Downhole Sand Screen Coating for Complex-Geometry Erosion Resistance

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Solution Overview

Problem

Conventional sand screen assemblies suffer from erosion of the drainage layer and/or filter medium due to impingement of particles in the fluid stream, leading to production of undesirable particles that cause excessive erosion and maintenance costs.

Innovation Solution

A method of coating sand screen components using non-line-of-sight processes such as chemical vapor deposition or reactive infiltration to uniformly apply a hard, erosion-resistant coating on interior and exterior surfaces, including complex geometries, with a thickness of 5 to 100 microns, using materials like hard carbides and nitrides.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If line-of-sight coating processes (PVD, thermal spraying) are used to coat sand screen components, then coating can be applied to exterior surfaces, but the inner portions of tubular components and inner portions of mesh/wire layers cannot be coated

Engineering Contradiction:

Improvecoating coverage areaVSAvoidcoating process adaptability to complex geometries

Core Design Contradiction:

Area of stationary objectVSAdaptability or versatility

Solution Approach 1:

The patent replaces mechanical line-of-sight coating processes with a chemical vapor deposition process. The coating composition is introduced as vapor that chemically reacts with the substrate surface, allowing uniform coating on complex geometries including inner surfaces of tubular components and mesh/wire layers without requiring direct line-of-sight access.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state of the coating material from solid/liquid (in conventional processes) to vapor phase. This parameter change enables the coating to penetrate and uniformly deposit on complex internal geometries that are inaccessible to conventional coating equipment.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If drainage layer and/or filter medium are not coated with erosion resistant material, then manufacturing is simpler, but erosion by particle impingement causes particle production leading to excessive erosion of production equipment and high maintenance costs

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoiderosion resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent creates a composite structure by coating the drainage layer and/or filter medium with an erosion-resistant composition. The coating layer (containing hard carbide, boride, nitride, carbo-nitride, or silicide phases) combines with the base material to form a composite that resists particle impingement while maintaining the original component's functional properties.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies erosion-resistant coating to the drainage layer and/or filter medium before these components are deployed in the wellbore. This preliminary protective action prevents erosion damage before it occurs, eliminating the need for maintenance and replacement during the production lifecycle.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If conventional sand screen assemblies are deployed, then initial production can occur, but erosion of drainage layer and/or filter medium leads to particle production that causes excessive erosion and downtime

Engineering Contradiction:

Improveinitial production capabilityVSAvoidservice life

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The patent applies an erosion-resistant coating to the drainage layer and/or filter medium before deployment, creating a protective barrier that cushions against particle impingement. This prior protection prevents the erosion that would otherwise lead to particle production and extended downtime, thereby extending the service life of the sand screen assembly.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 non-line-of-sight coating process enhances erosion resistance, reducing wear rates and maintaining production efficiency by preventing particle production, thus extending the service life and performance of sand control screen assemblies.

Implementation Method 1

applying a coating to the sand screen component using a non-line-of-sight coating process... the non-line-of-sight coating process is selected from the group consisting of: chemical vapor deposition, chemical vapor infiltration, bath deposition, and reacting the base structure with reactive vapor or liquid species

Methodology Applied

Scientific EffectChemical vapor deposition: Chemical Vapour Deposition

Implementation Method 2

reacting the base structure with reactive vapor or liquid species

Methodology Applied

Scientific EffectReactive infiltration:

Data Source

PatentUS12352136B2Downhole sand control screen system

Publication Date: 2025.07.08 CHEVRON USA INC

AI summary

System and method of non-line-of-sight coating of a sand screen for use in wellbores during the production of hydrocarbon fluids from subterranean formations. The coatings can have uniformly coated internal and external surfaces.