Degradable Inorganic Sand Control Device for Erosion Resistance

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Solution Overview

Problem

In the resource recovery industry, sand and particles entrained in production fluids erode screen assemblies in wellbores, leading to clogs and breaches, which necessitates frequent replacements and increases production costs.

Innovation Solution

A sand control device is formed using a curable inorganic cementitious mixture infused with an engineered degradable material, which is activated by an external stimulus to create pores, allowing formation fluids to flow while withstanding erosion forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a screen assembly is used to exclude particles, then particle exclusion is achieved, but erosion and clogging occur over time reducing reliability

Engineering Contradiction:

Improvescreen assembly durabilityVSAvoiderosion and clogging

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent employs a porous cementitious matrix as the base material for the sand control device. This porous structure provides inherent filtration capability while maintaining structural integrity, allowing the device to exclude particles through its porous architecture rather than relying solely on screen openings that are susceptible to erosion and clogging.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent creates a composite material by infusing degradable material into the curable inorganic cementitious mixture. This composite structure combines the erosion-resistant properties of the cementitious matrix with the controlled degradability of the infused material, resulting in a sand control device that maintains reliability while adapting to operational conditions.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If a robust screen assembly is used to withstand erosion, then erosion resistance improves, but particle exclusion capability may be compromised

Engineering Contradiction:

Improveerosion resistanceVSAvoidparticle exclusion effectiveness

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The porous cementitious matrix provides both erosion resistance and particle exclusion through its interconnected pore structure. The pore size and distribution can be controlled during manufacturing to ensure effective particle filtration while maintaining structural robustness against erosion forces.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The degradable material is infused throughout the cementitious matrix, creating localized variations in material properties. This allows different regions of the sand control device to have tailored characteristics, with the degradable material providing particle exclusion pathways while the cementitious matrix provides erosion resistance.

Inventive Principle:

Principle #3Local quality

3Reliability

If screen assembly replacements are performed to address erosion and clogging, then reliability is restored, but production time is lost increasing costs

Engineering Contradiction:

Improvescreen assembly functionalityVSAvoidproduction delay

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The degradable material is pre-infused into the cementitious matrix during manufacturing, preparing the sand control device for future operational needs. This preliminary incorporation of functional material allows the device to adapt in-situ without requiring removal or replacement, eliminating production delays associated with assembly changes.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The degradable material provides self-service functionality by automatically degrading in response to environmental stimuli such as pH changes or microbial activity. This self-adjusting mechanism maintains particle exclusion effectiveness over time without requiring human intervention or assembly replacement, thereby preventing production interruptions.

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides a robust sand control device with enhanced abrasion and erosion resistance, reducing the need for frequent replacements and minimizing production delays and costs.

Implementation Method 1

introducing an external stimulus onto the sand control device causing the degradable material to dissolve

Methodology Applied

Scientific EffectDissolution:

Implementation Method 2

forming a sand control device formed from a curable inorganic cementitious mixture

Methodology Applied

Scientific EffectCuring:

Data Source

PatentUS20240084665A1Method of forming a sand control device from a curable inorganic mixture infused with degradable material and method of producing formation fluids through a sand control device formed from a curable inorganic mixture infused with degradable material

Publication Date: 2024.03.14 BAKER HUGHES OILFIELD OPERATIONS LLC

AI summary

A method of excluding particles entrained in formation fluids includes introducing a tubular into a wellbore, forming a sand control device formed from a curable inorganic cementitious mixture infused with an engineered degradable material about the tubular, introducing an external stimulus onto the sand control device causing the degradable material to dissolve, and flowing formation fluids through the sand control device into the tubular.