Rod-Based Sand Screen Wire Wrapping Welding Precision
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Solution Overview
Problem
Sand production in hydrocarbon wells leads to equipment damage and increased operational costs due to abrasive sand entering the wellbore, requiring effective filtration methods to prevent sand migration and erosion.
Innovation Solution
A wire-wrapping assembly for manufacturing sand screens, which includes a pipe support, wire feeder, and electrodes for wrapping and welding wire around rods on a base pipe, with adjustable contacts to clear obstructions and optimize the welding current path, ensuring a secure and efficient filtration system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire is wrapped and welded to rods on a base pipe to create a sand screen, then filtration effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The base pipe is segmented into multiple rods that extend along its outside surface, with wire wrapped around each rod individually to form helical coils. This segmentation allows the welding process to be broken down into discrete, manageable operations at each rod location, improving filtration effectiveness through precise wire-to-rod attachment while managing manufacturing complexity through modular construction
Solution Approach 2:
The wire acts as an intermediary element that connects the rods to the base pipe structure. By wrapping wire around each rod and welding it to both the rod and the base pipe, the invention creates a secure mechanical and electrical connection that enhances filtration reliability without requiring direct complex bonding between the base pipe and filtration structure
2Manufacturing precision
If individual contacts are used to engage each rod for welding, then welding precision is improved, but device complexity increases
Solution Approach 1:
Each rod is engaged by its own individual contact that can move radially inward and outward independently. This local quality approach ensures that welding precision is optimized at each specific rod location without requiring all contacts to be perfectly positioned simultaneously, as each contact operates independently to establish precise electrical connection for welding its associated wire
Solution Approach 2:
The individual contacts are designed to move radially inward and outward along the mounting ring, providing dynamic adjustment capability. This movement allows each contact to automatically position itself for optimal engagement with its corresponding rod during the wire wrapping and welding process, improving welding precision while the mounting ring structure manages the overall device complexity
3Adaptability or versatility
If the mounting ring has a large inner diameter to clear obstructions, then adaptability is improved, but structural integrity may be compromised
Solution Approach 1:
The mounting ring is designed with an inner diameter that is larger than the outer diameter of the base pipe, creating a parameter change that allows the ring to clear obstructions on the base pipe surface. This dimensional adjustment provides adaptability to accommodate various base pipe configurations and obstructions while the ring's structural design maintains sufficient integrity to support the individual contacts and welding operations
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 prevents sand migration by creating a robust sand screen assembly that maintains production rates and reduces maintenance costs by ensuring proper filtration and minimizing equipment damage.
Implementation Method 1
a first electrode positioned to engage the wire and weld the wire to each rod as the wire is wrapped around the rods; and a second electrode having a mounting ring and a plurality of separate individual contacts with each individual contact engaging only one of the rods
Data Source
AI summary
A rod-based well screen is formed in place on a perforated pipe base by wrapping wire around the pipe base and a plurality of rods located around the outside of the pipe. The wire is welded sequentially to each individual rod as it is wrapped around the pipe. The welding and ground electrodes engage the wire and the rods respectively. The rod engaging ground electrode is positioned a short distance ahead of the wire being wrapped around the rods and the pipe base. The ground electrode includes a plurality of contacts. Each contact is mounted to pivot toward and away from a rod. Springs urge each contact toward a rod to hold the rod against the outside surface of the pipe base and to maintain good electrical contact between the contact and the rod. Each contact has a groove to guide the rod into position for welding to the wire.