Downhole Screen Exterior Bypass Coupling Assembly
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Solution Overview
Problem
Existing screen assemblies face challenges in achieving even gravel distribution and assembly ease, particularly in horizontal completions, with issues like gravel bridging and limited bypass orientations, and complex assembly processes.
Innovation Solution
A screen assembly with exterior bypass tubes connected through a coupling assembly using an internal mandrel, featuring slanted gravel outlet passages and optional blank bypasses, allowing rapid fluid connection and multiple circumferential orientations without complex structures, enabling efficient gravel distribution and assembly across threaded connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If bypasses are connected individually across joints or using clamshell designs, then fluid connection is achieved, but assembly complexity and time increase
Solution Approach 1:
The patent merges multiple bypass connections into a single integrated coupling assembly. The coupling connects multiple screen sections simultaneously while providing fluid communication between their annular spaces through a unified structure, eliminating the need for separate connection operations for each bypass.
Solution Approach 2:
The coupling assembly is segmented into distinct functional components including bypass openings, sealing elements, and connection interfaces. This segmentation allows for modular assembly where screen sections can be connected independently while the coupling integrates them fluidly, simplifying the overall assembly process.
2Adaptability or versatility
If bypass orientations are limited to fixed patterns, then manufacturing is simplified, but adaptability to different completion configurations is reduced
Solution Approach 1:
The coupling assembly incorporates rotatable bypass tubes that can be positioned at different angular orientations around the central axis. This dynamic positioning capability allows the bypasses to be oriented vertically, horizontally, or at any intermediate angle, adapting to various completion configurations without requiring multiple specialized coupling designs.
Solution Approach 2:
The coupling assembly is designed as a universal component that can accommodate different screen section configurations and bypass orientations through a single standardized design. The rotatable bypass tubes and standardized connection interfaces enable the same coupling to serve multiple functions across different well completion scenarios.
3Reliability
If gravel outlets are positioned without standoffs, then device complexity is reduced, but gravel distribution effectiveness deteriorates
Solution Approach 1:
The standoff acts as an intermediary element between the gravel outlet and the screen annular space. It positions the outlet at an optimized distance from the screen, allowing gravel to be distributed effectively into the annular space without requiring complex outlet geometries or additional distribution mechanisms.
4Ease of operation
If threaded connections are used for joining screen sections, then assembly is simplified, but durability and sealing reliability may be compromised
Solution Approach 1:
The coupling assembly incorporates self-sealing features where the act of threading the connections together automatically compresses sealing elements between the coupling and screen sections. This self-service sealing mechanism ensures reliable fluid containment without requiring separate sealing operations or complex sealing structures.
Data Source
AI summary
An assembly of screens made of connected joints with exterior bypasses that span the threaded connections among the joints features common fluid connections for the bypasses adjacent joint threaded ends that are connected with a coupling. A mandrel spans from one joint to the next inside the threaded coupling and is sealed to the respective bases pipes on opposed ends of the coupling. At each end of the mandrel the surrounding base pipe has openings from the common fluid connection where the bypasses terminate to define an annular flow path between pairs of common fluid connections. The bypasses can have slanted gravel outlet passages or no gravel openings at all. The bypasses can span over screen or blank pipe with an option to mount a shroud over the generally parallel bypasses.