Spherical Chamber Sand Control Media
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Solution Overview
Problem
Existing sand control screens in hydrocarbon production are prone to clogging, failing to effectively prevent the entry of sand and debris into the production flow.
Innovation Solution
A sand filtering media with a solid matrix of substantially spherical chambers and connecting channels of smaller diameter, created using additive manufacturing technology, such as 3D printing, to form a filtering matrix that traps debris while allowing fluid to pass through, with the channels arranged in a helical pattern within filtering plugs that can be threaded or press-fit into production nipples.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sand control screens are used to prevent sand entry, then sand control is improved, but the screens are prone to clogging
Solution Approach 1:
The filtering media is segmented into a matrix of spherical chambers connected by channels, creating multiple discrete filtering pathways. This segmentation prevents clogging by providing numerous alternative routes for fluid flow, so if one chamber or channel becomes blocked, fluid can still pass through other pathways.
Solution Approach 2:
The filtering media features varying local qualities with chambers having larger diameters and connecting channels having smaller diameters. This local variation optimizes filtering at different locations - larger chambers provide bulk filtering capacity while smaller channels provide fine filtering, creating a multi-scale filtering system that resists clogging more effectively than uniform structures.
2Strength
If bonding material is used to create filtering media, then structural integrity is improved, but the design becomes more prone to clogging
Solution Approach 1:
The invention extracts and eliminates the bonding material component from traditional bead filtering media. By removing the binder entirely and using a sintered metal matrix structure, the design achieves structural integrity through the sintered framework itself rather than through bonding agents, thereby avoiding the clogging issues associated with bonded bead designs.
Solution Approach 2:
The filtering media utilizes a composite structure combining spherical chambers and connecting channels within a sintered metal matrix. This composite architecture provides both structural integrity and filtering functionality without requiring separate bonding materials, as the sintered metal framework inherently provides mechanical strength while the chamber-channel structure provides filtering capability.
3Ease of manufacture
If additive manufacturing is used to create filtering media, then manufacturing complexity is reduced, but the structure becomes more intricate
Solution Approach 1:
Additive manufacturing enables precise control of geometric parameters such as chamber diameter, channel diameter, and channel length. By varying these parameters during the printing process, complex filtering structures with optimized flow paths can be created in a single manufacturing step, achieving intricate designs that would be impossible with traditional manufacturing methods.
Solution Approach 2:
The additive manufacturing process creates three-dimensional fluid pathways within the filtering media, transitioning from traditional two-dimensional screen surfaces to volumetric filtering structures. This dimensional change allows fluid to travel through chambers and channels in multiple directions, creating intricate filtering paths that maximize surface area and filtering efficiency within a compact volume.
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 removes sand and debris from hydrocarbon fluids, reducing clogging issues and ensuring efficient production flow by utilizing a robust and corrosion-resistant stainless steel matrix with intricate fluid pathways that trap debris, enhancing the reliability of sand control in hydrocarbon production.
Implementation Method 1
a 3D printing device is used to create a filtering medium by depositing sequential layers of solid material which will form a filtering matrix
Implementation Method 2
Passage of fluid through sequential chambers and channels causes solid matter to be removed
Data Source
AI summary
A filtering medium for removal of solids from a fluid. A solid filtering matrix contains fluid passages that are made up of a plurality of chambers with connecting channels. The chambers have a greater diameter than the connecting channels.