Flow Restriction Openings in Sand Screen Base Pipe
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Solution Overview
Problem
High flow rates in gas wells can cause erosion of sand screens due to excessive velocity, leading to potential failure and risk of erosion to other completion components, especially when annular flow enters through screen joints, and gravel packing is not uniformly effective across the entire screen.
Innovation Solution
A base pipe with a plurality of flow restriction openings of reduced size, arranged in a selected pattern, is used to surround the sand screen, reducing peak radial fluid flow rates below the erosion threshold and separating peak annular flows from peak radial flows to prevent erosive particle entrainment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high flow rates are maintained in gas wells, then productivity is improved, but erosion of sand screen components occurs due to excessive velocity
Solution Approach 1:
The base pipe is divided into multiple flow restriction elements distributed along its length, segmenting the high velocity flow into multiple lower velocity streams that pass through the sand screen, thereby reducing erosive forces while maintaining overall productivity
Solution Approach 2:
Flow restriction elements are strategically positioned at specific locations along the base pipe where erosive forces are most problematic, creating localized flow control zones that address erosion vulnerabilities without compromising overall system productivity
2Reliability
If gravel packing is used to limit particulate velocity, then erosion is reduced, but non-uniform packing results in high flow rates through poorly packed regions
Solution Approach 1:
The flow restriction elements act as an intermediary flow control mechanism between the annular space and the base pipe interior, regulating flow distribution independently of gravel pack quality and preventing concentrated high-velocity flows through poorly packed regions
3Productivity
If annular flow enters through screen joints, then flow distribution is achieved, but erosion of the sand screen results from high velocity entry
Solution Approach 1:
Flow restriction elements are pre-positioned in the base pipe to control and reduce flow velocity before the annular flow enters through screen joints, preventing erosive conditions from developing at critical entry points
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 effectively reduces the risk of sand screen erosion by distributing fluid flow evenly across the screen, maintaining flow rates below erosive levels and increasing the longevity of completion components while allowing higher production rates.
Implementation Method 1
The size and arrangement of the flow restriction openings reduces the peak flux of radial fluid flow through the sand screen to a rate less than a sand screen erosion rate
Implementation Method 2
The variation of perforation density also brings a separation of peak annular flows from peak radial flows to reduce the probability of erosive particle entrainment
Data Source
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AI summary
A system and methodology utilizes a technique for filtering sand; distributing a flow of fluid; e.g. distributing an inflow of gas or condensate; and limiting the potential for erosion of completion components in a wellbore. The technique may be useful in production applications, but the technique also can be used in fluid injection applications, e.g. gas injection applications. The technique employs a base pipe and a sand screen surrounding the base pipe. The base pipe comprises a plurality of flow restriction openings of reduced size and deployed in a selected pattern along the base pipe. The size and arrangement of the flow restriction openings reduces the peak flux of radial fluid flow through the sand screen to a rate less than a sand screen erosion rate.