Segmented Sand Screen Wraps for Even Wellbore Fluid Flow
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Solution Overview
Problem
Conventional flow control devices in wellbores face challenges in achieving even fluid flow due to uneven formation properties and the presence of solid particles, leading to reduced hydrocarbon production and potential blockages from larger particles.
Innovation Solution
The development of a flow control device with a tubular member featuring adjacent wraps with tortuous flow paths and integrated sand screens, allowing radial fluid flow and inhibiting the passage of solids, which is formed by wrapping a longitudinal member with channels around a tubular or mandrel, providing a unified structure with standoffs and flow control elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sand screens are used to inhibit solid particles, then sand control is achieved, but larger particles can still block the annular flow area
Solution Approach 1:
The screen is segmented into multiple adjacent wraps with progressively larger openings from the outside wrap inward. This segmentation allows different sized particles to be filtered at different stages, preventing blockages while maintaining flow capacity.
Solution Approach 2:
Different portions of the screen have different opening sizes tailored to local requirements. The outer wraps have smaller openings for fine sand control, while inner wraps have larger openings to accommodate larger particles and prevent annular flow blockage.
2Reliability
If discrete flow control devices are used, then flow control is achieved, but radial space is consumed reducing internal diameter
Solution Approach 1:
The flow control device is merged with the sand screen into a single integrated structure. The screen wraps are formed with embedded flow control elements, combining sand filtration and flow regulation functions in one component, thereby conserving radial space and maintaining larger internal diameter.
Solution Approach 2:
The screen structure serves multiple functions simultaneously: it acts as a sand filter, a flow control device, and a structural support element. This multi-functionality eliminates the need for separate discrete devices, optimizing space utilization.
3Device complexity
If single entry point is used, then device simplicity is maintained, but production efficiency is limited
Solution Approach 1:
The device transitions from a single-point entry configuration to a distributed multi-point entry system along the annular flow path. Multiple entry points are created through the adjacent wraps structure, allowing fluid to enter at multiple locations simultaneously, thereby increasing production efficiency without significantly increasing device complexity.
4Device complexity
If conventional screens lack perforated base pipe, then screen structure is simplified, but fluid flow path is lengthened
Solution Approach 1:
The base pipe and screen structure are merged into an integrated design where the screen wraps are directly formed on the base pipe with continuous fluid communication. This eliminates the need for separate perforated sections and reduces the overall flow path length while maintaining structural simplicity.
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
This solution enhances even fluid flow and reduces the risk of blockages, optimizing hydrocarbon production by controlling the flow of fluids and inhibiting the passage of solids, thereby improving the efficiency and reliability of hydrocarbon extraction.
Implementation Method 1
each such flow control path includes a tortuous path to control flow of a fluid from the outer surface to the inner surface
Implementation Method 2
a sand screen system that inhibits flow of the solids above a certain size into the production tubular
Data Source
AI summary
A flow control device is disclosed. The device includes a tubular member having a plurality adjacent wraps, wherein each wrap has an outer surface and an inner surface. Some of the wraps include one or more flow control paths, wherein each such flow control path includes a tortuous path to control flow of a fluid from the outer surface to the inner surface.