Sand Control Screen Connectors with Thinned Flex Joints

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Solution Overview

Problem

Conventional sand control screen assemblies experience stress concentration issues at connection points between mesh materials and connectors, leading to potential rupture due to differences in strength, compromising their structural stability and effectiveness in filtering particulates from hydrocarbon fluids in wellbores.

Innovation Solution

The development of a sand control screen assembly with connectors that include areas of thinned material, such as grooves or pleats, to create a 'flex' joint that deforms similarly to the mesh material, reducing stress concentrations and enhancing structural stability by using thinner, annealed stainless steel connectors that yield under high stress, and optionally incorporating a support structure to limit differential deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional connectors are used to join mesh material sections, then the connection strength is high, but the mesh material deforms differently and may rupture due to stress concentration

Engineering Contradiction:

Improveconnection strengthVSAvoidmesh material integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The connector is designed with a nonuniform profile featuring a thinned section (groove) that creates a flex joint. This local modification allows the connector to deform in a manner matching the mesh material's deformation characteristics at the connection point, reducing stress concentration while maintaining overall connection strength.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The connector's thickness parameter is varied along its length, with a thinned section created by machining a groove. This parameter change enables the connector to yield under high stress in a controlled manner, allowing differential deformation between the connector and mesh material without causing rupture.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If uniform thickness connectors are used, then manufacturing is simple, but stress concentrations occur at connection points due to differential deformation

Engineering Contradiction:

Improveconnector manufacturing simplicityVSAvoidstress concentration

Core Design Contradiction:

Ease of manufactureVSStress or pressure

Solution Approach 1:

Instead of manufacturing the entire connector with varying thickness, only a localized thinned section (groove) is created at the connection point. This approach maintains simple manufacturing processes while introducing the necessary nonuniform profile to reduce stress concentration at the critical connection area.

Inventive Principle:

Principle #3Local quality

3Strength

If stronger connector material is used to prevent rupture, then connection strength increases, but differential deformation with mesh material worsens

Engineering Contradiction:

Improveconnector strengthVSAvoiddeformation compatibility

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The connector's cross-sectional area is reduced at the thinned section, which locally reduces its stiffness and strength. This allows the stronger connector material to maintain overall connection strength while the thinned section enables compatible deformation with the mesh material under stress.

Inventive Principle:

Principle #35Parameter changes

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 modified connectors minimize stress concentrations at connection points, improving the collapse value and structural stability of the screen assemblies, thereby preventing rupture and ensuring effective filtration of particulates while withstanding high stresses.

Implementation Method 1

The safe edge(s) include(s) one or more areas of thinned material, such as a groove. The areas of thinned material may be present on an inner surface or outer surface of the safe edge, thereby providing a nonuniform profile on the surface.

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

using thinner, annealed stainless steel connectors that yield under high stress

Methodology Applied

Scientific EffectAnnealing: Annealing

Implementation Method 3

using thinner, annealed stainless steel connectors that yield under high stress

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 4

the sand control screen assembly may comprise a base pipe having a plurality of openings through a thickness of the base pipe and a mesh layer positioned about the base pipe

Methodology Applied

Scientific EffectPhysical filtration: Filter (physical)

Data Source

PatentUS11555383B2Sand control screen assemblies and associated methods of manufacturing

Publication Date: 2023.01.17 CHEVRON USA INC

AI summary

A sand control screen assembly includes a base pipe having openings through its thickness, and a mesh layer having mesh material sections coupled to safe edges, or connectors, for connecting sections together. The safe edges include areas of thinning to provide flex joints that yield when exposed to high stresses. The mesh layer may be a drainage layer or a filter medium of the sand control screen assembly.