Tubular Screen Insert for Fracturing Fluid Debris Control
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Solution Overview
Problem
Debris in fracturing fluids can interfere with downhole equipment during wellbore fracturing operations, causing mechanical issues and potential blockages, as existing systems fail to effectively screen out debris from the fluid stream before it reaches the wellbore.
Innovation Solution
The implementation of tubular screen inserts with a plurality of openings in fracturing headers and equalization headers to filter out debris from the fracturing fluid before it reaches the wellbore, ensuring that only clean fluid is delivered, with the screen inserts being oriented to either block debris or capture it for later removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If no screen insert is installed in the fracturing fluid supply system, then the system complexity is reduced and fluid flow is unobstructed, but debris enters the wellbore and compromises downhole equipment reliability
Solution Approach 1:
The screen insert is nested within the existing fracturing header structure, fitting inside the fluid supply conduit without requiring external support structures. The insert integrates the screening function within the existing system geometry, adding minimal complexity while effectively preventing debris from reaching downhole equipment
Solution Approach 2:
The screen insert acts as an intermediary component between the fluid supply system and downhole equipment. It intercepts and removes debris from the fluid stream before the fluid reaches sensitive downhole tools, thereby protecting equipment reliability without requiring fundamental changes to the overall system architecture
2Reliability
If a screen insert with small openings is installed to effectively filter debris, then debris removal efficiency is improved, but the screen insert becomes prone to blockage and requires more frequent maintenance
Solution Approach 1:
The screen insert is designed with multiple segmented openings distributed across its surface rather than a single large opening. This segmentation provides numerous flow paths for the fluid, reducing the likelihood that any single opening will become blocked by debris. Even if some openings are obstructed, fluid can still pass through alternative paths, maintaining system operation
Solution Approach 2:
The screen insert incorporates a removable and replaceable design that allows for dynamic maintenance. When debris accumulation or blockage occurs, the insert can be quickly removed from the fracturing header and replaced, minimizing downtime. The modular design enables rapid maintenance without requiring complex disassembly of the entire fracturing system
3Object-affected harmful factors
If the screen insert is oriented with closed endwall upstream to shed debris, then debris deflection is improved, but the insert cannot store debris for later removal
Solution Approach 1:
The screen insert can be installed in reverse orientation depending on operational needs. When debris storage is required, the insert is installed with the closed endwall downstream, allowing debris to accumulate in the enclosed chamber. When debris deflection is prioritized, the insert is installed with the closed endwall upstream to shed debris. This reversible installation capability provides operational flexibility to address different priorities
4Reliability
If multiple screen inserts are installed in series to enhance filtering, then debris removal effectiveness is improved, but the system complexity and pressure drop increase
Solution Approach 1:
Rather than installing multiple screen inserts throughout the system, the invention concentrates the screening function at a single critical location - the fracturing header where fluid enters the wellbore. This localized approach provides sufficient debris removal effectiveness while minimizing the cumulative pressure drop that would result from multiple screening stages distributed throughout the fluid path
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 effectively prevents debris from compromising downhole tools and equipment, maintaining their performance and preventing blockages, while also reducing the erosive impact on coil tubing and other components, thereby ensuring efficient fracturing operations.
Implementation Method 1
A plurality of openings about the tubular wall provide fluid communication between the bore and an annular area outside the wall
Data Source
AI summary
Fracturing headers and connected conduits are fit with one or more fluid screening and wear minimizing inserts. Tubular screen inserts are provided to screen a flow of fracturing fluid through manifolds prior to, or at, the fracturing header. Each tubular screen insert has a tubular wall having an insert bore, an endwall and an open inlet. A plurality of openings, about the tubular wall, provide fluid communication between the bore and an annular area outside the wall. Oriented in a flow conduit with the closed endwall upstream, the insert excludes and sheds debris therefrom. Oriented with the closed endwall downstream, the insert receives and stores debris. Pairs of inserts, retained in opposing inlet ports, serve to screen fluid and deflect erosive flow from tools such as coil tubing extending therethrough. A fracturing block fit with opposing inlet ports can also be fit with an outlet port for flowback operations.