Sand Control Screen Peak Flux Reducing Assembly
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Solution Overview
Problem
Sand control screen assemblies in the oil and gas industry are prone to early failure due to high velocity fluid flow, which causes erosion, especially in open-hole completions without gravel packing, leading to plugging and equipment damage.
Innovation Solution
A sand control screen assembly with a peak flux reducing assembly arranged axially adjacent to the wellbore isolation device, which reduces the peak velocity of fluid flow through the screens by splitting the flow into multiple paths or progressively reducing the volumetric flow area, thereby mitigating erosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sand control screen assemblies are installed in high-pressure, high-productivity formations with high permeability streaks, then production efficiency is improved, but the sand screens become vulnerable to erosion damage and early failure
Solution Approach 1:
The screen assembly is divided into multiple flow paths by creating a multi-layer screen structure with alternating flow directions. This segmentation distributes the high-velocity fluid flow across multiple smaller paths, reducing the erosional impact on any single screen layer while maintaining overall production capacity.
Solution Approach 2:
The invention introduces an additional dimensional layer by stacking multiple screen layers in series with alternating flow orientations (radial and axial directions). This multi-dimensional flow distribution approach spreads the erosional stress across different spatial dimensions, protecting the sand screens from concentrated high-velocity erosion while preserving productivity.
2Device complexity
If stand-alone screens are used without gravel packing, then device complexity is reduced, but the screens are more susceptible to erosion damage
Solution Approach 1:
The invention changes the flow velocity parameter by distributing high-velocity flow across multiple screen layers with alternating flow directions. This parameter transformation converts a concentrated high-velocity erosional force into distributed lower-velocity flows, reducing erosion susceptibility without requiring gravel packing or increasing overall device complexity.
3Productivity
If high velocity fluid flow is allowed through sand screens, then productivity is maintained, but localized erosion and hotspot formation occur leading to premature failure
Solution Approach 1:
The screen assembly segments the single high-velocity flow path into multiple parallel flow paths through alternating radial and axial screen layers. This segmentation maintains total fluid flow rate (productivity) while distributing the velocity across multiple paths, preventing localized erosion hotspots from forming.
Solution Approach 2:
The alternating screen layers act as intermediaries that redirect and distribute the fluid flow. Each screen layer serves as a mediator that transforms the flow direction and distributes it across multiple paths, reducing the direct erosional impact on any single screen while maintaining overall productivity.
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 localized erosion of the sand screens, extending their usable life by distributing the fluid flow velocity and minimizing hotspot formation, thus preventing premature failure.
Implementation Method 1
A peak flux reducing assembly arranged axially adjacent the wellbore isolation device and operable to reduce a peak velocity of fluids traversing the sand screen
Data Source
AI summary
A method of reducing erosional peak velocity includes arranging a sand control screen assembly in an open hole section of a wellbore, the sand control screen assembly including a base pipe defining a plurality of flow ports, a sand screen arranged about the base pipe, and a wellbore isolation device deployed within an annulus defined between the sand control screen assembly and an inner wall of the wellbore. A fluid from a surrounding subterranean formation is circulated within the annulus, and the fluid within the annulus is diverted through the sand screen and into the base pipe upon approaching the wellbore isolation device. A peak velocity of the fluid flowing through the sand screen is reduced with a peak flux reducing assembly arranged axially adjacent the wellbore isolation device.