Downhole Sand Screen With Bypass Conduits and Flow Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for an improved sand control assembly that provides bypass technology during gravel packing and offers flow control between a base pipe and a surrounding annular region during production operations, particularly for modern sand screen arrangements with Internal Shunt Alternate Path (ISAPT) technology, which requires additional fluid flow control hardware.
Innovation Solution
A sand screen assembly is designed with an elongated base pipe, filter media, coupling assemblies, transport conduits, and an in-flow control section that selectively permits fluid leak-off during gravel packing and production, providing a less restrictive flow path for gravel slurry and a more restrictive path for production fluids to ensure controlled fluid communication between the sand screen and the base pipe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If bypass conduits are provided for gravel slurry flow during gravel packing, then uniform gravel packing is achieved, but device complexity increases due to additional flow control hardware
Solution Approach 1:
The sand screen assembly is divided into multiple functional sections: a gravel packing section with bypass conduits for slurry flow, and a production section with flow control devices. This segmentation allows different flow paths for different operations (gravel packing vs. production), achieving uniform packing while managing complexity through functional separation.
Solution Approach 2:
The assembly transitions from a static structure to a dynamic system where flow paths change based on operational phase. During gravel packing, bypass conduits are open for slurry flow; during production, flow control devices regulate production fluid flow. This dynamic adaptability resolves the contradiction by making the system complex only when needed.
2Ease of operation
If flow control devices are installed in the base pipe for production fluid control, then production fluid flow is controlled, but device complexity increases
Solution Approach 1:
Flow control devices are integrated directly into the base pipe structure, merging the flow control function with the existing structural component. This reduces overall device complexity by eliminating separate flow control assemblies while still providing the necessary production fluid flow control capability.
Solution Approach 2:
The base pipe serves multiple functions: it provides structural support, contains production fluids, and incorporates flow control devices. This multi-functionality reduces the need for additional separate components, thereby controlling device complexity while achieving production fluid flow control.
3Reliability
If the base pipe is sealed to prevent fluid communication during production, then wellbore integrity is improved, but gravel packing becomes difficult due to restricted fluid leak-off
Solution Approach 1:
The assembly is configured in advance with distinct gravel packing and production sections. The gravel packing section includes bypass conduits and is designed to allow fluid leak-off during the gravel packing operation. After gravel packing is complete, the assembly transitions to the production configuration where the base pipe is sealed. This preliminary configuration resolves the contradiction by ensuring gravel packing can occur before the seal is activated.
Solution Approach 2:
The fluid communication characteristics of the base pipe are made dynamic rather than static. During gravel packing, the base pipe allows fluid communication through bypass conduits; during production, it is sealed to prevent communication. This dynamic behavior allows the system to satisfy both requirements at different operational stages.
Data Source
AI summary
A sand screen assembly offering alternate flow path technology for gravel slurry is provided. The sand screen assembly utilizes transport conduits along an outer diameter of a base pipe for transporting gravel slurry from sand screen to sand screen, thereby providing for a consistent gravel packing along the wellbore. The assembly also includes a unique in-flow control section. The in-flow control section allows the operator to restrict or control the flow of production fluids into the sand screen assembly once a gravel packing operation is completed. Multiple assemblies may be connected using a unique coupling assembly. A method for completing a wellbore in a subsurface formation using the sand screen assembly is also provided herein.