U.S. patent application number 12/420499 was filed with the patent office on 2010-10-14 for well screen with drainage assembly.
This patent application is currently assigned to HALLIBURTON ENERGY SERVICES, INC.. Invention is credited to Aaron James Bonner, Jean-Marc Lopez.
Application Number | 20100258302 12/420499 |
Document ID | / |
Family ID | 42933424 |
Filed Date | 2010-10-14 |
United States Patent
Application |
20100258302 |
Kind Code |
A1 |
Bonner; Aaron James ; et
al. |
October 14, 2010 |
Well Screen With Drainage Assembly
Abstract
A well screen assembly has an elongate base pipe having
apertures therein. A filtration layer resides around the base pipe.
A drainage assembly resides between the base pipe and the
filtration layer. The drainage assembly includes a plurality of
elongate risers carried on a mesh. The drainage layer supports the
filtration layer apart from the elongate base pipe and defines an
elongate passage between the base pipe and the filtration layer
that communicates fluid laterally through the drainage
assembly.
Inventors: |
Bonner; Aaron James; (Flower
Mound, TX) ; Lopez; Jean-Marc; (Plano, TX) |
Correspondence
Address: |
FISH & RICHARDSON P.C.
P.O. BOX 1022
MINNEAPOLIS
MN
55440-1022
US
|
Assignee: |
HALLIBURTON ENERGY SERVICES,
INC.
Carrollton
TX
|
Family ID: |
42933424 |
Appl. No.: |
12/420499 |
Filed: |
April 8, 2009 |
Current U.S.
Class: |
166/244.1 ;
166/230 |
Current CPC
Class: |
E21B 43/084
20130101 |
Class at
Publication: |
166/244.1 ;
166/230 |
International
Class: |
E21B 43/08 20060101
E21B043/08; E21B 43/00 20060101 E21B043/00 |
Claims
1. A well screen assembly, comprising: an elongate base pipe having
apertures therein; a filtration layer around the base pipe; and a
drainage assembly between the base pipe and the filtration layer,
the drainage assembly comprising a plurality of elongate risers
carried on a mesh, the drainage layer supporting the filtration
layer apart from the elongate base pipe and defining an elongate
passage between the base pipe and the filtration layer that
communicates fluid laterally through the drainage assembly.
2. The well screen assembly of claim 1, wherein the plurality of
risers comprise wires of a second mesh carried by the first
mentioned mesh.
3. The well screen assembly of claim 2, wherein the second mesh is
a non-woven mesh.
4. The well screen assembly of claim 1, wherein the plurality of
risers are not arranged in a mesh.
5. The well screen assembly of claim 1, wherein the risers are
oriented substantially longitudinally with respect to the elongate
base pipe and the elongate passage extends substantially the entire
length of the drainage assembly unobstructed by structures
transversely crossing the passage.
6. The well screen assembly of claim 1, wherein the risers define a
plurality of elongate passages and the of passages are
substantially parallel to one another.
7. The well screen assembly of claim 1, wherein the filtration
layer is a wire mesh and the risers are of a lower gage than the
wires of the filtration layer wire mesh.
8. The well screen assembly of claim 1, wherein the filtration
layer is a wire mesh and a greatest dimension between wires of the
filtration layer wire mesh is smaller than a greatest dimension
between risers of the drainage assembly.
9. The well screen assembly of claim 8, wherein the filtration
layer is a wire mesh and a greatest dimension between wires of the
filtration layer wire mesh is smaller than a greatest dimension
between wires of the drainage assembly mesh.
10. The well screen assembly of claim 1, further comprising an
apertured shroud pipe around the filtration layer.
11. A screen assembly for use in a well, comprising: an elongate
apertured tubing; a first mesh layer carried on the tubing; a
second mesh layer between the first mesh layer and the apertured
tubing; and a third, non-woven mesh layer between the second mesh
layer and the apertured tubing, the third, non-woven mesh layer
formed from a planar non-woven mesh sheet wrapped into a
cylindrical shape, the planar sheet having a first plurality of
wires oriented in generally the same direction and residing in a
first plane and a second plurality of wires affixed to the first
plurality of wires and residing in a second plane.
12. The screen assembly of claim 11, wherein the third, non-woven
mesh layer comprises a square mesh.
13. The screen assembly of claim 11, wherein the first plurality of
wires are oriented substantially longitudinally along the elongate
apertured tubing and define an elongate passage that extends
substantially the entire longitudinal dimension of the third,
non-woven mesh layer unobstructed by structures transversely
crossing the passage.
14. The screen assembly of claim 11, wherein first mesh layer is a
wire mesh and the first plurality of wires of the third, non-woven
mesh are of a lower gage than the wires of the first mesh
layer.
15. The screen assembly of claim 11, wherein the first mesh layer
is a wire mesh and a greatest dimension between wires of the first
mesh layer is smaller than a greatest dimension between the first
plurality of wires of the third, non-woven mesh.
16. The screen assembly of claim 11, wherein the third, non-woven
mesh is affixed to the second mesh.
17. A method of communicating fluids in a well, comprising:
filtering particulate from a fluid with a filtration layer of a
well screen assembly; and communicating the fluid laterally through
the well screen assembly via an elongate passage defined in a
drainage assembly of the well screen assembly, the drainage
assembly residing between the filtration layer and a base pipe of
the well screen assembly and comprising a plurality of elongate
risers carried on a mesh that support the filtration layer apart
from the elongate base pipe and define the elongate passage.
18. The method of claim 17, wherein the plurality of risers
comprise wires of a second, non-woven mesh carried by the first
mentioned mesh.
19. The method of claim 17, wherein the plurality of risers are not
arranged in a mesh.
20. The method of claim 17, wherein the risers are oriented
substantially longitudinally with respect to the elongate base pipe
and the elongate passage extends substantially the entire length of
the drainage assembly unobstructed by structures transversely
crossing the passage.
Description
TECHNICAL FIELD
[0001] This description relates to filtration apparatus for use in
subterranean wellbores.
BACKGROUND
[0002] For centuries, wells have been drilled to extract oil,
natural gas, water, and other fluids from subterranean formations.
In extracting the fluids, a production string is provided in a
wellbore, both reinforcing the structural integrity of the
wellbore, as well as assisting in extraction of fluids from the
well. To allow fluids to flow into production string, apertures are
often provided in the tubing string in the section of the string
corresponding with production zones of the well. Although
perforations allow for ingress of the desired fluids from the
formation, these perforations can also allow unwanted materials to
flow into the well from the surrounding foundations during
production. Debris, such as formation sand and other particulate,
can fall or be swept into the tubing together with formation fluid,
contaminating the recovered fluid. Not only do sand and other
particulates contaminate the recovered fluid, this particulate can
cause many additional problems for the well operator. For example,
as the particulate flows through production equipment, it gradually
erodes the equipment. Unwanted particulate can block flow passages,
accumulate in chambers, and abrade components. Repairing and
replacing production equipment damaged by particulate in-flow can
be exceedingly costly and time-consuming, particularly for downhole
equipment sometimes located several thousand feet below the earth's
surface. Consequently, to guard against particulate from entering
production equipment, while at the same time preserving sufficient
fluid flow pathways, various production filters and filtration
methods have been developed and employed including gravel packs and
well screen assemblies.
[0003] A number of well screen filtration designs have been
employed. A well screen assembly is a screen of one or more layers
installed in the well, capable of filtering against passage of
particulate of a specified size and larger, such as sand, rock
fragments and gravel from surrounding gravel packing. The specific
design of the well screen can take into account the type of
subterranean formation likely to be encountered, as well as the
well-type.
SUMMARY
[0004] An aspect encompasses well screen assembly with an elongate
base pipe having apertures therein. A filtration layer resides
around the base pipe. A drainage assembly resides between the base
pipe and the filtration layer. The drainage assembly includes a
plurality of elongate risers carried on a mesh. The drainage layer
supports the filtration layer apart from the elongate base pipe and
defines an elongate passage between the base pipe and the
filtration layer that communicates fluid laterally through the
drainage assembly.
[0005] An aspect encompasses a screen assembly for use in a well.
The screen assembly includes an elongate apertured tubing and a
first mesh layer carried on the tubing. The screen assembly further
includes a second mesh layer between the first mesh layer and the
apertured tubing and a third, non-woven mesh layer between the
second mesh layer and the apertured tubing. The third, non-woven
mesh layer is formed from a planar non-woven mesh sheet wrapped
into a cylindrical shape. The planar sheet has a first plurality of
wires oriented in generally the same direction and residing in a
first plane and a second plurality of wires affixed to the first
plurality of wires and residing in a second plane.
[0006] An aspect encompasses a method of communicating fluids in a
well. In the method particulate is filtered from a fluid with a
filtration layer of a well screen assembly. The fluid is
communicated laterally through the well screen assembly via an
elongate passage defined in a drainage assembly of the well screen
assembly. The drainage assembly resides between the filtration
layer and a base pipe of the well screen assembly and includes a
plurality of elongate risers carried on a mesh that support the
filtration layer apart from the elongate base pipe and define the
elongate passage.
[0007] One or more of the aspects can include some, none or all of
the following features. The plurality of risers can be wires of a
second mesh carried by the first mentioned mesh. The second mesh
can be a non-woven mesh. The plurality of risers can be risers that
are not arranged in a mesh. The risers can be oriented
substantially longitudinally with respect to the elongate base pipe
and the elongate passage call extend substantially the entire
length of the drainage assembly unobstructed by structures
transversely crossing the passage. The risers can define a
plurality of elongate passages and the of passages can be
substantially parallel to one another. The filtration layer can be
a wire mesh and the risers can be of a lower gage than the wires of
the filtration layer wire mesh. The filtration layer can be a wire
mesh and a greatest dimension between wires of the filtration layer
wire mesh can be smaller than a greatest dimension between risers
of the drainage assembly. The filtration layer can be a wire mesh
and a greatest dimension between wires of the filtration layer wire
mesh can be smaller than a greatest dimension between wires of the
drainage assembly mesh. The well screen assembly can include an
apertured shroud pipe around the filtration layer.
DESCRIPTION OF DRAWINGS
[0008] FIG. 1A is a side cross-sectional view of an example well
system including a plurality of well screen assemblies.
[0009] FIG. 1B is a side cross-sectional view of an example well
screen assembly.
[0010] FIG. 2A is a perspective view of an example drainage
assembly.
[0011] FIG. 2B is an axial cross-sectional view taken intermediate
the ends of an example well screen assembly incorporating the
drainage assembly of FIG. 2A.
[0012] FIG. 2C is a perspective view of an example drainage
assembly incorporating a welded wire mesh.
[0013] FIG. 2D is an axial cross-sectional view taken intermediate
the ends of an example well screen assembly incorporating the
drainage assembly of FIG. 2C.
[0014] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0015] FIG. 1 illustrates an example well system 10 including a
plurality of well screen assemblies 12. The well system 10 is shown
as being a horizontal well, having a wellbore 14 that deviates to
horizontal or substantially horizontal in the subterranean zone of
interest 24. A casing 16 is cemented in the vertical portion of the
wellbore and coupled to a wellhead 18 at the surface 20. The
remainder of the wellbore 14 is completed open hole (i.e., without
casing). A production string 22 extends from wellhead 18, through
the wellbore 14 and into the subterranean zone of interest 24. A
production packer 26 seals the annulus between the production
string 22 and the casing 16. The production string 22 operates in
producing fluids (e.g., oil, gas, and/or other fluids) from the
subterranean zone 24 to the surface 20. The production string 22
includes one or more well screen assemblies 12 (two shown). In some
instances, the annulus between the production string 22 and the
open hole portion of the wellbore 14 may be packed with gravel
and/or sand (hereinafter referred to as gravel packing 26 for
convenience). The well screen assemblies 12 and gravel packing 26
allow communication of fluids between the production string 22 and
subterranean zone 24. The gravel packing 26 provides a first stage
of filtration against passage of particulate and larger fragments
of the formation to the production string 22. The well screen
assemblies provide a second stage of filtration, and are configured
to filter against passage of particulate of a specified size and
larger into the production string 22.
[0016] Although shown in the context of a horizontal well system
10, well screen assemblies 12 can be provided in other well
configurations, including vertical well systems having a vertical
or substantial vertical wellbore, multi-lateral well systems having
multiple wellbores deviating from a common wellbore and/or other
well systems. Also, although described in a production context,
well screen assemblies 12 can be used in other contexts, including
injection, well treatment and/or other applications.
[0017] As shown in FIG. 1A example well screen assembly 12 includes
an apertured base pipe 100 (with square, round, slotted and/or
other shaped apertures 140) that carries well screen layers 105
including a drainage assembly 110. The drainage assembly 110
includes a standoff layer 120 adjacent, and in some instances
bonded to (e.g. welded, brazed and/or adhered) and carried by, a
support layer 115. In some implementations, the standoff layer 120
can be disposed between the support layer 115 and the base pipe 100
(as shown), between the support layer 115 and other layers 105
exterior the drainage assembly 110, or a standoff layer 120 can be
disposed both between the support layer 115 and the base pipe 100
and between the support layer 115 and other Layers 105 surrounding
the drainage assembly 110. The drainage assembly 110 is configured
to facilitate passage of fluids laterally through the well screen
assembly 12, and in certain instances, facilitate passage of fluid
axially along the length of the well screen assembly 12. For
example, standoff layer 120 creates a standoff between the base
pipe 100 and other layers 105, thereby forming elongate passageways
122 through which flow of fluid is communicated. In some
implementations, the passageways 122 can be continuous and
unobstructed for the length (the entire or substantially entire
length) of the drainage assembly 110 or for only a portion of the
length of the drainage assembly 110 (e.g., approximately 3/4, 1/2,
1/4, 1/8, 1/16, 1/32 the length or other portion of the length of
the drainage assembly). Support layer 115 supports other layers 105
exterior to the support layer 115 from collapsing into, and thus
obstructing or partially obstructing, the passageways 122 created
by the standoff layer 110. Communication of fluids through the
standoff layer 120 can facilitate more uniform distribution of flow
to the apertures 140 intermediate the ends of the base pipe 100,
thus improving fluid flow between the interior and exterior of the
well screen assembly 12. Communication of fluids through the
standoff layer 120 can facilitate passage of fluids to the ends of
the well screen assembly 12. For example, communicating fluids to
the ends of the well screen assembly 12 may be desirable in
instances where flow is communicated between the well screen layers
105 and the interior of the base pipe 100 at the ends of the well
screen assembly 12 via a screen valve, inflow control device,
and/or otherwise.
[0018] Well screen layers 105 further include a filtration layer
125 that operates as the primary fine filtering mechanism of the
well screen assembly 12, and is configured to allow flow of fluid
and filter against passage of the smallest particulate filtered by
the well screen assembly 12. The filtration layer 125 can have the
highest mesh per inch count and/or the smallest apertures
therethrough of ally the other well screen layers 105. Although
only one filtration layer 125 is shown, in some instances,
additional filtration layers can be included and/or the filtration
layer can be incorporated into the drainage assembly 110 (such as
support layer 115). If multiple filtration layers 125 are provided,
they can each be configured to filter against passage of the same
size particulate or one or more of the filtration layers 125 can be
configured to filter against passage of different size
particulate.
[0019] Well screen assembly 12 includes an outer shroud 130
surrounding the well screen layers 105 and forming the exterior of
the well screen assembly 12 to protect and preserve the integrity
of the layers beneath. In certain instances, the outer shroud layer
130 is an apertured pipe having square, circular, slotted and/or
other shaped apertures 135 that allow passage fluid through the
outer shroud layer 130. The outer shroud 130 may perform an initial
filtering function, filtering against passage of larger particulate
into the well screen layers 105 beneath.
[0020] Although only a drainage assembly 110 and filtration layer
125 have been discussed above, the well screen assembly 12 can
include additional layers of additional types and/or additional
drainage assemblies 110 and/or filtration layers 125 can be
included beneath the outer shroud 130.
[0021] FIG. 2A illustrates a perspective view of an example
drainage assembly 200 having a standoff layer 210 that resides
within a support layer 225. The standoff layer 210 includes a
plurality of longitudinal (i.e., parallel or substantially parallel
to the longitudinal axis of the drainage assembly, and thus well
screen assembly) oriented, elongate risers 205 bonded to all
interior surface 220 of a support layer 225. The longitudinally
oriented risers 205 form elongate longitudinal passageways 215
therebetween that facilitate passage of fluid longitudinally along
the drainage assembly 200. The longitudinal passageways, as shown,
are continuous for the length (the entire length or substantially
the entire length) of the drainage assembly 200, and wholly
unobstructed by transverse crossing wires or other transverse
structures. Although shown as round wire or rods, risers 205 can
may have cross-sectional profiles exhibiting a variety of different
geometries. For example, risers 205 can have rectangular,
triangular, or other-shaped cross-sections. Also, risers 205 can be
continuous members, or non-continuous members, such as raised
nodules formed into and/or bonded to the surface of the support
layer 225. Although shown as longitudinal passageways 215, the
risers 205 can be arranged to define passageways 215 in other
directions (e.g., circumferential, helical, and/or other).
[0022] In some implementations, see for example FIG. 2C, a welded
mesh (e.g., a square welded mesh, and/or other mesh) can be used in
lieu of or in addition to the plurality of individual risers 205. A
welded mesh is a non-woven mesh that includes a first plurality of
parallel wires 250 oriented in one direction with a second
plurality of parallel wires 255 welded, brazed and/or otherwise
affixed to the first plurality of wires, and oriented in a second
direction. In a square welded mesh, the first and second directions
are substantially perpendicular and the spacing between crossing
wires is substantially equal to define square spaces between the
wires. Typically all of the first plurality of wires 250 reside on
one side of the mesh and all of the second plurality of wires 255
reside on the opposite side of the mesh. Welded mesh is typically
pre-manufactured and commercially available formed in a flat sheet,
and could be rolled into a tubular shape for use as standoff layer
210. For example, when the mesh is flat, the first plurality of
wires 250 reside entirely in one plane and the second plurality of
wires 255 reside entirely in a different plane. In some
implementations, the welded mesh may be positioned in the drainage
assembly 200 with the wires on the inner surface of the standoff
layer 210 oriented longitudinally along the drainage assembly 200
(i.e., defining risers) and wires on the outer surface of the
standoff layer 210, adjacent the support layer 225,
circumferentially around the drainage assembly 200. As such, the
longitudinally oriented wires of the wire mesh define risers 205
and the longitudinal passageways between. The circumferentially
oriented wires, being on the outside of the mesh, do not obstruct
the longitudinal passageways. In some implementations, the gage of
the wires on the inner surface of the standoff layer 210 can be
smaller (i.e., larger diameter) than the gage of the wires on the
outer surface of the standoff Layer 210. In some instances, the
spacing between adjacent wires on the inner surface of wire mesh
standoff layer 210 can be greater than the spacing between adjacent
wires on the outer surface of the wire mesh standoff layer 210.
[0023] Support layer 225 can be a welded and/or woven mesh (e.g., a
square welded mesh, a square woven mesh, and/or other mesh). In
certain instances, the mesh per inch count of the support layer 225
is higher (i.e., able to filter against passage of a smaller
particulate) than the mesh per inch count of the standoff layer
210. In certain instances, the wire gage of the support layer 225
is higher (i.e., smaller diameter) than the wire gage of some or
all of the wires in the standoff layer 210. In certain instances,
the wire gage of warp wires in the standoff layer 210 are larger
than the warp and/or weft layers of the support layer 225. Of note,
the use of the term "mesh" herein is used to exclude wrapped wire
screen, i.e. a screen formed in a cylinder by helically wrapping
wire about a plurality of longitudinal wires arranged in a
generally cylindrical shape.
[0024] FIG. 2B is an axial cross-sectional view taken intermediate
the ends of an example well screen assembly 240 incorporating
drainage assembly 200 carried on a base pipe 230. FIG. 2B also
shows the inclusion of a mesh filtration layer 235 and protective,
outer shroud layer 245 in the well screen assembly 240. As is
shown, risers 205 contact the outer surface of base pipe 230,
supporting and separating the support layer 225 from the base pipe
230. Risers 205 can be bonded (e.g., welded, brazed, adhered and/or
otherwise bonded) to the support layer 225 prior to wrapping the
support layer 225 (and risers 205) around the base pipe. In other
examples, risers 205 can be bonded to, and positioned around the
exterior surface of base pipe 230 prior to the support layer 225
being wrapped around the base pipe 230. The skeleton of risers 205
surrounding the base pipe 230 provide an offset h between the base
pipe 230 and support layer 225. Both the offset h and the width w
between risers 205 is greater than the height or width of any other
passage in the filtration layer 235. Indeed, in other
implementations, the base pipe 230 can be manufactured so as to
form the rib members 205 or other standoff risers, into the
structure of the base pipe 230 itself.
[0025] FIG. 2D is an axial cross-sectional view taken intermediate
the ends of an example well screen assembly 240' incorporating
welded wire mesh drainage assembly 200'. The well screen assembly
240' has a similar construction to well screen assembly 240, except
that the drainage assembly 200' incorporates a welded wire mesh as
standoff layer 210'.
[0026] A number of embodiments of the invention have been
described. Nevertheless, it will be understood that various
modifications may be made without departing from the spirit and
scope of the invention. Accordingly, other embodiments are within
the scope of the following claims.
* * * * *