Spiral-Wound Well Screen Filter Media Assembly

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Solution Overview

Problem

Existing well screens in the petrochemical industry face issues with seam welding damaging the filter media, leading to potential inflow of detritus, increased costs due to downtime and potential catastrophic collapse, especially under high hydraulic pressures and unstable well conditions.

Innovation Solution

The method involves spiral winding of layers around a base pipe, including an inner drainage layer, a filter layer, and an outer drainage layer, eliminating the need for seam welding and allowing for inspection and reduced gaps, which strengthens the well screen and prevents misalignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If seam welding is used to join filter media sheets, then the filter media can be assembled into a well screen, but the filter media is damaged creating areas of weakness and potential failure

Engineering Contradiction:

Improveassembly of filter mediaVSAvoidfilter media integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention extracts and eliminates the harmful seam welding process from the filter media assembly. Instead of joining sheets through welding, the filter media is applied as a continuous sheet that wraps around the base pipe without seam welding, thereby removing the source of damage and weakness while still achieving the assembly function.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Rather than joining multiple sheets through welding, the invention inverts the approach by using a single continuous sheet of filter media that wraps around the base pipe. This reverses the conventional assembly method and avoids the harmful effects of seam welding entirely.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If the filter media is damaged, then localized failure occurs, but the entire intake of fluid may be contaminated requiring full extraction and repair

Engineering Contradiction:

Improvefilter media performanceVSAvoiddowntime for extraction and repair

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The invention applies a protective outer shroud around the filter media before it is installed in the well. This shroud acts as a cushioning protective layer that prevents damage to the filter media during installation and operation, thereby preventing localized failures that would require time-consuming extraction and repair.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The invention extracts the filter media from its vulnerable encapsulated position within the shroud during installation, allowing for visual inspection and ensuring it is properly positioned and undamaged before the shroud is installed, thereby preventing future failures.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If the filter media is encapsulated within an external shroud, then protection is provided, but non destructive testing is required to detect damaged portions

Engineering Contradiction:

Improvefilter media protectionVSAvoiddamage detection

Core Design Contradiction:

ReliabilityVSDifficulty of detecting and measuring

Solution Approach 1:

The invention performs preliminary visual inspection of the filter media before it is encapsulated within the shroud during the installation process. This preliminary action allows for detection of any damage or misalignment before the protective shroud is installed, making inspection easier and eliminating the need for complex non-destructive testing later.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The installation process serves as an intermediary stage where the filter media is temporarily exposed for inspection before final encapsulation. This intermediary step allows for quality control and damage detection without requiring the shroud to be removed or complex testing equipment.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of manufacture

If a single sheet of filter media is used, then assembly is simplified, but misalignment and gaps may occur allowing detritus inflow

Engineering Contradiction:

Improvefilter media applicationVSAvoidfilter layer alignment

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention uses the natural elasticity and flexibility of the filter media sheet to allow it to self-adjust and conform to the base pipe surface as it wraps around. This self-service mechanism ensures proper alignment and eliminates gaps without requiring complex alignment procedures or multiple joined sheets.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The invention changes the physical parameters of the filter media by selecting materials with appropriate elasticity and flexibility characteristics. These parameter changes allow the single sheet to maintain consistent contact with the base pipe surface, ensuring proper alignment and preventing gaps while simplifying the assembly process.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10577896B2Well screen and method of manufacture

Publication Date: 2020.03.03 COMPLETION PROD

AI summary

A method of construction of a well screen comprising the steps of providing a base pipe: spiral winding an inner drainage layer around the base pipe; spiral winding a filter layer around the inner drainage layer, then; spiral winding an outer drainage layer around the filter layer. Also disclosed is a well screen, comprising: a base pipe; a spiral-wound inner drainage layer disposed around the base pipe; a spiral-wound filter layer disposed around the inner drainage layer; and a spiral-wound outer drainage layer disposed around the filter layer.