Sand Screen Flow Restriction Elements for Erosion Control
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Solution Overview
Problem
In gas wells, high flow rates of inflowing gas can cause erosion and failure of sand screens, and gravel packing may not uniformly distribute flow rates, leading to erosive conditions in poorly packed regions.
Innovation Solution
A sand screen assembly with a base pipe equipped with flow restriction elements, arranged in specific patterns to control pressure drop and flow rate, preventing erosion by maintaining flow velocity below erosive levels across the entire sand screen.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high flow rate is maintained to maximize production, then productivity is improved, but erosion of sand screen components occurs leading to failure
Solution Approach 1:
The patent applies parameter changes by introducing flow restriction elements with specific flow coefficients (Cd) and varying sizes to control and distribute flow rates. By adjusting the flow parameters through strategically placed restrictions, the system maintains high overall productivity while limiting local velocities to prevent erosion, thus resolving the contradiction between productivity and reliability
Solution Approach 2:
The patent implements local quality by placing flow restriction elements at specific locations along the sand screen where erosion is most likely to occur. Each restriction element is positioned to address local flow conditions, creating non-uniform flow distribution that protects vulnerable areas while maintaining high flow rates in other regions, thereby balancing productivity and durability
2Object-affected harmful factors
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 patent addresses the non-uniformity of gravel packing by introducing flow restriction elements at specific locations where poor packing exists. These elements locally modify the flow characteristics to compensate for inadequate gravel packing, ensuring uniform flow distribution and preventing erosion in vulnerable regions while maintaining overall productivity
Solution Approach 2:
The flow restriction elements act as intermediary devices between the gravel pack and the sand screen. They mediate the flow distribution by introducing controlled restrictions that compensate for deficiencies in the gravel pack, thereby achieving uniform flow rates and preventing erosion without compromising productivity
3Object-affected harmful factors
If flow restriction elements are added to control velocity, then erosion is prevented, but device complexity increases
Solution Approach 1:
The patent employs porous flow restriction elements that allow fluid passage while creating the necessary pressure drop and velocity reduction. These porous structures integrate multiple functions (flow control, filtration, and erosion prevention) into single components, reducing overall device complexity while achieving the desired erosion protection
Solution Approach 2:
The flow restriction elements are designed to perform multiple functions simultaneously: controlling flow rates, distributing fluid uniformly, preventing erosion, and potentially filtering particles. This multi-functionality reduces the need for separate components, thereby managing device complexity while achieving comprehensive erosion protection
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 filters sand and distributes fluid flow, preventing sand screen degradation and erosion, ensuring consistent and controlled flow rates, even in non-uniformly packed regions, thereby protecting completion components.
Implementation Method 1
The flow restriction elements are configured to create a desired pressure drop across the base pipe and thereby provide a desired distribution of the flowing fluid
Data Source
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AI summary
A technique enables an improved filtering of sand, a desired distribution of produced or injected fluid, and a reduction in erosion of completion components positioned in a production or injection well. The technique employs a base pipe and a sand screen surrounding the base pipe. The base pipe comprises a plurality of flow restriction elements arranged in a selected pattern along the base pipe to provide a desired distribution of the fluid flowing into or out of the sand screen. The pattern of flow restriction elements also maintains a flow rate of the flowing fluid below an erosive flow rate across the entire sand screen.