant to indicate the boundary or edge of the thickness of the screen or layer. In some embodiments, the thickness of the filter layer and the support layer are essentially identical, the filter layer is 100% embedded within the support layer, and the input side of the screen is defined by the input side of both the filter layer and the support layer, and the discharge side of the screen is defined by the discharge side of both the filter layer and the support layer (FIG. 3). In some embodiments, the thickness of the filter layer and the support layer are essentially identical, less than 100% of the filter layer is embedded within the support layer, and the input side of the screen is defined by either, but not both, of the input side of the filter layer and the input side of the support layer. In some embodiments, the thickness of the filter layer and the support layer are essentially identical, less than 100% of the filter layer is embedded within the support layer, and the discharge side of the screen is defined by either, but not both, of the discharge side of the filter layer and the support layer (FIG. 4A).

[0114] In some embodiments, the thickness of the filter layer and the thickness of the support layer are not identical (FIG. 4B-4D). It should be apparent to a person skilled in the art that in this case the input side of the screen will be defined by the input side of the layer, filter or support, that is aligned with and forms the input side of the screen. Conversely, the discharge side of the screen will be defined by the discharge side of the layer, filter or support, that is aligned with the discharge side of the screen. Example configurations are shown, but not limited to those, in FIG. 4A-4D.

[0115] In some embodiments, the input side of the screen is defined by the input side of the filter layer (FIG. 4C, 4D). In some embodiments, the input side of the screen isdefined by the input side of the support layer (FIG. 4A, 4B). In some embodiments, the input side of the screen is defined by the input side of both the filter layer and the input side of the support layer (FIG. 3). In some embodiments, the discharge side of the screen is defined by the discharge side of the filter layer (FIG. 4A, 4D). In some embodiments, the discharge side of the screen is defined by the discharge side of the support layer (FIG. 4B, 40).

[0116] When considering the relative thicknesses and position of the filter and support layers it may be preferable to locate the filter layer on the input side of the screen, so that upon accumulation of particulate matter in the filter layer, at least a fraction of the support layer is downstream of the accumulation and can therefore continue to provide support to the filter layer and the screen as a whole.

[0117] The thickness of the screen can be determined by addition of the thickness of the filter layer and the support layer, minus the degree of overlap between the two layers. The thickness, or height, of the filter layer 20 may overlap to varying degrees with the thickness, or height, of the support layer 30, and vice versa. In FIG. 3, 100% of the height of the support layer 30 overlaps with, or is embedded within, 100% of the filter layer 20. Similarly, in FIG. 3, 100% of the height of the filter layer 20 overlaps with 100% of the support layer 30.

[0118] In some embodiments, at least 5% (i.e., 5% to 100%), at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% of the thickness of the support layer 20 is embedded within at least a fraction of the thickness of the filter layer 30. In some embodiments, at least 5% (i.e., 5% to 100%), at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% of the thickness of the filter layer 30 is embedded within at least a fraction of the thickness of the support layer 20. In other words, the support layer 20 can overlap with the filter layer 30 by from about 5% to 100%. In some embodiments, the support layer 20 can be completely embedded within the filter layer 30, such that both the input side and the discharge side of the screen are defined by the input side and discharge side of the filter layer 30 (FIG. 4D). In other embodiments, the support layer 20 can be partially embedded in the filter layer 30 (FIG. 4G), such that the filter layerdefines the input side, and the support layer defines the discharge side, or both the support layer and the filter layer define the input side and the discharge side.

[0119] The ability of the screen to restrict access to particles of predetermined size is a function of the filter layer, the filter layer comprising a geometry with a dimension for limiting access by size. The filter layer comprises inlets where fluid enters and outlets where fluid, minus particles with a restricted size, exit the filter layer. The inlets to the filter layer may comprise any shape that is configured to retain restricted particles, such as a slot shape or a square shape. In some embodiments, the filter layer defined by a single filter element in the form of a sheet with holes or other grid shape defining the inlets. The inlets are in the form of circles having a radius which defines the gauge. In other embodiments, the filter layer can be formed of multiple filter elements in the form of slats, wires, or other elongated members that define the inlets, with the spacing between the elements defining the gauge. The gauge refers the smallest distance between elements of the filter layer, which can be referred to as the restriction location. In some embodiments, the restriction location corresponds to the input side of the filter layer (FIG. 3). In some embodiments, the restriction location is located along the filter layer flow path between the input side and discharge side of the filter layer. Similarly, the outlets can have any shape and size that allow the screened fluid to exit the opening on the discharge side.

[0120] In some embodiments, the gauge, or smallest distance between filter layer elements, is from 0.006 inches (0.015 mm) to about 0.05 inches (0.127 mm) or higher.

[0121] As is understood in the art, the size and shape of the flow path through the screen is partially defined by the flow path through the filter layer. The flow path of the screen can have a radial cross-sectional area that allows for the retention of particles of a specific size and can be chosen based on the intended use of the screen and / or the nature of the material being screened. For example, when used as a sand screen, flow paths having an axial cross-sectional (from input side to discharge side) keystone slot shape can prevent plugging of the inlets by increasing the flow area immediately downstream of the restriction location. In some embodiments, the filter elements comprise elongated members having an axial cross-sectional area that decreases from the input side of the filter layer to the discharge side of the filter layer.

[0122] The support layer provides support for the screen, such that the screen, including the filter layer, does not deform under pressure of the fluid flow. The support layer comprises support elements that can have any size and shape that contribute significantly in providing structural support to prevent deformation of the screen, including the filter layer, to a predetermined pressure rating. The spacing of support elements is designed for supporting the screen in such a way that particles typically found in reservoir fluids, including sand particles, will not be restricted solely due to interacting with support elements.

[0123] While design of the support layer is with a view to structural support, it should be understood the skilled person that the enmeshment of the filter and support layers indicates that both the filter layer and the support layer may contribute, to varying degrees, to the pressure rating of the screen. In some embodiments, the screen has a pressure rating of between about 1 PSI and about 20,000 PSI, or about 100 PSI and about 15,000 PSI, as measure by finite element analysis. Design tweaks with a view to improving the pressure rating should be focused on the support layer and the support layer elements.

[0124] As is understood in the art, the height and geometry of the support elements, as well as the placement and orientation of the support layer relative to the filter layer, impacts the overall strength of the screen. As the thickness of the support layer (defined by the support elements) decreases, the overall strength of the screen decreases. By embedding or overlapping the support layer with the filter layer, the overall thickness of the screen can be reduced without reducing the strength. In other words, when 100% of the filter layer is embedded in the support layer, the thickness of the screen is equal to the thickness of the support layer. Alternatively, when 100% of the support layer is embedded within the filter layer, the thickness of the screen is equal to the thickness of the filter layer. The filter layer and the support layer can have individual thicknesses that are different from each other. For example, the filter layer can have a thickness that is between 10% and 100% of a thickness of the support layer. Similarly, the support layer can have a thickness that is between 10% and 100% of the thickness of the filter layer.

[0125] The support layer can be distinguished from the filter layer based on the design, composition, and spacing of the filter elements and support elements. The filter layer, whether a single element in the form of a sheet with holes or in the form of a plurality offilter elements, includes holes that are sized for or spacing between filter elements that provides the restriction in the flow path, whereas the support layer elements are spaced apart and comprise materials and or a cross-sectional area indicative of providing structural support.

[0126] It is understood that the geometry of and degree of overlap of the filter layer and the support layers influence the shape and configuration of the inlets, the outlets, and the plurality of flow paths of the screen from the input side to the discharge side. For example, depending on the degree and orientation of the overlap of the support and filter layers, the inlets of the screen be defined by the filter layer or the filter layer and the support layer. Similarly, depending on the degree and orientation of the overlap, the outlets can be defined by the support elements, by the filter elements, or by the filter elements and the support elements. Additionally, when the boundaries of the filter layer and support layer are not aligned on one or both of the input side and discharge side of the screen, there may a first and second inlet, and or a first and second outlet.

[0127] Referring now to FIG. 5A, FIG. 5B, and FIG. 5C, enlarged cross-sectional, input side, and discharge side views of a screen according to another implementation are shown. The screen includes openings having first inlets 112a (dashed box in FIG.5B), second inlets 112b (dotted box in FIG. 7B), and outlets 114a. The openings are defined by a support layer 20 having a plurality of support elements 120 and a filter layer 30 having a plurality of filter elements 130. In this implementation, the filter layer 30 is defined by the plurality of filter elements 130 that are entirely embedded in the support layer 20 having a plurality of support elements 120. Accordingly, a first inlet 112a and the outlets 114a are defined between adjacent side walls of adjacent support elements 120 and have a flow through area that is defined by the length of the support elements 120 and the distance between adjacent support elements 120.

[0128] The first inlet 112a can have a size that is configured to strain large particulate matter, while allowing the majority of the fluid being screened to flow to the second inlet 112b. The second inlet 112b is thus defined by the filter layer 30 having a plurality of filter elements 130 and the support layer 20. In this implementation, the second inlet 112b is defined between adjacent side walls of adjacent support elements 120 and adjacent side walls of adjacent filter elements 130. Therefore, the second inlet 112b has a flow througharea that is defined by the distance between adjacent support elements 120 and the distance between adjacent filter elements 130. In the exemplary implementation, the filter area and filter size ( / .e., the particulate size the screen is configured to prevent from flowing through to the discharge side) is defined by the filter layer.

[0129] Referring now to FIG. 6A, FIG. 6B, and FIG. 26C, enlarged cross-sectional, input side, and discharge side views of a screen according to another implementation is shown. The screen includes a filter layer 30 comprising a filter sheet 131 having openings 110 with inlets 112b and outlets 114b and a support layer 20 comprising a plurality of support elements 120. In this implementation, the filter sheet 131 is a flat sheet with openings positioned spatially apart from each other. The openings define the inlets 112b and outlets 114b. In some embodiments, the inlets 112b (dashed circle in FIG. 6B) and the outlets 114b (dashed square in FIG. 6B) have a different shape, such that the internal flow path of the openings 110 defined in the filter sheet 131 change between the inlet 112b and the outlet 114b. In the exemplary implementation, the inlets 112b have a circular shape whereas the outlets 114b have a square shape.

[0130] In the exemplary implementation, the filter layer 30 is entirely embedded in the support layer defined by the plurality of support elements 120. As the filter layer is entirely embedded in the support layer, the support layer defines a first inlet and a second outlet. As there are two inlets, a first inlet 112a (dashed box in FIG. 6B) and a second inlet 112b, and two outlets, a first outlet 114a and second outlet 114b. As such, in this implementation, fluid would enter the screen on the input side through the first inlet 112a defined between adjacent support elements 120, flow through the second inlet 112b defined by the circular openings on the input side of filter sheet 131 , flow out the second outlet 114b defined by the square openings on the discharge side of filter sheet 131 , and flow out the first outlet 114a (dashed box in FIG. 6C) defined between adjacent support elements 120. It is understood that the pluralities of flow paths, F, that extend from the input side of the screen to the discharge side of the screen are a function of the relationship between the size, shape, and orientation of the filter and support layers, which can provide a large or endless variety of geometries. Design of the support and filter layers can be tailored to provide preferred flow through patterns (internal slow surfaces or radial space available), flow efficiencies, and pressure ratings of the screen, and can be modified to fit a predetermined requirement for the fluid being screened.

[0131] The flow paths are defined by openings in the screen that extend from one or more inlets on the input side to one or more outlets on the discharge side and depend on the orientation and shape of the filter and support layers. Consideration to the flow through area should be given when determining the shape and size of the inlets and outlets. In some embodiments, the flow through area between the inlets and the outlets can increase, linearly or non-linearly, from the input side to the discharge side. Having an increase in the flow through area between the inlet and the outlet (in other words, for a given opening the flow through area of the outlet or outlets is greater than the flow through area of the inlet or inlets in) can prevent or reduce plugging in the openings. In some embodiments, a ratio of inlet flow through area to outlet flow through area is between 1 :1 and 1 :8, or in some instances, between 1 :1.1 and 1 :3. However, it is understood that the flow through area of the outlets can be equal to or less than the flow through area of the inlets, for example between 1 :0.9 and 1 :0.5. When the ratio of inlet flow through area to outlet flow through area is less than 1 :1 ( / .e., the outlet flow through area is less than the inlet flow through area), consideration to the possibility of plugging the inlets should be given.

[0132] In some embodiments, the geometry of the plurality of flow paths are all similar, with the geometry of each flow path through the screen resembling the geometry for all the other flow paths in the screen. For example, if a single flow path has a circular inlet at the input side of the screen and a square outlet at the discharge side of the screen, the plurality of flow paths will mirror this geometry. In this embodiment, the ratio of total inlet flow through area to total outlet flow area will approximate the ratio of inlet flow through area to outlet flow area for a single flow path.

[0133] In some embodiments, the geometry of the plurality of flow paths are not all similar, and the geometry of each flow path through the screen may not resemble the geometry for all the other flow paths in the screen. For example, one type of flow path may have a circular inlet at the input side of the screen and a square outlet at the discharge side of the screen, while other flow paths may have circular inlets and circular outlets. In this embodiment, the ratio of total inlet flow through area to total outlet flow area may be similar or dissimilar than the ratio of inlet flow through area to outlet flow area for any single flow path.

[0134] Another consideration is the directionality of the flow path through the screen. The geometry of each of the filter and support layers inform the flow path. In some embodiments, the screen allows for a direct flow path (F in FIG. 3) from the input side to the discharge side of the screen, without requiring the flow path to traverse axially. In some embodiments, the screen is provided as a cylindrical barrel (a cylindrical screen) having a radial flow path from an input side through to the discharge side of the screen and into the wellbore string passage 7. The cylindrical screen can allow for a primarily direct radial flow path, as opposed to some conventional screens which require at least a fraction of the fluid to traverse axially before exiting the outlet in the direct radial flow path (FIG. 2B). In other embodiments, the screen can provide an irregular flow path.

[0135] In some embodiments, the support layer comprises support elements and the filter layer comprises filter elements, and the support elements and filter elements extend in transverse or substantially transverse directions to each other to define the flow path through the screen. In this embodiment, there is primarily a direct flow path from the input side to the discharge side of the screen, with minimal transverse flow along the width of support elements (e.g. Li FIG. 8B).

[0136] Another consideration for design is the flow area through the screen. In some embodiments, the filter layer that defines the filter area having the plurality of inlets can have a flow through area that is at least 1 % of a total surface area of the filter. For example, the total flow through area of the filter area can be between about 1% and about 90% of the total surface area of the screen, between about 2% and about 50% of the total surface area of the screen, or between about 4% and about 20% of the total surface area of the screen.

[0137] In some embodiments, the screen can be used in a screen assembly configured to screen a particulate. A screen assembly includes the screen and associated features that allow for incorporation within a larger structure or apparatus. In some embodiments, a screen assembly can include a cylindrical barrel, with a screen provided along a section of the cylindrical barrel and including various support elements and filter elements having certain orientations. The screen assembly can be deployed downhole as part of a completion system and can help prevent oversized solid particles from passing with theproduction fluid into the completion system. The support elements and filter elements that are part of the screen can be enmeshed to reduce the thickness of the screen.

[0138] In some embodiments, the screen assembly has a cylindrical shape, which can facilitate use within a tube, pipe, tubing string, and the like. In some embodiments, the screen can be superimposed on or directly adjacent to a cylindrical conduit to allow fluid flow therethrough. For example, the screen assembly can be used with a sleeve port to allow fluid flow from a subterranean reservoir into a wellbore string in downhole applications and prevent various particulates from entering various parts of the well completion system. The screen assembly can be used in various applications, such as within downhole valve assemblies, sand screens, flow control regulators, wellbore strings for injecting and / or recovering fluids, and so on. However, it is contemplated that the screen assembly described herein can be used in a number of different applications, including non-subterranean operations.

[0139] Implementation of an example screen and screen assembly is provided for additional understanding of the invention herein. Referring now to FIG. 7A to FIG. 9B, an example screen assembly is shown in a cylindrical application {e.g., a cylindrical screen) according to one implementation. The screen assembly 100 comprises a cylindrical screen 101 connected to flanges 104 at a first end 100c and at a second end 100d and having an interior flow passage 102. When the installed as part of a well completion system, the interior flow passage 102 of the screen assembly 100 may be axially aligned with and continuous with the wellbore string passage 7 of a completed well 1. The exterior surface of the cylindrical screen 101 defines the input side 100a of the cylindrical screen 101 and the interior surface defines the discharge side 100b of the cylindrical screen 101.

[0140] The flanges 104 may protect the ends of the screen or be configured to engage with a portion of another system. In some embodiments, the flanges 104 can provide a seal with the portion of another system the screen assembly 100 is being used with to prevent a fluid bypass around the screen assembly 100. For example, when used with a valve assembly, the flanges 104 can provide a seal between the valve assembly tubing walls that defines the fluid passage the screen assembly 100 is being used with. In some embodiments, the flanges 104 can include seal surfaces to facilitate the seal between the system, such as a valve assembly, and the screen assembly 100. In some embodiments,the flanges 104 can include attachment mechanisms, such as threading, to facilitate an attachment between the system the screen assembly 100 is being used with, such as a valve assembly, and the screen assembly 100. The flanges 104 can also include load surfaces to prevent movement of the screen assembly 100 relative to the system the screen assembly 100 is being used with.

[0141] The cylindrical screen assembly 100 includes a support layer defined by a plurality of support elements 120 extending in a first direction and a filter layer defined by a plurality of filter elements 130 extending in a second direction. The support elements 120 and the filter elements 130 can be substantially perpendicular with respect to each other or can be angled (at a non-90° angle) relative to each other. In this embodiment, the filter elements 130 extend axially from the first end 100c to the second end 100d. The support elements 120 extend circumferentially without a defined first and second end.

[0142] Openings 110 that extend from an inlet 112 (e.g. between dashed lines in FIG. 7C) on an input side 100a of the cylindrical screen 101 and through an outlet 114 (e.g. dashed box in FIG. 7D) into the interior flow passage 102 on a discharge side 100b of the cylindrical screen 101 to define a radial flow path F. In this implementation, the inlets 112 of the openings 110 extend axially along the length of the cylindrical screen assembly 100 {e.g., in an axial direction DA). However, other embodiments are also contemplated, such as having the inlets 112 of the openings 110 extend circumferentially e.g., in the circumferential direction De) or at an angle around the cylindrical screen 101. In the illustrated implementation, the screen assembly 100 has a cylindrical configuration. However, other configurations are possible, such as the screen assembly 100 being arranged in a conical or frustoconical shape or having a planar, flat, or two-dimensional shape. It is also contemplated that the screen assembly 100 can be used having a reverse flow path than the exemplary implementation, such that the fluid flows from the discharge side 100b to the input side 100a. In other words, the support elements 120 and filter elements 130 combined define the inlet and the filter elements 130 can define the outlet. In such embodiments, consideration to the ratio between the inlet flow through area and the outlet flow through area should be given to achieve the desired pressure drop coefficient of the screen. For example, when a reverse flow path is considered, the ratio of inlet flow through area to outlet flow through area can be close to 1 :1 such as between 1 :0.8 and 1 :1.2.

[0143] The openings 110 are defined by the outer walls of two adjacent support elements 120 and two adjacent filter elements 130. In some embodiments, the support elements 120 extend in a circumferential direction De and the filter elements 130 extend in an axial direction DA between the first and second ends 100c, 100d (e.g., between the flanges 104). In other embodiments, such as a flat screen, the support elements 120 and the filter elements 130 can each extend perpendicular to each other, such as extending between pairs of opposing walls of a frame (e.g., barrel or sleeve of a valve assembly).

[0144] The support elements 120 and filter elements 130 are configured to enmesh together which helps to reduce the overall thickness of the screen assembly 100. In other words, the support elements 120 are embedded in the filter elements 130 - that is, extending within the spaces defined by the filter elements 130 such that there is height, or thickness, overlap between the support elements 120 and filter elements 130. The degree and type of enmeshing of the support elements 120 and the filter elements 130 can vary depending on the design, and certain example aspects regarding this feature will be discussed further below.

[0145] As shown in FIG. 8B, the openings 110 are adapted to define fluid flow paths F that extend from inlets 112 on the input side 100a to outlets 114 on the discharge side 100b. For instance, for the cylindrical screen assembly 100, the radial fluid flow path F extends from an exterior of the cylinder into the interior flow passage 102. As is discussed herein, it is understood that the geometry of the inlets 112 and the outlets 114 define the flow through area of the openings 110 ( / .e., the internal flow path). As will be described further below, when the support elements 120 are enmeshed with the filter elements 130, the flow through area defined by the filter elements 130 on the input side 100a can be reduced by the support elements 120 in a middle section of the opening 110, such that the flow through area at the outlet 114 is less than at the inlet 112, which can increase the pressure drop coefficient of the screen assembly 100. In some embodiments, the geometry of the support elements 120 and the filter elements 130 are optimized to have a flow through area of the inlet 112 be substantially equal to or less than the flow through area of the outlet 114, so as to reduce the pressure drop coefficient of the screen assembly 100. The support elements 120 and filter elements 130 can be provided with walls with certain angles that define corresponding volume and flow features for the flow through area. In the illustrated implementation, the reduction of the flow through area by thesupport elements 120 is mitigated by the angle of the walls of the filter elements 130, such that the cross-sectional area of the filter element 130 at the discharge side 100b is less than the cross-sectional area of the filter elements 130 at the input side 100a .

[0146] The support elements 120 can extend in the circumferential direction De, in the axial direction DA, or at an angle to the circumferential and / or axial direction. In this implementation, the support elements 120 extend substantially in the circumferential direction De.

[0147] In some embodiments, and as shown in FIG. 8B, the support elements 120 have a height Hi that is equal to or less than a thickness Ti of the cylindrical screen 101. In some embodiments, the height Hi may exceed a height H2 of the filter elements 130; however, in such embodiments, consideration to the pressure drop coefficient and the overall thickness of the screen assembly 100 should be given when determining the geometry of the support elements 120 and the filter elements 130. In this implementation, the support elements 120 have a height Hi that is less than the thickness T1 of the screen assembly 100, which is equal to the height H2 of the filter elements 130. In other words, it should be understood that the height H2 of the filter elements 130 can define the thickness T1 of the screen assembly 100, although other configurations are possible.

[0148] The support elements 120 can have any shape that provides sufficient strength and stability in the first direction (e.g., in the circumferential direction De) to the screen assembly 100. For example, the support elements 120 can have a cross-sectional shape that is semi-circular, circular, semioval, semi-elliptical, triangular, trapezoidal, square, rectangular, discorectangular, semi-discorectangular, parallelogram, polygon, irregular polygon, etc. Consideration to the fluid turbulence can be given when determining the cross-sectional shape of the support elements 120, in particular the cross-sectional shape on the input side 100a of the screen assembly 100 (the input surface). In some embodiments, the input side 100a of the support elements 120 have a parabolic shape to reduce the fluid turbulence at the inlet 112.

[0149] In this implementation, as shown in FIG. 7B, FIG. 8A, and FIG. 8B, the support elements 120 have a semioval cross-sectional shape having a semi-major axis that extends in the thickness or radial direction DR of the screen assembly 100 and defines the height Hi of the support element 120, and a semi-minor axis of the support element 120extending in the axial direction DA. The support elements 120 can include two opposing walls 122 that are curved and end on the discharge side 100b at a base 124 of the support element 120, and at a support apex 126 in closer proximity to the input side 100a (which can also be referred to as an input surface of the support element 120, for example, when the support element 120 has a different shape, such as a frustum or triangle). As such, the fluid flowing from the input side 100a flows through the inlets 112 and is disrupted by the support apexes 126 (or input surface) of the support elements 120 to flow through the outlet 114 into the interior flow passage 102 on the discharge side 100b. In this implementation, the inlets 112 are defined between the longitudinal sides 132 (FIG. 9B) of two adjacent filter elements 130 and the flanges 104, and the outlets 114 are defined between the longitudinal sides 132 of two adjacent filter elements 130 and the opposing walls 122 of two adjacent support elements 120. The discharge side 100b surface of the screen assembly 100 includes the outlets 114 dispersed between the inner surfaces of the bases 124. Similarly, the input side 100a surface of the screen assembly 100 includes the inlets 112 arranged side-by-side and between the flanges 104 on either ends 100c, 100d of the screen assembly 100.

[0150] Referring back to FIG. 8B, in some embodiments, the base 124 of the support elements 120 have a length Li extending in the axial direction DA. It is also noted that the bases 124 of two adjacent support elements 120 define opposing walls of an outlet 114, such that length L2 of the outlet 114 is defined by the distance between the bases 124 of adjacent support elements 120. It is understood that the support elements 120 are spaced apart by a distance that is equal to the outlet length L2 of the outlet 114. As such, the outlet length L2 can be increased or decreased to meet predetermined specifications of the screen assembly 100 by increasing or decreasing the distance between adjacent support elements 120.

[0151] In some embodiments, such as when the height Hi of the support element 120 is substantially equal to the thickness T1 of the screen assembly 100, each opening 110 can define a single conduit between the inlet 112 and the outlet 114. Alternatively, and as seen in FIG. 8B, the height Hi of the support element 120 is less than a thickness T1 of the screen assembly 100 such that a single inlet 112 extending between the flanges 104 on the first and second ends 100c, 100d is disrupted by the support elements 120 to expel or discharge the fluid through several outlets 114. In other words, in this implementation,a single inlet 112 can provide access to multiple openings 110 and lead to multiple outlets 114. As shown in FIG. 8A, a single inlet 112 leads to twenty-two outlets 114 ( / .e., an inlet 112 defined by two filter elements 130 is divided into twenty-two outlets 114 by twenty- one support elements 120). It is understood that any number of support elements 120 can be used to define any corresponding number of outlets 114.

[0152] Referring now to FIG. 9B, the filter elements 130 can have any cross-sectional shape. For example, the filter elements 130 can have a cross sectional shape that is semicircular, circular, semioval, semi-elliptical, triangular, square, trapezoidal, rectangular, discorectangular, semi-discorectangular, parallelogram, polygon, irregular polygon, etc. Consideration to the inlet 112 and outlet 114 shapes and sizes, as well as the fluid turbulence within the openings 110 extending between the inlet 112 and the outlet 114, should be given when determining the cross-sectional shape of the filter elements 130.

[0153] In this implementation, the filter elements 130 have a triangular cross-sectional shape. Each of the filter elements 130 includes longitudinal sides 132 that extend in the axial direction DA of the screen assembly 100 from a base 134 on the input side 100a to a filter apex 136 on the discharge side 100b (which can also be referred to as an outlet surface of the filter element 130, such as when the filter elements 130 have a different shape, such as a frusto-triangular prism). The base 134 has a base width Wi extending in the circumferential direction De. The bases 134 of adjacent filter elements 130 are spaced apart at a distance that defines an inlet width W2 of the inlet 112. In other words, it should be understood that the inlet width W2 is equal to the distance between the adjacent filter elements 130 that define the inlet 112. In some embodiments, the base width W1 is between about 0.01 inches (0.25 mm) and about 0.4 inches (10 mm), or between about 0.02 inches (0.5 mm) and 0.25 inches (6.36 mm).

[0154] The longitudinal sides 132 are tapered inwardly towards the apex 136 (or outlet surface), such that an outlet width W3 of the outlet 114 on the discharge side 100b is greater than the inlet width W2 on the input side 100a . In some embodiments, the outlet width W3 is defined by the distance between the filter apexes 136 of adjacent filter elements 130 or when the filter apex 136 is a frustum or the filter element 130 has another shape, by the distance between the apexes of adjacent longitudinal sides 132 and a discharge side 100b surface of the adjacent filter elements 130. In this implementation,the outlet width W3 is defined between the filter apexes 136 of adjacent filter elements 130. It is readily understood that the inlet width W2 and the outlet width W3 can be adjusted to the desired parameters by adjusting the shape of the filter elements 130 and / or the distance between adjacent bases 134 and / or filter apexes 136 or discharge side 100b surfaces of the filter elements 130. In some embodiments, the outlet width W3 is between about 0.01 inches (0.25 mm) and about 0.4 inches (10 mm), or between about 0.02 inches (0.5 mm) and 0.25 inches (6.36 mm). As will be understood, when the inlets 112 are defined only by the filter layer, the gauge of the screen is defined by the inlet size (in this case, by the inlet width W2). In some embodiments, the inlet width W2 can accommodate a gauge of 0.006 inches (0.015 mm) to about 0.05 inches (0.127 mm) or higher. As technology improves, the ability to machine or 3D print the screen, or the filter layer, even smaller gauges may be contemplated (i.e. 0.004 inches or lower).

[0155] The inlets 112 can have any shape that is configured to retain the material being screened, such as a slot shape or a square shape or a circular shape. In the exemplary implementation, the inlets 112 have a keystone slot shape, which allows for an increase in the flow through area defined between the filter elements 130 from the input side to the discharge side. Having an increasing flow area between the inlet 112 and the outlet 114 can prevent or reduce plugging in the opening 110. In some embodiments, the inlets 112 of the screen assembly 100 have a slot size (corresponding to the width W2 of the inlet 112) of between about 0.006 inches (0.015 mm) to about 0.050 inches (0.127 mm). In this implementation, the width W2 of the inlet 112 is about 0.010 inches (0.025 mm).

[0156] As shown in FIG. 8B and FIG. 9B, the support elements 120 are embedded in the filter elements 130, such that at least a portion of the height Hi of the support elements 120 is within a height H2 of the filter elements 130. In this implementation, the entirety of the height Hi of the support elements 120 is within the height H2 of the filter elements 130. Therefore, it is appreciated that the thickness T1 of the cylindrical screen 101 can be substantially equal to a height H2 of the filter elements 130 and, due to the tapered nature of the filter elements 130, can be slightly less than a length L4 of the longitudinal sides 132 of the filter elements 130. In some embodiments, the cylindrical screen 101 can have an overall thickness T1 of less than 10 mm (less than 0.4 inches), or between about 3 and about 8 mm (0.12 inches to 0.31 inches). In the exemplary implementation, the cylindrical screen 101 has a thickness T1 of about 5 mm (0.2 inches).

[0157] It is understood that multiple shapes, sizes, and configurations are possible for the support elements 120 and filter elements 130. Consideration to the opening area of the inlet 112 and the outlet 114 should be given when determining the height Hi , length Li of the base 124, shape, and placement {e.g., the bases 124 being spaced apart by a distance that defines the outlet length L2) of the support elements 120 and the width W1 of the base 134, shape, and placement {e.g., the bases 134 being spaced apart by a distance that defines the inlet width W2 and the filter apex 136 (or outlet surface) being spaced apart by a distance defining the outlet width W3) of the filter elements 130. In some embodiments, the length Li is between about 0.02 inches (0.5 mm) and about 0.8 inches (20 mm), or between about 0.05 inches (1.27 mm) and 0.5 inches (12.7 mm).

[0158] It is further understood that the embedded relationship between the support elements 120 and the filter elements 130 can vary depending on the shape, size, and configuration of the support elements 120 and the filter elements 130. Consideration can be given to the overall thickness T1 of the screen assembly 100 and structural properties of the screen assembly 100 when determining the embedded relationship. For example, in this implementation, the screen assembly 100 includes support elements 120 having a height Hi that is entirely {i.e., about 100%) embedded in the height H2 of the filter elements 130, such that the height H2 of the filter elements 130 defines the thickness T1 of the screen assembly 100. Other configurations are also contemplated, such as a portion of the height Hi of the support elements 120 being embedded in the height H2 of the filter elements 130 or a portion of the height H2 of the filter elements 130 being embedded in the height Hi of the support elements 120. In some embodiments, at least 5% i.e., 5% to 100%), at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% of the height Hi of the support element 120 is embedded within the height H2 of the filter element 130. In some embodiments, at least 5% {i.e., 5% to 100%), at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% of the height H2 of the filter elements 130 is embedded within the height H2 of the support elements 120.

[0159] In this implementation, shown in FIG. 7A, FIG. 8A, and FIG. 9A, the inlets 112 of each opening 110 has an inlet width W2 in the circumferential direction De defined between the longitudinal sides 132 of adjacent filter elements 130 and an inlet length L3 in the axial direction DA (shown in FIG. 8A) defined between the flange 104 on the first end100c and the flange 104 on the second end 100d. In this implementation, the inlets 112 have a length L3 that extends the entire length of the screened area of the screen assembly 100. In contrast, the openings 110 which have a single inlet 112, have a plurality of outlets 114 as the fluid flow is partitioned into the plurality of outlets 114 by the support elements 120. In this implementation, the outlets 114 have an outlet width W3 in the circumferential direction De defined between the longitudinal sides 132 of adjacent filter elements 130 and an outlet length L2 in the axial direction DA (shown in FIG. 8B) defined between the bases 124 of adjacent support elements 120. For greater clarify, in the exemplary implementation where the inlets 112 have a length L3 that extends the entire length of the screened area, the inlet width W2 defines the filter size ( / .e., particulates having a size greater than the inlet width W2 are prevented from flowing through the inlet 112). Accordingly, it is understood that filter size of the screen assembly 100 can be adjusted by adjusting the inlet width W2 and in some embodiments, the inlet length L3.

[0160] As is understood, the flow through area (or cross-sectional area) of one inlet 112 is defined as the inlet width W2 by the inlet length L3 (i.e., W2 x L3) and the flow through area of one outlet 114 is defined as the outlet width W3 by the outlet length L2 (i.e., W3 x L2). In some embodiments, the shape, size, and placement of the support elements 120 and the filter elements 130 are configured such that the flow through area of the inlet 112 is equal to or less than the total flow through area of the outlets 114. In some embodiments, a ratio of the flow through area of the inlet 112 to a total flow through area of the outlets 114 for one of the openings 110 (i.e., the ratio of inlet 112 to outlet 114 cross sectional area) is between about 1 :1 and about 1 :8. In some embodiments, the ratio of inlet 112 to outlet 114 cross sectional area is between about 1 :1.1 and about 1 :1.5. In this implementation, the ratio of inlet 112 to outlet 114 cross sectional area is about 1 :2.

[0161] In some embodiments, the screen assembly 100 can be manufactured as a single unitary piece. For example, the screen assembly 100 can be manufactured using 3D printing, such as 3D metal printing. In such embodiments, 3D printing allows the plurality of support elements 120 to be integrated directly into the plurality of filter elements 130 so that an overall cross-sectional thickness of the screen assembly 100 is reduced (e.g., compared to typically used and known screens) without compromising the pressure rating. The reduced thickness T1 of the screen assembly 100 (equaling half of the outside diameter OD minus the internal diameter ID, as shown in FIG. 4A) can be an advantage,for example, with wellbore components where the outside diameter OD and / or overall occupied space is an important consideration. By embedding the entire height Hi of the support elements 120 within the height H2 of the filter elements 130, the inside diameter ID of the interior flow passage 102 of the screen assembly 100 can be increased. In other words, the reduced thickness T1 of the screen assembly 100 allows for a greater flow area of the internal flow passage 102.

[0162] Other methods of manufacturing are possible, such as electrical discharge machining (EDM) and / or mould casting, followed by finish machining. Consideration to the small size of the screen and the accuracy in the inlet and outlet size and shape, and thus their respective flow through areas, should be given when determining a method of manufacturing.

[0163] Example Embodiments

[0164] With reference to FIG. 1 , and FIG. 10 to FIG. 16, in some embodiments, the screen assembly 100 can be used with a valve assembly or flow control apparatus 200 for producing hydrocarbon material from a subterranean formation 4. The flow control apparatus 200 includes a housing 202 having a wall, such as a tubular wall, defining a fluid passage 224 therethrough for enabling fluid communication through the housing 202. A flow communicator, such as one or more ports 210, extends through the housing 202 to provide fluid communication between the fluid passage 224 and the subterranean formation 4. In some embodiments, the flow control apparatus 200 includes a flow controller 250 disposed within the housing 202 that is configured to modulate (e.g., control) the fluid communication through the ports 210 between the housing passage 224 and the subterranean formation 4.

[0165] In this implementation, the flow controller 250 is configured to be operated in an open configuration (shown in FIG. 12A) where fluid can freely flow through the ports 210 between the housing passage 224 and the subterranean formation 4, a closed configuration (shown in FIG. 12B) where the ports 210 are occluded, in some instances because the inner barrel 254 is aligned with the ports 210, thereby preventing fluid flow between the housing passage 224 and the subterranean formation 4, and a production configuration or screened configuration (shown in FIG. 12C) where the screen assembly100 is aligned with the ports 210 such that fluid can flow through the screen assembly 100 and into the housing passage 224.

[0166] In this implementation, the flow controller 250 includes a screen assembly, such as the screen assembly 100. The screen assembly 100 can function to prevent passage of oversized solid particulate matter from the input side 100a, which can correspond to the subterranean formation 4, to the discharge side 100b, which can correspond to the housing passage 224. In some embodiments, the housing passage 224 can be concentric with the internal flow passage 102 of the screen assembly 100, although other configurations are possible.

[0167] With reference to FIG. 1 , a wellbore 2 extends from the surface 3 and into a reservoir (e.g., subterranean formation 4). A well completion system including one or more valve assemblies can be integrated as part of a wellbore string 5 extending within the wellbore 2. The wellbore string 5 defines a wellbore string passage 7 for conducting fluid between the surface 3 and the subterranean formation 4. In some embodiments, the screen assembly 100 can be provided directly in the wellbore string 5, such that the wellbore string passage 7 is aligned with and / or concentric with the interior flow passage 102 of the screen assembly 100. In other embodiments, a flow control apparatus that includes a screen, such as screen assembly 100, is provided in the wellbore string 5, such that the wellbore string passage 7, the housing passage 224, and an interior flow passage of the screen are aligned and / or concentric.

[0168] In some embodiments, the valve assemblies each include at least one passage allowing fluid flow therethrough. More specifically, the housing passage 224 defined by the housing 202 can include an uphole opening 201 at an uphole end 200a and a downhole opening 203 at a downhole end 200b thereof. The housing passage 224 thus extends between the uphole opening 201 and the downhole opening 203. It should therefore be understood that the valve assemblies include passages that can form part of the wellbore string passage 7 along at least a portion of the wellbore, such that fluid communication between the surface 3 and the subterranean formation 4 can be established via the valve assemblies 200.

[0169] As described, the valve assembly 200 are provided with one or more ports 210 at respective locations along the wellbore for establishing fluid communication betweenthe wellbore string 5 and the subterranean formation 4. In this implementation, the wellbore string passage 7 includes flow communication stations at stages 8 that are each aligned with a port 210 to establish the fluid communication between the wellbore string 5 and the subterranean formation 4. It is also noted that conduits of the wellbore string 5 can be located on either end of the valve assemblies 200 and can be coupled to respective ends thereof by any suitable method. It is also possible to connect some or all of the valve assemblies end-to-end without any intervening conduits.

[0170] In some embodiments, for example, the wellbore 2 includes a cased-hole completion, in which case, the wellbore string 5 includes a casing, which at least contributes to the stabilization of the subterranean formation 4 after the wellbore 2 has been completed, such as by contributing to the prevention of the collapse of the subterranean formation 4 that is defining the wellbore 2.

[0171] It is noted that the completion system and the valve assemblies 200 can be implemented in various wellbores, formations, and applications including hydrocarbon recovery and geothermal applications. In some embodiments, the wellbore can be straight, curved, or branched, and can have various wellbore sections. A wellbore section should be considered to be an axial length of a wellbore. A wellbore section can be characterized as “vertical” or “horizontal” even though the actual axial orientation can vary from true vertical or true horizontal, or can tend to undulate or corkscrew or otherwise vary. The term “horizontal”, when used to describe a wellbore section, refers to a horizontal or highly deviated wellbore section as understood in the art, such as a wellbore section having a longitudinal axis that is between 70 and 110 degrees from vertical. For simplicity, it is noted that most of the conduits, channels, passageways, pipes, tubes and / or other similar components referred to in the present disclosure have a cross-section that is preferably circular or annular, although it should be appreciated that other shapes are also possible.

[0172] In some embodiments, reservoir fluids are recovered from the reservoir by initially injecting a fluid (which can be referred to as a mobilizing fluid or an injection fluid) within the reservoir via the injection segments of the well completion system or via an injection well. In some applications, the injection fluid is adapted to mobilize hydrocarbons contained in the reservoir and drive the hydrocarbons towards the production segmentsor a production well for recovery of the hydrocarbons. In hydrocarbon recovery operations, the production segments are adapted for receiving fluid that can include mobilized hydrocarbons from the reservoir and for producing the mobilized hydrocarbons to ultimately recover the hydrocarbons at surface.

[0173] In some embodiments, the screen assembly 100 can be used with the process for stimulating hydrocarbon production from the subterranean formation 4. The process includes, amongst other things, injecting mobilizing fluid into the subterranean formation 4 via the wellbore string 5 and valve assemblies 200 operated in the open configuration and recovering treated hydrocarbon material from the subterranean formation via the wellbore string 5 and valve assemblies 200 operated in the production configuration.

[0174] In some embodiments, the flow controller 250 includes an outer barrel 252 and an inner barrel 254 slidably coupled within the housing 202. The outer barrel 252 can define a screen assembly 300’ having a plurality of openings 310’ that define a screening area. The outer barrel 252 is configured to engage with the inner barrel 254, which can include, for example, a shroud-defining counterpart. The screen assembly 300’ is substantially similar to the screen assembly 100 shown in FIG. 7A to FIG. 9B, except that the inlets on the input side extend in a circumferential direction as opposed to an axial direction, although other configurations are possible.

[0175] In some embodiments, the inner barrel 254 is nested within the outer barrel 252. The inner barrel 252 and the outer barrel 254 can be concentric, such that their relative movement within the housing 202 can enable selective operation of the valve assembly 200 by opening and closing of the ports 210. Opening and closing of the port is achieved by relative alignment of the inner barrel 252 and the port 210.

[0176] When in the production configuration (shown in FIG. 12C), the stimulated hydrocarbon material in the subterranean formation 4 can flow radially through the openings 310’ in the screen assembly 300’ and into the interior flow passage of the screen assembly 300’, and therefor into the housing passage 224 of the flow control apparatus 200. The screened hydrocarbon material can then be recovered at the surface 3 via the wellbore string passage 7. In such embodiments, the screen assembly 300’ can be adapted to prevent various particulates and / or debris from entering the valve assembly and / or the housing passage 224 and potentially clogging up the assembly.

[0177] Referring now to FIG. 13 and FIG. 14, enlarged views of a screen according to another implementation is shown. The screen includes openings having an inlet 412 and a plurality of outlets 414 defined by a plurality of support elements 420 and a plurality of filter elements 430. In this implementation, the inlet 412 is defined by the longitudinal sides 432 of adjacent ones of the plurality of filter elements 430 and the outlet 414 is defined by the longitudinal sides 432 of adjacent ones of the plurality of filter elements 430 and opposing sides 422 of adjacent ones of the plurality of support elements 420. The support elements 420 can have a triangular cross-sectional shape and the filter elements 430 can have a trapezoidal cross-sectional shape. In this implementation, each of the support elements 420 has an elongated triangular prism shape with the opposing sides 422 being a lateral face of the triangular prism, while each of the filter elements 430 has an elongated frusto-triangular prism shape with the longitudinal sides 432 being a lateral face of the frusto-triangular prism. In the exemplary implementation, an entirety ( / .e., about 100%) of the height of the support elements 420 is embedded within the height of the filter elements 430.

[0178] Referring now to FIG. 15 and FIG. 16, enlarged views of a screen according to another implementation is shown. The screen includes openings having inlets 512 and outlets 514 defined by a plurality of support elements 520 and a plurality of filter elements 530. In this implementation, the support elements 520 and the filter elements 530 are offset from each other, such that a thickness T2 of the screen is greater than a height H3 of the support elements 520 and a height H4 of the filter elements 530 but less than the combined height of the support elements 520 and filter elements 530 as the support elements 520 and filter elements 530 at least partially intersect each other. In other words, it is understood that a portion of the height H3 of the support elements 520 is embedded within the height H4 of the filter elements 530 and a portion of the height H4 of the filter elements 530 is embedded in the height H3 of the support elements 520. In this implementation, about 80 - 85% of the height H3 of the support element 520 is embedded in the height H4 of the filter element 530 and about 60 - 65% of the height H4 of the filter element 530 is embedded in the height H3 of the support elements 520. For greater clarity, the height direction (for example, for heights Hi, H2, H3, and H4) is the same as the thickness direction (for example, for thickness T1, T2), both of which extend in the radial direction DR.

[0179] In this implementation, the inlet 512 is defined by the longitudinal sides 532 of adjacent filter elements 530 and the outlet 514 is defined by opposing sides 522 of adjacent support elements 520. In other words, a single inlet 512 extends the length of the filter elements 530 (in this implementation, the axial length of the screening area) and a single outlet 514 extends the length of the support elements 520 (in this implementation, the interior circumference of the screen).

[0180] In some embodiments, the support elements 520 have a cross-sectional shape that is a square with truncated corners 521 on the input side and the filter elements 530 have a cross-sectional shape that is a triangle. In this implementation, each of the support elements 520 have an elongated cuboid shape with chamfered edges (truncated corners 521) with the opposing sides 522 being a lengthwise face of the cuboid and the filter elements 430 have an elongated triangular prism shape with the longitudinal sides 532 being a lateral face of the triangular prism.

[0181] The present disclosure may be embodied in other specific forms without departing from the subject matter of the claims. The described example embodiments are to be considered in all respects as being only illustrative and not restrictive.

[0182] The present disclosure intends to cover and embrace all suitable changes in technology. The scope of the claims should not be limited by the embodiments set forth in the examples but should be given the broadest interpretation consistent with the description as a whole. Furthermore, in the present disclosure, an implementation is an example or embodiment of the valve assembly and surrounding components. The various appearances of “one implementation,” “an implementation” or “some embodiments” do not necessarily all refer to the same embodiments. Although various features may be described in the context of a single implementation, the features may also be provided separately or in any suitable combination. Conversely, although the screen and related components may be described herein in the context of separate embodiments for clarity, it may also be implemented in a single implementation. Reference in the specification to “some embodiments”, “an implementation”, “one implementation”, or “other embodiments”, means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily in all embodiments.

[0183] As used herein, the terms “coupled”, “coupling”, “attached”, ’’connected” or variants thereof as used herein can have several different meanings depending in the context in which these terms are used. For example, the terms coupled, coupling, connected or attached can have a mechanical connotation. For example, as used herein, the terms coupled, coupling or attached can indicate that two elements or devices are directly connected to one another or connected to one another through one or more intermediate elements or devices via a mechanical element depending on the particular context.

[0184] In the above description, the same numerical references refer to similar elements. Furthermore, for the sake of simplicity and clarity, namely, so as to not unduly burden the figures with several reference numbers, not all figures contain references to all the components and features, and references to some components and features may be found in only one figure, and components and features of the present disclosure which are illustrated in other figures can be easily inferred therefrom. Labels are not included for each instance of an element when multiple iterations are present within the same figure The embodiments, geometrical configurations, materials mentioned and / or dimensions shown in the figures are optional and are given for exemplification purposes only.

[0185] In addition, although the optional configurations as illustrated in the accompanying drawings comprises various components and although the optional configurations of the screen and related components and assemblies as shown may consist of certain geometrical configurations as explained and illustrated herein, not all of these components and geometries are essential and thus should not be taken in their restrictive sense, i.e. should not be taken as to limit the scope of the present disclosure. It is to be understood that other suitable components and cooperations therebetween, as well as other suitable geometrical configurations may be used, as briefly explained and as can be easily inferred therefrom, without departing from the scope of the disclosure.

[0186] As used herein, “substantially”, “approximately”, and / or “about” means an acceptable variation according to conventional standards, otherwise at most a 5% to 10% variation from an indicated effect or value.

Claims

CLAIMS1. A screen for screening fluids containing a particulate, wherein the screen comprises an input side and a discharge side, the screen comprising: a screen thickness spanning from the input side to the discharge side; a filter layer comprising a gauge and a filter layer thickness; a support layer for providing structural support and comprising a support layer thickness; and a plurality of size-restricted flow paths having at least one inlet and at least one outlet and extending through both the filter layer and the support layer and configured to provide fluid communication from the input side to the discharge side; and wherein at least a fraction of the thickness of each of the support layer and the filter layer are embedded within each other such that the screen thickness is less than the sum of the support layer thickness and the filter layer thickness; and wherein the gauge represents the smallest dimension in the plurality of size- restricted flow paths passing through the filter layer.

2. The screen of claim 1 , wherein; the filter layer comprises a filter layer input side and a filter layer discharge side; and the support layer comprises a support layer input side and a support layer discharge side; wherein the input side of the screen is formed by the filter layer input side, the support layer input side, or a combination of the filter layer input side and the support layer side.

3. The screen of claim 2, wherein; the input side is formed by the filter layer input side.

4. The screen of claim 2, wherein;the input side is formed by the support layer input side.

5. The screen of claim 1 , wherein the filter layer thickness is essentially the same as the support layer thickness.

6. The screen of claim 1 , wherein the filter layer thickness is not the same as the support layer thickness.

7. The screen of claim 5 or claim 6, wherein from 5% to 100% of the thickness of the support layer is embedded within at least a fraction of the thickness of the filter layer.

8. The screen of claim 5 or claim 6, wherein from 50% to 100% of the thickness of the support layer is embedded within at least a fraction of the thickness of the filter layer.

9. The screen of claim 5 or claim 6, wherein from 5% to 100% of the filter layer is embedded within at least a fraction of the thickness of the support layer.

10. The screen of claim 5 or claim 6, wherein from 50% to 100% of the filter layer is embedded within at least a fraction of the thickness of the support layer.

11. The screen of claim 6, wherein the thickness of the support layer is completely embedded with the filter layer.

12. The screen of claim 6, wherein the thickness of the filter layer is completely embedded with the support layer.

13. The screen of any one of claims 1 to 12, wherein the gauge is from 0.006 inches to 0.05 inches.

14. The screen of any one of claims 1 to 13, wherein the support layer is configured to provide a pressure rating15. The screen of any one of claims 1 to 14, wherein the pressure rating of the screen is from about 1 PSI to about 20,000 PSI.

16. The screen of claim 15, wherein the pressure rating of the screen is from about 100 PSI to about 15,000 PSI.

17. The screen of any one of claims 1 to 16, wherein a total cross-sectional flow area of each of the one or more inlets is substantially equal to or less than a total cross- sectional flow area of each of the one or more outlets.

18. The screen of any one of claims 1 to 16, wherein a total cross-sectional flow area of each of the one or more outlets is substantially equal to or less than a total cross- sectional flow area of each of the one or more inlets.

19. The screen of any one of claims 1 to 16, wherein the one or more inlets comprise a total cross-sectional flow area that is from about 1 % to about 90% a total surface area of the screen.

20. The screen of any one of claims 1 to 19, wherein; the filter layer comprises a sheet comprising a plurality of holes that contribute to the shape of the plurality of flow paths.

21. A wellbore component comprising the screen of any one of claims 1 to 20.

22. A screen for screening fluids containing a particulate, wherein the screen comprises an input side and a discharge side and is configured to provide fluid communication therebetween, the screen comprising: a support layer comprising a plurality of support elements extending in a first direction; and a filter layer comprising a plurality of filter elements extending in a second direction; wherein the first direction is transverse to the second direction such that the plurality of support elements and the plurality of filter elements define a plurality of flow paths each having at least one inlet and at least one outlet, wherein the plurality of flow paths are configured to provide the fluid communication; and wherein the plurality of support elements are embedded in the plurality of filter elements.

23. The screen of claim 22, wherein the plurality of support elements are embedded in the plurality of filter elements, such that at least a portion of a height of the plurality of support elements is contained within a height of the plurality of filter elements.

24. The screen of claim 23, wherein an entirety of the height of the plurality of support elements is embedded in the height of the plurality of filter elements, such that a thickness of the screen is equal to the height of the plurality of filter elements.

25. The screen of claim 23, wherein the at least a portion of the height of the plurality of support elements is at least 5% of the height of the plurality of filter elements.

26. The screen of claim 23, wherein the at least a portion of the height of the plurality of support elements is at least 50% of the height of the plurality of filter elements.

27. The screen of claim 23, wherein the at least a portion of the height of the plurality of support elements is at least 80% of the height of the plurality of filter elements.

28. The screen of any one of claims 23 to 27, wherein the height of the plurality of support elements is equal to or less than the height of the plurality of filter elements.

29. The screen of any one of claims 23 to 28, wherein at least 5% of the height of the plurality of filter elements is contained in the height of the plurality of support elements.

30. The screen of any one of claims 23 to 29, wherein at least 50% of the height of the plurality of filter elements is contained in the height of the plurality of support elements.

31. The screen of any one of claims 23 to 30, wherein at least 80% of the height of the plurality of filter elements is contained in the height of the plurality of support elements.

32. The screen of any one of claims 22 to 31 , wherein each of the plurality of support elements comprise opposing side walls extending in the first direction, a base facing the discharge side, and an input surface facing the input side; and wherein each of the plurality of filter elements have longitudinal sides extending in the second direction, a base facing the input side, and an outlet surface facing the discharge side.

33. The screen of claim 32, wherein the thickness of the screen is equal to or less than a length of the longitudinal sides of the plurality of filter elements.

34. The screen of claim 32 or 33, wherein each of the inlets are defined by the longitudinal sides of adjacent ones of the plurality of filter elements; and wherein each of the outlets are defined by the longitudinal sides of the adjacent ones of the plurality of filter elements and the opposing side walls of adjacent ones of the plurality of support elements.

35. The screen of any one of claims 32 to 34, wherein the base of each of the plurality of filter elements has a width in the first direction that is greater than a width of the outlet surface in the first direction.

36. The screen of any one of claims 32 to 35, wherein the base of each of the plurality of support elements has a length in the second direction that is greater than a length of the input surface in the second direction.

37. The screen of any one of claims 32 to 36, wherein the input surface of each of the plurality of support elements is a support apex.

38. The screen of claim 37, wherein the support apex is curved.

39. The screen of any one of claims 22 to 38, wherein a total cross-sectional flow area of each of the inlets is substantially equal to or less than a total cross-sectional flow area of each of the outlets.

40. The screen of any one of claims 22 to 38, wherein a given one of the flow paths comprises a given one of the inlets and a plurality of the outlets.

41. The screen assembly of claim 40, wherein a total cross-sectional flow area of the given one of the inlets is substantially equal to or less than a total cross-sectional flow area of each of the plurality of outlets.

42. The screen of any one of claims 22 to 41 , wherein the screen comprises a cylindrical barrel having a longitudinal axis and the first direction is a circumferential direction and the second direction is an axial direction relative to the longitudinal axis.

43. The screen of any one of claims 22 to 41 , wherein the screen comprises a cylindrical barrel having a longitudinal axis and the second direction is a circumferential direction and the first direction is an axial direction relative to the longitudinal axis.

44. The screen of any one of claims 22 to 41 , wherein the screen comprises a cylindrical barrel having a longitudinal axis and a given one of the first direction and the second direction is provided at an angle relative to the longitudinal axis and an opposing one of the first direction and the second direction is substantially perpendicular to the given one of the first direction and the second direction.

45. The screen of any one of claims 22 to 44, wherein a cross-sectional shape of the plurality of support elements is one of: a semioval, a semicircle, a circle, a triangle, a square, a rectangle, a trapezoid, a discorectangle, a semi-discorectangle, a parallelogram, a polygonal, or an irregular polygonal.

46. The screen of claim 45, wherein the cross-sectional shape of the plurality of support elements is the semioval.

47. The screen of any one of claims 22 to 46, wherein a cross-sectional shape of the plurality of filter elements is one of: a semioval, a semicircle, a circle, a triangle, a square, a rectangle, a trapezoid, a discorectangle, a semi-discorectangle, a parallelogram, a polygonal, or an irregular polygonal.

48. The screen assembly of claim 47, wherein the cross-sectional shape of the plurality of filter elements is the triangle.

49. A screen assembly for use in a subterranean wellbore, the screen assembly comprising: a cylindrical barrel having a longitudinal axis and comprising a frame having opposing flanges and defining an internal flow passage; and a screen extending between the opposing flanges and having an input side comprising inlets and a discharge side comprising outlets, wherein the discharge side faces the internal flow passage, the screen comprising flow paths defined through the cylindrical barrel enabling fluid communication between the input side and the discharge side, the screen comprising: a support layer comprising a plurality of support elements; and a filter layer comprising at least one filter element;wherein the support layer is embedded in the filter layer such that at least a portion of a height of the plurality of support elements is contained within a height of the at least one filter element.

50. A screen for screening fluids containing a particulate, wherein the screen comprises an input side and a discharge side and is configured to provide fluid communication therebetween, the screen comprising: a support layer comprising a plurality of support elements extending in a first direction and comprising a base facing the discharge side and an input surface facing the input side; a filter layer comprising a plurality of filter elements extending in a second direction and comprising a base facing the input side and an outlet surface facing the discharge side; and a plurality of flow paths each having at least one inlet and at least one outlet, wherein the plurality of flow paths are configured to provide the fluid communication; and wherein the plurality of support elements are embedded in the plurality of filter elements.

51. The screen of claim 50, wherein the outlet surfaces of adjacent ones of the plurality of support elements and the base facing the discharge side of adjacent ones of the plurality of filter elements form the at least one outlet.

52. The screen of claim 50 or 51 , wherein the input surfaces of adjacent ones of the plurality of filter elements form the at least one inlet.

53. A screen for screening fluids containing a particulate, the screen comprising a plurality of flow paths having at least one inlet and at least one outlet; wherein a thickness of the screen is equal to or less than 8 mm and wherein a width of the at least one inlet is between about 0.015 mm and about 0.051 mm.

54. The screen of claim 53, wherein the width of the at least one inlet is about 0.025 mm.

55. The screen of claim 53 or 54, wherein a ratio of inlet to outlet cross-sectional area is between 1:1 and 1 :3.

56. A flow control apparatus comprising: a housing including a housing passage and a flow communicator for effecting flow communication between an environment external to the housing and the housing passage; a flow controller for controlling flow communication via the flow communicator between the housing passage and the external environment, the flow controller comprising: o an outer barrel comprising a screen assembly; and o an inner barrel comprising a shroud-defining counterpart; wherein the screen assembly comprises a single layer screen comprising a plurality of flow paths defined by a support layer comprising a plurality of support elements and a filter layer comprising at least one filter element extending transversely to the plurality of support elements, wherein each of the plurality of flow paths have at least one inlet defined by the filter layer and at least one outlet; wherein the outer barrel and the inner barrel are selectively movable such that the flow control apparatus is configured to move between a production configuration and a closed configuration.

57. The flow control apparatus of claim 56, wherein the at least one outlet is defined by adjacent ones of the plurality of support elements and / or the filter layer.

58. The flow control apparatus of claim 56 or 57, wherein the at least one inlet is further defined by the adjacent ones of the plurality of support elements.

59. The flow control apparatus of any one of claims 56 to 58, wherein a thickness of the single layer screen is equal to a height of the plurality of filter elements.

60. A process for recovering a subterranean fluid wherein the subterranean fluid passes though the screen as defined in any one of claims 22 to 55 and is recovered to surface.

61. The process of claim 61 , wherein the subterranean fluid comprises a hydrocarbon or water.

62. A screen for screening fluids containing a particulate, the screen comprising a support layer and a filter layer defining flow paths having at least one inlet and at least one outlet, wherein at least 5% of the support layer is embedded in the filter layer.

63. The screen of claim 62, wherein a width of the at least one inlet is between about 0.015 mm and about 0.051 mm.

64. The screen of claim 63, wherein the width of the at least one inlet is about 0.025 mm.

65. The screen of any one of claims 62 to 64, wherein a ratio of inlet to outlet cross- sectional area is between 1 :1 and 1 :5.

66. The screen of claim 65, wherein the ratio of inlet to outlet cross-sectional area is 1 :2.

67. The screen of any one of claims 62 to 66, wherein at least 50% of the support layer is embedded in the filter layer.

68. The screen of any one of claims 62 to 66, wherein at least 80% of the support layer is embedded in the filter layer.

69. The screen of any one of claims 62 to 68, wherein a thickness of the screen is equal to or less than 20 mm.

70. The screen of any one of claims 62 to 68, wherein a thickness of the screen is equal to or less than 8 mm.

71. The screen of any one of claims 62 to 68, wherein a thickness of the screen is equal to or less than 5 mm.

72. The screen of any one of claims 62 to 71 , wherein the screen has a pressure rating of at least 100 PSI.

73. A screen for screening fluids containing a particulate, the screen comprising a support layer and a filter layer, wherein the screen layer and the filter layer overlap.

74. The screen of claim 73, wherein the filter layer defines a filter area comprising a plurality of inlets and wherein a flow through area of the plurality of inlets is between 1 % and 90% of a total surface area of the filter.

75. The screen of claim 73, wherein the filter layer defines a filter area comprising a plurality of inlets and wherein a flow through area of the plurality of inlets is between 2% and 50% of a total surface area of the filter.

76. The screen of claim 73, wherein the filter layer defines a filter area comprising a plurality of inlets and wherein a flow through area of the plurality of inlets is between 4% and 20% of a total surface area of the filter.

77. A screen for screening fluids containing a particulate, wherein the screen comprises an input side and a discharge side, the screen comprising: a screen thickness spanning from the input side to the discharge side; a filter layer comprising a gauge and a filter layer thickness; a support layer for providing structural support and comprising a support layer thickness; and a plurality of size-restricted flow paths having at least one inlet and at least one outlet and extending through both the filter layer and the support layer and configured to provide fluid communication from the input side to the discharge side; and wherein at least a fraction of the thickness of each of the support layer and the filter layer are embedded within each other such that the screen thickness is less than the sum of the support layer thickness and the filter layer thickness.

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