Prepacked Sand Screen Assemblies for Erosion Mitigation

Solution Overview

Problem

Sand control screen assemblies in hydrocarbon production systems face erosion issues due to fluid velocity concentration, leading to premature failure and uncontrolled sand production, which causes maintenance problems and downtime.

Innovation Solution

Incorporating prepack porous media and flow collectors within the production annulus between the base pipe and sand screen to distribute fluid flow evenly and create a pressure drop, mitigating erosion by providing tortuous flow paths and redundant filtration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sand control screen assemblies are used to prevent formation particle influx, then sand control effectiveness is improved, but screen erosion and premature failure occur due to fluid velocity concentration at the end of the screen

Engineering Contradiction:

Improvesand control effectivenessVSAvoidscreen service life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The screen assembly is divided into multiple sections with varying screen element densities. The first section has a first density and the second section has a second density, creating segmented flow paths that distribute fluid velocity more evenly throughout the screen length, preventing concentration at the end.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the sand control screen assembly are given different local properties through varying screen element densities in different sections. This allows each section to be optimized for its specific flow conditions, with higher density areas handling higher velocity zones and lower density areas handling lower velocity zones.

Inventive Principle:

Principle #3Local quality

2Reliability

If screen jackets and screen elements are used to restrict sand influx, then formation particle control is improved, but erosion and deformation occur due to high fluid velocities at the end of the screen

Engineering Contradiction:

Improveformation particle controlVSAvoidfluid velocity concentration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The screen assembly is divided into multiple sections with varying screen element densities. The first section has a first density and the second section has a second density, creating segmented flow paths that distribute fluid velocity more evenly throughout the screen length, preventing concentration at the end.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the sand control screen assembly are given different local properties through varying screen element densities in different sections. This allows each section to be optimized for its specific flow conditions, with higher density areas handling higher velocity zones and lower density areas handling lower velocity zones.

Inventive Principle:

Principle #3Local quality

3Device complexity

If conventional sand screens are used without prepack porous media, then device complexity is reduced, but erosion resistance and filtration reliability are insufficient

Engineering Contradiction:

Improvescreen assembly structureVSAvoiderosion resistance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The prepack porous media is nested within the production annulus between the base pipe and the sand screen, creating a nested structure where the porous media is contained within the existing screen assembly geometry. This adds filtration capability without requiring a completely separate external filtration system.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

Prepack porous media is incorporated into the screen assembly to provide additional filtration and erosion resistance. The porous material creates tortuous flow paths that reduce fluid velocity and provide a safety filtration barrier even if the screen elements are damaged.

Inventive Principle:

Principle #31Porous materials

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 erosion and maintains sand screen integrity by distributing fluid flow uniformly and providing additional filtration, ensuring continuous production even if the sand screen is damaged.

Implementation Method 1

generating a pressure drop as the incoming fluids must pass through tortuous flow paths defined by each of the prepack porous media and the mass of porous media

Methodology Applied

Scientific EffectPressure drop: Pressure Drop

Implementation Method 2

tortuous flow paths defined by each of the prepack porous media and the mass of porous media

Methodology Applied

Scientific EffectTortuous flow:

Implementation Method 3

sand control screen assemblies used to resist erosion and distribute fluid flow more evenly through sand screens

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS10053962B2Prepacked sand screen assemblies

Publication Date: 2018.08.21 HALLIBURTON ENERGY SERVICES INC

AI summary

A sand control screen assembly includes a base pipe defining one or more flow ports that provide fluid communication into an interior of the base pipe. A sand screen is arranged about an exterior of the base pipe and thereby defines a production annulus between the exterior of the base pipe and the sand screen. A prepack porous media is positioned in and fills the production annulus. A flow collector is positioned within at least one of the one or more flow ports and provides a retainer and a mass of porous media positioned within the retainer.