U.S. patent application number 15/113675 was filed with the patent office on 2017-07-27 for improvements in and relating to screens.
The applicant listed for this patent is WEATHERFORD U.K. LIMITED. Invention is credited to Matthew Manning, Andrew McGeoch, Daniel George Purkis, Stephen Reid.
Application Number | 20170211361 15/113675 |
Document ID | / |
Family ID | 50239304 |
Filed Date | 2017-07-27 |
United States Patent
Application |
20170211361 |
Kind Code |
A1 |
Reid; Stephen ; et
al. |
July 27, 2017 |
IMPROVEMENTS IN AND RELATING TO SCREENS
Abstract
A screen assembly, such as a downhole/sand screen assembly,
comprising first and second screen portions or screens
longitudinally coupled together, wherein there is provided a fluid
flow path between the first and second screen portions or screen.
Optionally, the first and second sleeves are coupled or connected
by a centraliser or further sleeve or screen, and/or optionally by
or via first and second support ring.
Inventors: |
Reid; Stephen;
(Loughborough, Leicestershire, GB) ; McGeoch; Andrew;
(Loughborough, Leicestershire, GB) ; Manning;
Matthew; (Loughborough, Leicestershire, GB) ; Purkis;
Daniel George; (Loughborough, Leicestershire, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
WEATHERFORD U.K. LIMITED |
|
|
|
|
|
Family ID: |
50239304 |
Appl. No.: |
15/113675 |
Filed: |
January 21, 2015 |
PCT Filed: |
January 21, 2015 |
PCT NO: |
PCT/GB2015/050133 |
371 Date: |
March 15, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 43/088 20130101;
E21B 17/1078 20130101; E21B 43/08 20130101; E21B 43/086 20130101;
E21B 43/162 20130101; E21B 34/06 20130101; E21B 43/084 20130101;
E21B 43/082 20130101; E21B 43/045 20130101; E21B 2200/06
20200501 |
International
Class: |
E21B 43/08 20060101
E21B043/08; E21B 34/06 20060101 E21B034/06; E21B 17/10 20060101
E21B017/10 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 22, 2014 |
GB |
1401066.4 |
Claims
1. The assembly of claim 150, wherein the at least one flow control
element comprises first and second screen portions or screens
longitudinally coupled together, wherein there is provided a fluid
flow path between the first and second screen portions or
screens.
2-3. (canceled)
4. The assembly of claim 1, wherein the at least one tubular
comprises a first pipe for the first screen and comprises a second
pipe for the second screen, wherein the first and second pipes are
coupled by a threaded coupling.
5. The assembly of claim 1, wherein the first and second screens
are coupled or connected by at least one of a centralizer, a
further sleeve or screen, and first and second support rings.
6. The assembly of claim 1, wherein the fluid flow path is
annular.
7. The assembly of claim 1, wherein a centralizer or a further
sleeve or screen forms a portion of the fluid flow path; and/or
wherein the first and second screen portions or screens and/or the
further sleeve or screen extend circumferentially around the at
least one tubular.
8. The assembly of claim 150, wherein the at least one flow control
element comprises first and second screens longitudinally disposed
relative to one another, wherein a further screen or screen portion
is provided between adjacent ends of the first and second
screens.
9-10. (canceled)
11. The assembly of claim 150, wherein the at least one tubular
comprises a pipe, wherein the at least one flow control element
comprises a sleeve, and wherein the assembly comprises at least one
support provided between the pipe and the sleeve, wherein the at
least one support has a cross-section comprising first and second
points, vertices, surface discontinuities and/or corners.
12-23. (canceled)
24. The assembly of claim 150, wherein the at least one flow
control element comprises a screen, and wherein the screen
comprises wire having a cross-section comprising first and second
points, vertices, surface discontinuities and/or corners.
25-37. (canceled)
38. The assembly of claim 150, wherein the at least one flow
control element comprises a screen, and wherein the screen
comprises wire having a cross-section comprising a rectilinear
shape or parallelogram.
39-42. (canceled)
43. The assembly of claim 150, wherein the at least one flow
control element comprises coated and/or hardened wire.
44-49. (canceled)
50. The assembly of claim 150, wherein the at least one tubular
comprises a pipe, and wherein the at least one flow control element
comprises a plurality of ceramic discs around the pipe.
51-66. (canceled)
67. The assembly of claim 150, wherein the at least one tubular
comprises a pipe and/or tubular, and wherein the at least one flow
control element comprises a plurality of slotted ports or
longitudinally extending ports on the pipe and/or tubular.
68-70. (canceled)
71. The assembly of claim 150, wherein the at least one tubular
comprises a pipe, wherein the pipe comprises a solid or
non-perforated pipe.
72. (canceled)
73. The assembly of claim 2, wherein the pipe comprises a base pipe
or production tubing.
74. The assembly of claim 150, wherein the at least one flow
control element is an erosion resistant microporous sleeve.
75. The assembly of claim 74, wherein the microporous sleeve
comprises a material selected from a metal foam or a ceramic
foam.
76. The assembly of claim 75, wherein the microporous sleeve
comprises a material selected from the group consisting of
microporous polymeric foams, microporous metal foams, microporous
carbide monoliths, silicon carbide, tungsten carbide, or titanium
carbide monoliths or microporous nitride monoliths, such as boron
nitride.
77. The assembly of claim 74, wherein the microporous sleeve
intimately contacts and/or is bonded to an outer surface of the at
least one tubular.
78. The assembly of claim 150, wherein that at least one tubular
comprises a pipe, wherein the at least one flow control element
comprises a sleeve, wherein the pipe comprises openings or ports,
and wherein the sleeve comprises a foam or microporous material,
the sleeve being bonded with or to an exterior surface of the
pipe.
79. (canceled)
80. The assembly of claim 150, wherein the at least one tubular
comprises a pipe having at least one port or perforation or hole,
wherein the at least one flow control element comprises an
associated valve of each port or perforation or hole.
81-92. (canceled)
93. The assembly of claim 150, wherein the at least one tubular
comprises a pipe having at least one port or perforation or hole,
and wherein the at least one flow control element comprises at
least one sleeve provided within the pipe, the at least one sleeve
having at least one respective port or perforation or hole which in
a closed position is not aligned or is misaligned with the at least
one port or perforation or hole in the pipe but which in an open
position is alignable or aligned with the at least one port or
perforation or hole in the pipe.
94-99. (canceled)
100. The assembly of claim 150, wherein the at least one tubular
comprises a pipe, wherein the at least one flow control element
comprises a plurality of sleeves, and wherein the sleeves are
provided within the pipe.
101-106. (canceled)
107. The assembly of claim 150, wherein the at least one tubular
comprises a pipe comprising at least one port/perforation/hole, and
wherein the at least one flow control element comprises a
respective seal or plug of or each port.
108-120. (canceled)
121. The assembly of claim 150, wherein the at least one tubular
comprising comprises a pipe, wherein the at least one flow control
element comprises a sleeve, wherein the pipe comprises a port(s),
and wherein the sleeve comprises a solid or wall portion(s) or
baffles at or near the port(s).
122-124. (canceled)
125. The assembly of claim 150, wherein the at least one flow
control element comprises first and second screens longitudinally
disposed relative to one another, wherein a centralizer is provided
between adjacent ends of the first and second screens.
126-127. (canceled)
128. The assembly of claim 150, wherein the at least one tubular
comprises a pipe, and wherein the at least one flow control element
comprises a plurality of ceramic discs stacked on each other,
wherein at least one spacer is provided between two adjacent discs,
wherein each at least one spacer is aligned with a respective hole
or slot or perforation in the pipe.
129. The assembly of claim 150, wherein the at least one tubular
comprises a pipe, and wherein the at least one flow control element
comprises a plurality of ceramic discs stacked on each other,
wherein at least one spacer is provided between at least two
adjacent discs, wherein each spacer is shaped to diffuse fluid flow
exiting a hole or slot or perforation in the pipe.
130-143. (canceled)
144. The assembly of claim 150, wherein the at least one tubular
comprises a plurality of pipes, wherein the at least one flow
control element comprises a plurality of screens, wherein each
screen comprises a shifting sleeve, wherein the assembly is
arranged such that the shifting sleeves are capable of being opened
(and/or closed) sequentially.
145. (canceled)
146. The assembly of claim 150, wherein the at least one tubular
comprises a pipe having a port, and wherein the at least one flow
control element comprises an inner sleeve and a pin within the
port.
147. (canceled)
148. The assembly of claim 1, having enhanced erosion resistance
claim 1.
149. (canceled)
150. An assembly for a downhole/sand screen or screen assembly, the
assembly comprising: at least one tubular; and at least one flow
control element disposed relative to the at least one tubular.
Description
FIELD OF INVENTION
[0001] The present invention relates to downhole tools. The present
invention relates to screens, such as downhole screens, such as
sand screens.
[0002] Screens are used in tubular systems to separate particulate
from fluids. Such systems are used in the downhole completion field
to separate sand and other particulate from fluids, e.g. production
fluids or hydrocarbons, such as oil, water and gas.
BACKGROUND TO INVENTION
[0003] As outlined in WO2004/099560 (BP EXPLORATION), in the course
of completing an oil and/or gas well, it is common practice to run
a string of casing into the well-bore and then to run the
production tubing inside the casing. The casing is perforated
across one or more hydrocarbon bearing zones (hereinafter
`producing zones`) to allow produced fluids to enter the casing
bore. After the well is completed and placed in production,
formation sand from unconsolidated formations may be swept into the
flow path along with produced fluids. This sand is relatively fine
and causes erosion of tubing, downhole equipment and surface
equipment. In some completions, however, the well bore is uncased,
and an open face is established across the producing zone, in
particular, in horizontal well completions. Similarly, after the
well is completed and placed in production, formation sand from
unconsolidated formation may be swept into the flow path along with
produced fluids.
[0004] With either cased or uncased well-bores, one or more sand
screens may be installed in the flow path between the production
tubing and the producing zone(s). A packer may be set above and
below the sand screen to seal off the annulus in the producing zone
from non-producing zones of the formation. The annulus around the
screen may be packed with a relatively coarse sand or gravel which
acts as a filter to reduce the amount of fine formation sand
reaching the screen. Nevertheless, the remaining sand contained in
the produced fluids may impinge on a screen with sufficient
velocity so as to cause erosion of the screen. As the velocity of
the flow of the produced fluids is increased, the rate of erosion
also increases. Where the fluid flow rate from one portion of the
formation is greater than the fluid flow rate from another portion
of the formation, the screen will erode more rapidly opposite the
high flow rate portion than it will opposite the lower flow rate
portion.
[0005] WO2004/099560 (BP EXPLORATION) discloses a sand screen
comprising a perforated base pipe and an erosion resistant
microporous sleeve. The erosion resistant microporous material of
the sleeve is selected from the group consisting of microporous
polymeric foams, microporous metal foams, microporous carbide
monoliths, and microporous nitride monoliths.
[0006] WO2011/130122 (BAKER HUGHES) discloses a screen device
including a foam body having a passageway that extends
longitudinally through the foam body, the foam body having an open
cell structure such that at least two surfaces of the foam body are
in fluidic communication with one another through the foam
body.
[0007] In well completions having screened pipe, the screened pipe
typically comprises base pipe (or inner pipe) overlaid by a screen
(or outer jacket). The base pipe can be solid or slotted. The outer
screen has hole or port dimensions selected to filter out particles
above a desired size during production. The screen can be attached
to the base pipe by axial support rods welded to an outer surface
of the base pipe, which rods are then overlaid circumferentially by
wire with a triangular cross-section. The points of the triangular
wire are welded to the axial support rods. Between the rods, at
least partly annular spaces are created between the circumferential
wire wrap screen and the base pipe.
[0008] There has been identified a need for the base pipe to be
isolated from the through-bore initially so that some other
operations can be performed. Therefore, if the base pipe is solid,
the openings that provide through-bore communication need to be
initially closed. If the base pipe is perforated/slotted, the
perforations need initially to be sealed. Prior to production,
there may be a wish to stimulate the well by injecting fluids into
the hydrocarbon (HC) formation in a reverse direction to
production. Since injection involves pumping of high pressure/flow
rate fluids through the screen in a reverse direction, the screen
must be able to withstand erosion in both directions (covering
injection followed by production). In addition there may be a wish
to distribute injected fluids in a uniform manner across the
hydrocarbon formation (if possible) to seek to ensure all portions
of the formation are equally stimulated.
[0009] There may be a desire that the annulus between the screen
and the base pipe of all adjacent sand screen joints can be or is
inter-connected.
[0010] It is an object of at least one general solution or aspect
of the present invention to obviate or at least mitigate one or
more problems and/or disadvantages in the prior art.
SUMMARY OF INVENTION
[0011] According to a first aspect of the present invention there
is provided a screen or screen assembly, such as a downhole/sand
screen or screen assembly, comprising a pipe and a sleeve and at
least one support provided between the pipe and the sleeve, wherein
the at least one support has a cross-section comprising first and
second points, vertices, surface discontinuities and/or corners.
Such support shape may provide enhanced erosion resistance. The
pipe may be referred to as a base pipe or production tubing. The
pipe may be perforated and/or comprise a plurality of ports.
Alternatively the pipe may be solid, e.g. comprise a solid tubular
wall or tubular wall section(s). The first and second points,
vertices, surface discontinuities and/or corners (hereinafter
`points`) may comprise a pair of points. The first and second
points may face in substantially opposing directions, e.g. along a
radial direction, e.g. of the pipe and/or the sleeve. The at least
one support may comprise a plurality of supports, e.g. axial
supports and/or support rods. The supports may be disposed in an
annular space between the pipe and the sleeve. The sleeve may be
provided around the pipe.
[0012] In one implementation the/each support may have a
cross-section comprising a polygon having at least four sides
and/or which is a parallelogram, rectilinear, or beneficially
square or diamond shape.
[0013] In another implementation the/each support may have a
cross-section comprising a polygon having six sides, e.g. a polygon
having opposing triangular end portions and a rectilinear or square
mid-portion. A first point may be welded to the pipe, e.g. an outer
surface of the pipe. A second point may be welded to the sleeve,
e.g. an inner surface(s) of the sleeve. The support(s) may be made
from steel.
[0014] According to a second aspect of the present invention there
is provided a screen or screen assembly, such as a downhole/sand
screen or screen assembly, wherein the screen comprises wire having
a cross-section comprising first and second points, vertices,
surface discontinuities and/or corners. Such wire shape may provide
enhanced erosion resistance. The first and second points, vertices,
surface discontinuities and/or corners (hereinafter `points`) may
comprise a pair of points. The first and second points may face in
substantially opposing directions, e.g. along a radial direction,
e.g. of a pipe and/or a sleeve. The screen may comprise a pipe and
a sleeve (the sleeve comprising the wire/screen), and at least one
support. The pipe may be referred to as a base pipe or production
tubing. The at least one support may comprise a plurality of
supports, e.g. axial supports and/or support rods. The pipe may be
perforated and/or comprise a plurality of ports. Alternatively the
pipe may be solid, e.g. comprise a solid tubular wall or tubular
wall section(s). The supports may be disposed in an annular space
between the pipe and the sleeve. The sleeve may be provided around
the pipe.
[0015] In one implementation the/each wire may have a cross-section
comprising a polygon having at least four sides and/or which is
rectilinear or beneficially square or diamond shape.
[0016] In another implementation the/each wire may have a
cross-section comprising a polygon having six sides, e.g. a polygon
having opposing triangular end portions and a rectilinear or square
mid-portion. A first point may be welded to a support or to the
pipe, e.g. to an outer surface of the support or pipe. A second
point may face radially out, e.g. towards a formation or inner
facing surface of a borehole. The wire may be made from steel.
[0017] According to a third aspect of the present invention there
is provided a screen or screen assembly, such as a downhole/sand
screen or screen assembly, wherein the screen comprises wire having
a cross-section comprising a rectilinear shape or parallelogram.
Such wire shape may provide enhanced erosion resistance. The
rectilinear shape or parallelogram may comprise a rectangle or in a
preferred implementation may comprise a square or diamond shape.
The wire may be disposed such that a line of symmetry of the
rectilinear shape is provided along a radial direction of the
screen. The screen may comprise a pipe and a sleeve (the sleeve
beneficially comprising the wire/screen), and at least one support.
A side of the wire may be welded to the supports(s).
[0018] According to a fourth aspect of the present invention there
is provided a screen or screen assembly, such as a downhole/sand
screen or screen assembly, comprising coated and/or hardened wire.
The wire may be made from steel. In one implementation the coating
may be tungsten carbide, e.g. hardide tungsten carbide. The coating
may be applied or deposited by chemical vapour deposition
(CVD)--which may be applied to steel. The wire may be heat treated
so as to harden. The screen may comprise a pipe and a sleeve, the
sleeve comprising the wire, and optionally at least one support.
The wire may be provided in coated and/or hardened lengths and
made-up or assembled in longer lengths so as to provide the
sleeve.
[0019] Accordingly to a fifth aspect of the present invention there
is provided a screen or screen assembly, such as a downhole or sand
screen or screen assembly, comprising a pipe and a plurality of
ceramic discs around the pipe. Such may provide enhanced erosion
resistance. The ceramic discs may be stacked on each other. The
pipe may be referred to as a base pipe or production tubing. The
pipe may be perforated and/or comprise a plurality of ports. The
pipe may be slotted. Alternatively the pipe may be solid. The pipe
may comprise a plurality of ports, e.g. slots, e.g.
circumferentially and/or axially spaced thereupon. One or more of
the discs may be arranged so as to provide circumferential/annular
spaces between the pipe and the respective disc.
[0020] Between adjacent circumferential/annular spaces the disc(s)
may be arranged such that there is no gap (e.g. radial gap) between
the pipe and the disc. Such arrangement may be provided by portions
of the disc having reduced internal diameter, e.g. such that the
pipe and the disc(s) radially abut or contact one another at said
portions. The space(s) may extend longitudinally between adjacent
discs. The space(s) may be aligned, e.g. rotationally aligned, with
at least one port in the pipe. A valve member may be provided
between a port and a respective space. The/each valve member may
comprise a slidable member, e.g. a longitudinally slidable member.
Each valve member may comprise at least one further port and/or at
least one reed valve which may be (longitudinally) selectively
alignable with or out of alignment with a port of the pipe. The
screen or screen assembly may also comprise an inner sleeve. The
inner sleeve may be slidable relative to the pipe. An outer surface
of the inner sleeve may abut or contact an inner surface of the
pipe. The inner sleeve may comprise at least one yet further port
or further reed valve which may be (longitudinally) selectively
alignable with or out of alignment with a port of the pipe.
[0021] Accordingly to a sixth aspect of the present invention there
is provided a screen or screen assembly, such as a downhole/sand
screen or screen assembly, comprising a pipe and/or tubular and a
sleeve, wherein the pipe and/or tubular comprises a plurality of
slotted ports or longitudinally extending ports. Such arrangement
may provide enhanced erosion resistance. The sleeve may comprise a
microporous sleeve. The pipe may comprise a base pipe or production
tubing. The tubular may comprise a further sleeve, e.g. inner
sleeve, e.g. sliding sleeve.
[0022] According to a seventh aspect of the present invention there
is provided a screen or screen assembly, such as a downhole screen
or screen assembly, comprising a pipe or sleeve, wherein the pipe
comprises a solid or non-perforated pipe. Such arrangement may
provide enhanced erosion resistance. The solid or non-perforated
pipe may comprise an opening(s) or port(s) at or adjacent an end(s)
thereof, e.g. to deliver injection fluid to a formation.
[0023] The following optional features apply to any foregoing
aspect such as the sixth and seventh aspects. The pipe may be
referred to as a base pipe or production tubing. The microporous
sleeve may be an erosion resistant microporous sleeve. The
microporous sleeve may comprise a material selected from a metal
foam or a ceramic foam. The microporous sleeve may comprise a
material selected from the group consisting of microporous
polymeric foams, microporous metal foams, microporous carbide
monoliths, in particular, silicon carbide, tungsten carbide, or
titanium carbide monoliths or microporous nitride monoliths, such
as boron nitride. The microporous sleeve may intimately contact
and/or be bonded to an outer surface of the pipe.
[0024] According to an eighth aspect of the present invention there
is provided a screen or screen assembly, such as a downhole/sand
screen or screen assembly, comprising a pipe and a sleeve, wherein
the pipe comprises openings or ports (such as longitudinal or axial
opening(s) or slot(s)) and the sleeve comprises a foam or
microporous material, the sleeve being bonded with or to an
exterior surface of the pipe.
[0025] Such arrangement may provide enhanced erosion resistance.
Such arrangement may provide relatively even distribution of
injection fluids. The pipe may be referred to as a base pipe. The
openings or slots may comprise or be referred to as daisy passages.
The opening or slots may, in use, fluidically communicate with the
sleeve.
[0026] Accordingly to the ninth aspect of the present invention
there is provided a screen or screen assembly, such as a
downhole/sand screen or screen assembly, comprising a pipe having
at least one port or perforation or hole, the/each port or
perforation or hole having an associated valve. The pipe may be
referred to as a base pipe. The/each valve may be a check valve.
The pipe may comprise a plurality of ports or perforations or holes
(hereinafter "port"), each port having an associated valve.
The/each valve may, in use, initially be provided to isolate the
inner diameter of the pipe from the outer diameter of the pipe.
Upon opening the valve(s) the provision of multiple ports in the
pipe may provide improved distribution of injection fluid. The/each
valve may comprise a valve member. The/each valve member may be
deployable by or comprise a sliding sleeve and/or be deployable by
pressure of fluid flow, in use. The sliding sleeve may slide
relative to an inner surface of the pipe. The sliding sleeve may
comprise a port(s) which may be controllably aligned with ports of
the pipe. The valve member(s) may be biased into a closed position,
e.g. by biasing means.
[0027] In one implementation the valve member(s) may comprise a
spherical member(s), e.g. biased spherical member(s). The/each
spherical member may be provided, e.g. movably provided, within a
space provided by a port in the pipe and a recessed portion in a
sleeve. In yet another implementation the valve member(s) may
comprise a flap, e.g. thin metallic or steel flap or reed valve. In
still yet another implementation the valve member(s) may comprise
one or more sliding sleeve(s).
[0028] According to a tenth aspect of the present invention there
is provided a screen or screen assembly, such as a downhole/sand
screen or screen assembly, comprising a pipe having at least one
port or perforation or hole, and at least one sleeve provided
within the pipe, the screen having at least one respective port or
perforation or hole which in a closed position is not aligned or is
misaligned with the at least one port or perforation or hole in the
pipe but which in an open position is alignable or aligned with the
at least one port or perforation or hole in the pipe.
[0029] The pipe may be referred to as a base pipe or production
tubing. The/each sleeve (internal sleeve) may comprise a shift
sleeve. The/each sleeve may beneficially be provided internal of or
within the pipe. The/each sleeve may be slidable relative to the
pipe so as to move from a closed to open position and optionally
vice versa. The pipe may comprise a plurality of ports or
perforations or holes. The/each sleeve (internal sleeve) may
comprise a plurality of respective ports or perforations or holes.
The presence of multiple ports/perforations/holes may allow for
improved distribution of injection fluid. The screen may comprise
an (outer) sleeve or screen sleeve, e.g. comprising wire.
[0030] According to an eleventh aspect of the present invention
there is provided a screen or screen assembly, such as a
downhole/sand screen or screen assembly, comprising a pipe and a
plurality of sleeves. The pipe may be referred to as a base pipe.
The sleeves (inner sleeves) may be provided within the pipe. The
sleeves may each comprise a sliding/shift sleeve. The sleeves may
be tubular. There may be provided first and second sleeves, e.g.
one provided within the other. Movement, e.g. sequential movement,
of the sleeves may cause alignment or misalignment, of ports in the
pipe and the sleeve(s), e.g. opening or closing, of the screen.
Sliding movement of a first sleeve may cause sliding movement of a
second sleeve, e.g. to open the screen. Sliding movement of a
second sleeve may cause sliding movement of a first sleeve, e.g. to
close the screen.
[0031] According to a twelfth aspect of the present invention there
is provided a screen or screen assembly, such as a downhole/sand
screen or screen assembly, comprising a pipe comprising at least
one port/perforation/hole, the or each port having a respective
seal or plug. The pipe may be referred to as a base pipe. The pipe
may comprise a plurality of ports. In a closed disposition the
respective seal or plug may be received or be provided within or
adjacent to the respective port. In an open disposition the
respective seal or plug may be provided distal the respective port.
A transition from a closed disposition to an open disposition may
be achieved at or above a predetermined threshold flow rate of
fluid acting on the plug. The seal(s) or plug(s) may be carried by
a sleeve, e.g. on an outer surface of a shifting/sliding sleeve
provided within the pipe.
[0032] According to a thirteenth aspect of the present invention
there is provided a screen assembly, such as a downhole/sand screen
assembly, comprising at least a first screen according to any
preceding aspect of the present invention and a second screen. The
first screen and second screen may be longitudinally disposed
relative to one another. The first screen may be selected to be
provided in high(er) flow areas, e.g. production and/or injection
fluid flow areas. The first screen may have a higher erosion
resistance than the second screen. The first screen may comprise or
include a microporous material, e.g. ceramic material, for example,
a foamed ceramic or metal, or ceramic discs. The second screen may
be selected to be provided in low(er) flow areas, e.g. production
and/or injection fluid flow areas. The second screen may comprise
wire having a cross-section comprising a triangular shape.
Alternatively the second screen may comprise wire having a
cross-section comprising a square shape.
[0033] According to a fourteenth aspect of the present invention
there is provided a screen or screen assembly, such as a
downhole/sand screen or screen assembly, comprising a pipe and a
sleeve, wherein the screen or pipe comprises a port(s) and the
sleeve comprises a solid or wall portion(s) or baffles at or near
the port(s). The solid or wall portions or baffles may be provided
radially outward of the port(s). The pipe may be referred to as a
base pipe. The port(s) may be provided on the pipe and/or at each
end of the pipe; in the latter case the pipe optionally having a
solid wall. The solid or wall portion(s) may be provided radially
adjacent the port(s), e.g. radially outward of the port(s). This
arrangement may provide that injection flow, e.g. high rate
injection flow, may meet or hit a solid or wall portion, change
direction and flow axially along an annulus between the pipe and
the sleeve. In this way an area of highest erosion is deflected to
an area of pipe having a solid outer wall.
[0034] According to a fifteenth aspect of the present invention
there is provided a screen assembly, such as a downhole/sand screen
assembly, comprising first and second screen portions or screens
longitudinally coupled together, wherein there is provided a fluid
flow path between the first and second screen portions or screen.
The first screen may comprise a first pipe and a first sleeve. The
second screen may comprise a second pipe and a second sleeve. The
first and second pipes may be coupled, e.g. by a coupling, e.g. a
threaded coupling. The first and second sleeves may be coupled or
connected by a centraliser or further sleeve or screen, and/or
optionally by or via first and second support rings. The fluid flow
path may be annular. The centralizer or further sleeve or screen
may form a portion of the fluid flow path.
[0035] According to a sixteenth aspect of the present invention
there is provided a screen assembly, such as a downhole/sand screen
assembly, comprising first and second screens longitudinally
disposed relative to one another, wherein a centraliser is provided
between adjacent ends of the first and second screens. A first
support ring may be provided between an end of a sleeve of the
first screen and a first end of the centralizer. A second support
ring may be provided between an end of a sleeve of the second
screen and a second end of the centralizer.
[0036] According to a seventeenth aspect of the present invention
there is provided a screen assembly, such as a downhole/sand screen
assembly, comprising first and second screens longitudinally
disposed relative to one another, wherein a further screen or
screen portion is provided between adjacent ends of the first and
second screens. A first support ring may be provided between an end
of a sleeve of the first screen and a first end of the further
screen. A second support ring may be provided between an end of a
sleeve of the second screen and a second end of the further
screen.
[0037] According to an eighteenth aspect of the present invention
there is provided a screen or screen assembly, such as a
downhole/sand screen or screen assembly comprising a pipe and a
plurality of ceramic discs stacked on each other, wherein at least
one spacer is provided between two adjacent discs, wherein the/each
at least one spacer is aligned with a respective hole or slot or
perforation in the pipe. Such may provide enhanced erosion
resistance. The pipe may be referred to as a base pipe or
production tubing.
[0038] According to a nineteenth aspect of the present invention
there is provided a screen or screen assembly, such as a
downhole/sand screen or screen assembly, comprising a pipe and a
plurality of ceramic discs stacked on each other, wherein at least
one spacer is provided between at least two adjacent discs, wherein
the/each spacer is shaped to diffuse fluid flow exiting a hole or
slot or perforation in the pipe. Such may provide enhanced erosion
resistance. The spacer may comprise first and second surfaces. The
first and second surfaces may be concave. The first and second
surfaces may face in opposing directions. Each of the first and
second surfaces may be radially diverging. The pipe may be referred
to as a base pipe or production tubing.
[0039] The eighteenth and nineteenth aspects may be combined. The
following optional features apply at least to the eighteenth and
nineteenth aspects: The discs may be provided around the pipe. The
disc may be annular. Beneficially each spacer may be integrally
formed with a disc. Beneficially each disc and/or each spacer may
be made from a ceramic material.
[0040] In one implementation a plurality of longitudinally adjacent
discs may provide a plurality of circumferentially adjacent
spacers. Such may be rotationally aligned with a
hole/slot/perforation in the pipe. The discs may provide a filter
media. Adjacent discs may be spaced from one another, e.g. by the
spacer(s). The spacer(s) may be provided on a surface or face of
the/each disc. Spacer(s) may be provided around the surface or face
of the/each disc.
[0041] According to a twentieth aspect of the present invention
there is provided a screen assembly, such as a downhole/sand screen
assembly, comprising a plurality of screens, wherein each screen
comprises a pipe and a shifting sleeve, wherein the assembly is
arranged such that the shifting sleeves are capable of being opened
(and/or closed) sequentially. The sleeves may be opened in sequence
from the furthest downhole towards surface.
[0042] According to a twenty first aspect of the present invention
there is provided a downhole apparatus or assembly, or screen or
screen assembly, such as a downhole/sand screen assembly,
comprising a pipe having a port and an inner sleeve and a pin
within the port. The pin may cause rotational locking or alignment
between the pipe and the sleeve.
[0043] According to a twenty second aspect of the present invention
there is provided a screen, or screen assembly, such as a
downhole/sand screen or screen assembly, having enhanced erosion
resistance.
[0044] It will be appreciated that the foregoing general solution
or aspects of the present invention may be combined. It will be
appreciated that any feature or features of one general solution or
aspect of the present invention may be adopted or used in another
general solution or aspect.
[0045] Any feature(s) of any one general solution or aspect may be
combined with any feature(s) of any other general solution or
aspect. Thus feature(s) defined in relation to one general solution
or aspect may be provided in combination with feature(s) of any
other general solution or aspect.
[0046] It will be appreciated that the pipe (or tubular) and/or the
screen, first and/or second screens and/or the further screen may
each comprise a hollow cylindrical shape, and may be disposed
substantially co-axially, the sleeve typically surrounding the
pipe.
[0047] The wire may comprise wire mesh. The screen or screen
assembly may be configurable for one or more of fluid injection,
stimulation, fracturing and/or production. The pipe may comprise
production tubing. The pipe may comprise a first tubular. The pipe
may be permeable or impermeable. The pipe may comprise a perforated
tubular member or tubular member having a plurality of ports or may
comprise a solid walled tubular member. The screen or sleeve (e.g.
outer sleeve) may comprise a second tubular. The screen or sleeve
(e.g. outer sleeve) may be permeable. The pipe may be disposed
within a or the sleeve (e.g. outer sleeve). The pipe may define an
axial through-bore. An annulus may be provided between the pipe and
the sleeve (e.g. outer sleeve). The (further) sleeve(s), e.g.
sliding sleeves, may comprise further tubulars. The wire may be
circumferentially disposed or wound.
BRIEF DESCRIPTION OF DRAWINGS
[0048] Embodiments of the present invention will now be described
by way of example only and with reference to accompanying drawings
which are:
[0049] FIG. 1 is a cross-sectional view of a sand screen
operatively positioned in a subterranean well-bore;
[0050] FIG. 2 is a cross-sectioned view of another sand screen
operatively positioned in a subterranean well-bore;
[0051] FIG. 3(a) is a transverse cross-sectional view of a screen
according to the prior art;
[0052] FIGS. 3(b)-(c) are partial longitudinal cross-sectional
views of the screen of FIG. 3(a);
[0053] FIG. 4 is a transverse cross-sectional view of a screen
according to an embodiment of the present invention;
[0054] FIG. 5 is a transverse cross-sectional view of a screen
according to an embodiment of the present invention;
[0055] FIG. 6 is a partial longitudinal cross-sectional view of a
screen according to an embodiment of the present invention;
[0056] FIG. 7 is a partial longitudinal cross-sectional view of a
screen according to an embodiment of the present invention;
[0057] FIGS. 8(a)-(b) are partial longitudinal cross-sectional
views of a screen according to an embodiment of the present
invention;
[0058] FIG. 8(c) is a partial longitudinal cross-sectional view of
a screen according to an embodiment of the present invention;
[0059] FIG. 8(d) is a partial longitudinal cross-sectional view of
a screen according to an embodiment of the present invention;
[0060] FIG. 9(a) is a transverse cross-sectional view of a screen
according to an embodiment of the present invention;
[0061] FIGS. 9(b)-(e) are a series of longitudinal views of the
screen of FIG. 9(a) in closed and opened dispositions;
[0062] FIGS. 10(a)-(c) are a series of longitudinal cross-sectional
views of a screen according to an embodiment of the present
invention;
[0063] FIG. 11(a) is a partial longitudinal cross-sectional view of
a screen according to an embodiment of the present invention in a
closed position;
[0064] FIG. 11(b) is a partial longitudinal cross-sectional view of
a screen according to an embodiment of the present invention in a
closed position;
[0065] FIGS. 12(a)-(c) are a sequence of longitudinal
cross-sectional views illustrating opening of a screen according to
an embodiment of the present invention;
[0066] FIGS. 12(d)-(f) are a sequence of longitudinal
cross-sectional views illustrating closing of the screen of FIGS.
12(a)-(c);
[0067] FIGS. 13(a)-(b) is longitudinal cross-sectional views of a
screen assembly according to an embodiment of the present
invention;
[0068] FIGS. 13(c)-(d) are longitudinal cross-sectional views of a
screen assembly according to an embodiment of the present
invention;
[0069] FIG. 14(a) is a transverse cross-sectional view of a screen
according to an embodiment of the present invention;
[0070] FIG. 14(b) is a longitudinal view of the screen of FIG.
14(a);
[0071] FIGS. 15(a)-(c) are a series of longitudinal cross-sectional
views of a screen according to an embodiment of the present
invention;
[0072] FIG. 15(d) is a perspective view of a sliding sleeve of the
screen of FIGS. 15(a)-(c);
[0073] FIG. 16(a) is a transverse cross-sectional view of screen
according to an embodiment of the present invention;
[0074] FIGS. 16 (b)-(c) are partial longitudinal cross-sectional
views of the screen of FIG. 16(a) and a modification thereto; FIG.
16(d) a further partial longitudinal cross-sectional view of the
screen of FIG. 16(a);
[0075] FIGS. 17(a)-(c) are a sequence of longitudinal
cross-sectional views illustrating opening of a screen according to
an embodiment of the present invention;
[0076] FIG. 18(a)-(b) partial longitudinal cross-sectional views of
a screen assembly according to an embodiment of the present
invention;
[0077] FIG. 19(a) is a perspective longitudinal view of a screen
according to an embodiment of the present invention;
[0078] FIG. 19(b) is a partial longitudinal cross-sectional view of
the screen of FIG. 19(a) to an enlarged scale;
[0079] FIG. 19(c) is a stack of discs of the screen of FIG.
19(a);
[0080] FIG. 19(d) is a partial perspective view of a ceramic disc
of the stack of ceramic discs of FIG. 19(c);
[0081] FIG. 20 is a cross-sectional side view of a screen according
to an embodiment of the present invention; and
[0082] FIG. 21 is a cross-sectional side view of a downhole
apparatus or screen according to an embodiment of the present
invention.
DETAILED DESCRIPTION OF DRAWINGS
[0083] Referring to FIG. 1, there is illustrated a screen or sand
screen, generally designated 5a, operatively positioned in a
subterranean well-bore 10a adjacent to a formation 15a which has
been lined with protective casing 20a. The casing 20a has been
perforated 21a to permit fluid flow between formation 15a and
well-bore 10a. Screen 5a is suspended from pipe or production
tubing 25a which extends to a well-head 30a and comprises a
permeable sleeve 31a formed from wire.
[0084] During production of fluids--represented by arrows 35a--from
the formation 15a, the fluids enter the screen 5a and are
transported to the well-head through the tubing 25a. Any sand in
the fluid 35a should be filtered out by the screen 5a and not
permitted to flow into the pipe 25a. The screen 5a is gradually
eroded over time as the fluid 35a flows through the screen 5a.
Higher rates of flow of the fluid 35a through the screen 5a cause
faster erosion of the screen 5a. The screen 5a can also be used for
injection of fluids into the formation--in a direction opposite to
the arrows 35a.
[0085] If the rate of flow of the fluid through a particular
perforation 21a is greater than the rate of flow of the fluid 35a
through the other perforations 21a--as is frequently the case in
gas wells--a portion 45a of the screen 5a opposite the high flow
rate perforation 21a will erode faster than another portion or
portions of the screen 5a. When the portion 45a of the screen 5a
has eroded enough to permit sand and other debris to enter the
tubing, the entire screen 5a must be replaced at great cost to the
well operator, even though most of the screen 5a is not yet
eroded.
[0086] Referring next to FIG. 2, there is illustrated an
alternative screen or sand screen, generally designated 5b. The
screen 5b is shown within a well-bore 10b of an earth formation
15b. The screen 5b has a cylindrical sleeve or foam body 50b, which
in one implementation is an open cell foam body which surrounds a
pipe or tubular 25b positioned within a through-bore or void 55b
that extends longitudinally through the foam body or sleeve 50b.
The foam body or sleeve 50b is an open cell structured foam which
allows fluid to flow therethrough from an outside of the screen 5b,
defined by an outer surface, to the void 55b. The cell structured
foam provides filtering of fluid passing therethrough. Perforations
or ports 40b in the pipe 25b allow fluid passing through the screen
5b to flow to an inside of the through-bore 55b. Once the fluid is
on an inside of the through-bore 55b the fluid can flow
longitudinally through the pipe 25b in either direction. Fluid
initially on the inside of the through-bore 55b can also flow out
through the perforations 40b, through the open cell structured foam
and to the outside.
[0087] Referring now to FIGS. 3(a)-(c) there is shown a screen,
such as a downhole/sand screen, 5c according to the prior art. The
screen 5c comprises a pipe (tubular) 25c and a sleeve (permeable
sleeve) 31c and a plurality of circumferentially disposed supports
32c provided between the pipe 25c and the sleeve 31c, wherein each
support 32c has a cross-section comprising a triangular shape.
[0088] Further the sleeve 31c comprises wire 33c which has a
cross-section comprising a further triangular shape. The wire 33c
is circumferentially disposed or wound.
[0089] There will now be illustrated, by way of non-limiting
example only, a number of embodiments of screens or screen
assemblies according to the present invention which may find
utility in well-bore completions as shown in FIG. 1 and/or FIG.
2.
[0090] Referring now to FIG. 4, there is shown a screen or screen
assembly 105, such as a downhole/sand screen or screen assembly,
comprising a pipe 125 and a sleeve 131 and at least one support 132
provided between the pipe 125 and the sleeve 131, wherein the at
least one support 132 has a cross-section comprising first and
second points or vertices or surface discontinuities or corners
160. Such support shape can provide enhanced erosion
resistance.
[0091] The pipe 125 can be referred to as a base pipe or production
pipe or tubing. The pipe is perforated and comprises a plurality of
ports 162. The first and second points, vertices, surface
discontinuities or corners 160 (hereinafter `points`) comprise a
pair of points 160. The first and second points 160 face in
substantially opposing directions along a radius or radial
direction.
[0092] The at least one support 132 comprises a plurality of
supports 132, i.e. axial supports and/or support rods. The supports
132 are disposed in an annular space between the pipe 125 and the
sleeve 131.
[0093] In one implementation (shown in FIG. 4) the/each support 132
has a cross-section comprising a polygon having at least four
sides, parallelogram, rectilinear, square or diamond shape.
[0094] In another implementation (shown in FIG. 5) the/each support
132' has a cross-section comprising a polygon having six sides,
i.e. a polygon having opposing triangular end portions and a
rectilinear or square mid-portion.
[0095] A first point 160; 160' is welded to the pipe 125; 125',
i.e. an outer surface of the pipe. A second point 160; 160'; 132;
132' is welded to the sleeve 131; 131' i.e. an inner surface of the
sleeve 131.
[0096] The support(s) is/are typically made from steel.
[0097] Referring next to FIG. 6, there is shown a screen or screen
assembly 205, such as a downhole/sand screen or screen assembly,
comprising wire 233 having a cross-section comprising first and
second points or vertices or surface discontinuities or corners
261. Such wire shape can provide enhanced erosion resistance.
[0098] The first and second points, vertices, surface
discontinuities or corners 261 (hereinafter `points`) comprise a
pair of points 261. The first and second points 261 face in
substantially opposing directions, e.g. along a radius or radial
direction.
[0099] The screen 205 comprises a pipe 225 and a sleeve 231 (the
sleeve 231 comprising the wire 233/screen), and at least one
support 232. The pipe 225 can be referred to as a base pipe or
production tubing. The at least one support 232 comprises a
plurality 232 of supports, e.g. axial supports and/or support rods.
The supports 232 are disposed in an annular space 234 between the
pipe 225 and the sleeve 231.
[0100] In one implementation (shown in FIG. 6) the/each wire 233
has a cross-section comprising a polygon having at least four sides
or diamond shape.
[0101] In another implementation (shown in FIG. 7) the/each wire
233' has a cross-section comprising a polygon having six sides,
e.g. a polygon having opposing triangular end portions and a
rectilinear or square mid-portion.
[0102] A first point 261; 261' is welded to a support 232; 232',
e.g. an outer surface of the support 232; 232'. A second point 261;
261' faces radially out, e.g. towards a formation or inner facing
surface of a well-bore.
[0103] The wire 233; 233' is typically made from steel.
[0104] Referring next to FIGS. 8(a)-(b) there is shown a screen or
screen assembly 305, such as a downhole/sand screen or screen
assembly, wherein the screen 305 comprises wire 333 having a
cross-section comprising a rectilinear or square shape. Such wire
shape can provide enhanced erosion resistance.
[0105] The rectilinear shape comprises a rectangle or in this
preferred implementation comprises a square. The wire 333 is
disposed such that a line of symmetry of the rectilinear shape is
provided along a radial direction of the screen 305 or pipe
325.
[0106] The screen 305 comprises a pipe 325 and a sleeve 331 (the
sleeve comprising the wire/screen), and at least one support 332. A
side of the wire 333 is welded to the support(s) 332.
[0107] Referring next to FIG. 8(c) there is shown a screen or
screen assembly 305', such as a downhole/sand screen or screen
assembly. The screen 305' is similar to the screen 305, like ports
being identified by like numerals but suffixed `'`.
[0108] Referring next to FIG. 8(d) there is shown a screen or
screen assembly 305'', such as a downhole/sand screen or assembly.
The screen 305'' is similar to the screen 305; 305' like ports
being identified by like numerals, but suffixed `''`. In the screen
305'' of FIG. 8(d) the pipe 325 comprise a tubular having a solid
wall, i.e. which is not perforated.
[0109] Where wrap wires 333; 333'; 333'' of a square cross-section
are used to construct the filter media the smooth passage created
under such will reduce turbulence and tend flow to continue
longitudinally. This can promote a more even distribution of
injection fluid through the wire wrap 333; 333'; 333''.
[0110] The construction of the filter media can be used in
situations where the base pipe is perforated (shown in FIGS.
8(a)-(b) and FIG. 8 (c)) or where the base pipe is imperforated
(shown in FIG. 8 (d)) and flow enters the annulus between the base
pipe and the wrap wires at a point lower down the sand screen
joint.
[0111] It will be appreciated any combination of shape of wire
(wire wrap) and/or support is possible, e.g. wire and/or supports
selected from triangular, diamond shape, hexagonal, elongate
hexagonal, square or rectangular cross-sectional shape (though not
both triangular). It will be appreciated that any such combination
of wire and support shape may provide enhanced erosion resistance
in at least one of injection and production.
[0112] Regarding the wire of the screen or screen assembly of FIG.
6, FIG. 7, FIG. 8(a)-(b), FIG. 8(c) or FIG. 8(d), or indeed FIGS.
3(a)-(c), the wire comprises coated and/or hardened wire 233; 233';
333; 333'; 333''; 333c. The wire can beneficially be made from
steel.
[0113] The screen comprises a pipe and a sleeve, the sleeve
comprising the wire, and optionally at least one support.
[0114] In one implementation the coating is tungsten carbide, e.g.
hardide tungsten carbide. The coating is applied or deposited by
chemical vapour deposition (CVD), which can be applied to steel.
The wire can be heat treated so as to harden.
[0115] The wire can be provided in coated and/or hardened lengths
and made-up or assembled in longer lengths so as to provide the
sleeve.
[0116] Referring next to FIGS. 9(a)-(e) and FIG. 14(a)-(b) there is
shown a screen or screen assembly 405; 405', such as a downhole or
sand screen or screen assembly, comprising a pipe 425; 425' and a
plurality of ceramic discs 470; 470' around the pipe 425; 425'.
High hardness of the ceramic provides enhanced erosion
resistance.
[0117] The ceramic discs 470; 470' are stacked on each other. Gaps
between the discs 470; 470' determine a size of particulate to be
filtered, and can be modified to suit a well and a specification of
an operator.
[0118] The pipe 425 can be referred to as a base pipe or production
tubing. In one implementation (see FIGS. 9(a)-(e)) the pipe 425 is
perforated and/or comprises a plurality of ports 440. The pipe 425
is slotted. In another implementation (see FIGS. 14(a) and (b)) the
pipe 425' is non-permeable or solid.
[0119] The pipe 425 comprises a plurality of ports 440, e.g. slots,
e.g. circumferentially and axially spaced thereupon.
[0120] One or more of the discs 470; 470' are arranged so as to
provide circumferential/annular spaces 471; 471' between the pipe
425; 425' and the respective disc 470; 470'.
[0121] Between adjacent circumferential/annular spaces 471; 471'
the disc(s) 470; 470' are arranged such that there is no gap
between the pipe 425; 425' and the disc 470; 470'. Such arrangement
is provided by portions of the disc 470; 470' having reduced
internal diameter, i.e. such that the pipe 425; 425' and the
disc(s) 470; 470' radially abut or contact one another at said
portions.
[0122] The space(s) 471; 471' extend longitudinally between
adjacent discs 470; 470'. The space(s) 420; 420' are aligned, i.e.
rotationally aligned, with at least one port 440 in the pipe 425;
425'.
[0123] A valve member 473 is provided between a port 440 and a
respective space 471. The/each valve member 473 comprises a
slidable member, i.e. longitudinally slidable member. Each valve
member 473 comprises at least one further port 474 and/or at least
one reed valve 475, which is/are (longitudinally) selectively
alignable with or out of alignment with a port 440 of the pipe
425.
[0124] The screen or screen assembly also comprises an inner sleeve
476 (see FIG. 9(a)). The inner sleeve 476 is slidable relative to
the pipe 425. An outer surface of the inner sleeve 476 abuts or
contacts an inner surface of the pipe 425.
[0125] The inner sleeve 476 comprises at least one yet further port
477 and/or further reed valve 478, which is/are (longitudinally)
selectively alignable with or out of alignment with a port 440 of
the pipe 425.
[0126] Referring to FIGS. 14(a)-(b), there is shown a screen or
screen assembly 405, such as a downhole screen or screen assembly,
comprising a pipe 425' and/or sleeve comprising discs 470', wherein
the pipe comprises a solid or non-perforated pipe 425'. Such
arrangement can provide enhanced erosion resistance. The solid or
non-perforated pipe 425' can comprise or be provided with an
opening(s) or port(s) at or adjacent an end(s) thereof, e.g. to
deliver injection fluid to a formation.
[0127] Referring to FIGS. 10(a)-(c) there is shown a screen or
screen assembly 505, such as a downhole/sand screen or screen
assembly, comprising a pipe 525 and a sleeve 531, wherein the pipe
525 comprises openings or slots (e.g. longitudinally or axially
opening(s) or slot(s)) 540 and the sleeve 531 comprises a foam or
microporous material the sleeve 531 being bonded with or to an
exterior surface of the pipe. Such arrangement can provide enhanced
erosion resistance. Such arrangement can provide relatively even
distribution of injection fluids.
[0128] The pipe can be referred to as a base pipe or production
tubing. The openings or slots can comprise daisy passages. The
opening or slots, in use, fluidically communicate with the
sleeve.
[0129] Referring to FIGS. 15(a)-(d), there is shown a screen or
screen assembly 505', such as a downhole/sand screen or screen
assembly, comprising a pipe 525' and a microporous sleeve 531',
wherein the pipe 525' comprises a plurality of slotted ports 540'
or longitudinally extending ports 540'. Such arrangement can
provide enhanced erosion resistance, and operates in a similar
manner to the screen of FIGS. 10 (a)-(c).
[0130] The following optional features apply to any disclosed
embodiments.
[0131] The pipe is typically referred to as base pipe or production
tubing.
[0132] Where provided the microporous sleeve 531; 531' can be an
erosion resistant microporous sleeve. The microporous sleeve 531;
531' comprises a material selected from a metal foam or a ceramic
foam. The microporous sleeve 531; 531' comprises a material
selected from the group consisting of microporous polymeric foams,
microporous metal foams, microporous carbide monoliths, in
particular, silicon carbide, tungsten carbide, or titanium carbide
monoliths or microporous nitride monoliths, such as boron nitride.
The microporous sleeve 531; 531' intimately contacts and/or is
bonded to an outer surface of the pipe 525; 525'.
[0133] Referring now to FIGS. 9(a)-(e), FIGS. 10(a)-(c), FIG. 11(a)
and FIGS. 15 (a)-(c) there is shown screens or screen assemblies
405; 505; 605; 505', such as a downhole/sand screen or screen
assembly, comprising a pipe 425; 525; 625; 525' having at least one
port 440; 540; 640; 540' or perforation or hole, the/each port 440;
540; 640; 540' or perforation or hole having an associated valve
473; 573; 673; 573'.
[0134] The pipe 425; 525; 625; 525' can be referred to as a base
pipe or production tubing. The/each valve 473; 573; 673; 673' can
be a check valve.
[0135] The pipe 425; 525; 625; 625' comprises a plurality of ports
440; 540; 640; 640' or perforations, each port 440; 540; 640; 640'
or perforation having an associated valve 473; 573; 673; 673'.
[0136] The/each valve 473; 573; 673; 673' is, in use, initially
provided to isolate the inner diameter of the pipe 425; 525; 625;
525' from the outer diameter of the pipe 425; 525; 625; 525'. Upon
opening the valve(s) 473; 573; 673; 573' the provision of multiple
ports/perforations/holes in the pipe 425; 525; 625; 525' provides
improved distribution of injection fluid. The/each valve 473; 573;
673; 573' comprises a valve member.
[0137] The/each valve member 573; 673; 573' is deployable by a
sliding sleeve 580; 680; 580' and/or by pressure of fluid flow, in
use.
[0138] The sliding sleeve 580; 680; 580' can slide relative to an
inner surface of the pipe 525; 625; 525'. The sliding sleeve 580;
680; 580' comprises a port(s) 581; 681; 581' which is controllably
aligned with ports 540; 640; 540' of the pipe 525; 625; 525'.
[0139] The valve member(s) 573; 673; 573' may be biased into a
closed position, e.g. by biasing means 582; 682; 582'.
[0140] In one implementation (see FIGS. 10(a)-(c)) the valve
member(s) 573 comprises a spherical member(s) or balls, e.g. biased
spherical member(s). The/each spherical member or ball is provided,
i.e. movably provided, within a space provided by a port in the
pipe and a recessed portion in a sleeve.
[0141] Referring to FIG. 10(d), when run-in hole the balls are
press-fitted within a hole(s) in the base pipe, as shown. The balls
are supported by a sliding sleeve preventing differential pressure
from an outside passing through the filter media and forcing them
through the base pipe. Pressure is isolated between the outside and
the inside of the base pipe via seals positioned on the outer
diameter (OD) of a (long) sliding sleeve.
[0142] Referring to FIG. 10(b), when ready to open the sand screen
up to flow, a short shift of the base pipe will cause the recessed
area in the sliding sleeve to push the balls out of their
respective holes in the base pipe; the new surface against which
the balls rest prevents differential pressure from the outside
passing through the filter media and pushing the balls back into
the press fitted condition. Flow ports in the (long) sliding sleeve
are now exposed below the balls and a seal in the port within the
base pipe provides a pressure check preventing differential
pressure from production flow passing into the sand screen. A
(weak) spring excerpts (gentle) pressure on the ball allowing it to
seal at low differential pressures.
[0143] Referring to FIG. 10(c), when subjected to injection flow
the balls lift off of their respective seats and compress the
(weak) spring allowing flow to pass into the filter media.
[0144] Referring to FIG. 11(a) in the screen 605, the perforated
base pipe 625 can be sealed off by a number of sliding sleeves 680.
These can all be locked in place (opened and closed) by means of
latch fingers. Each sleeve 680 has a shift profile with a kick-down
shoulder on the rear of the sleeve 680 above it, meaning that as
the sift tool can be pulled through, the shift tool pulls open the
sleeve and auto-out from the above kick-down shoulder whereupon it
latches into the next profile and opens that, and so on.
[0145] Referring to FIG. 11(b) there is shown a screen or screen
assembly 605', similar to the screen 605 of FIG. 11(a), like ports
being identified by the numerals but suffixed `'`.
[0146] In the screen 605', the topmost sleeve 680' has a shifting
pole. The rest of the sleeves 680' are closely linked so that they
all open at the same time, but are segmented to account for
concentricity, friction, bends etc.
[0147] In another implementation the valve member(s) comprise a
flap, i.e. thin metallic or steel flap, or reed valve.
[0148] Referring next to FIGS. 12(a)-(f) there is shown a screen or
screen assembly 705, such as a downhole/sand screen or screen
assembly, comprising a pipe 725 having at least one port or
perforation or hole 740, and a sleeve 785 provided within the pipe
725, the sleeve 785 having at least one respective port or
perforation or hole 786 which in a closed position is not aligned
or is misaligned with the at least one port or perforation or hole
740 in or on the pipe 725 but which in an open position is
alignable or aligned with the at least one port or perforation or
hole 740 in or on the pipe 725. The pipe 725 can be referred to as
a base pipe or production tubing.
[0149] The sleeve 785 (internal sleeve) comprises a shift sleeve.
The sleeve 785 is slidable relative to the pipe 725 so as to move
from a closed to open position and optionally vice versa.
[0150] The pipe 725 comprises a plurality of ports or perforations
or holes 740. The/each sleeve 785 (internal sleeve) comprises a
plurality of respective ports or perforations or holes 786. The
presence of multiple ports/perforations/holes allows for improved
distribution of injection fluid. The screen 705 comprises an
(outer) screen sleeve 731, e.g. comprising wire.
[0151] Referring again to FIGS. 12(a)-(f) there is shown a screen
or screen assembly 705, such as a downhole/sand screen or screen
assembly, comprising a pipe 725, and a plurality of inner sliding
sleeves 785a; 785b provided within the pipe 725.
[0152] The pipe 725 can be referred to as a base pipe or production
tubing.
[0153] The sleeves 785a, 785b are provided within the pipe 725. The
sleeves 785a, 785b each comprise a sliding/shift sleeve. There are
provided first and second sleeves 785a; 785b, one within the
other.
[0154] Movement, i.e. sequential movement of the sleeves, causes
alignment or misalignment, of ports in the pipe 725 and the
sleeve(s) 785a; 785b, e.g. opening or closing, of the screen.
Sliding movement of a first sleeve 785a causes sliding movement of
a second sleeve 785b, i.e. to open the screen 705. Sliding movement
of a second sleeve 785b causes sliding movement of a first sleeve
785a, i.e. to close the screen 705.
[0155] Referring yet again to FIGS. 12(a)-(f) there is shown a
screen or screen assembly 705, such as a downhole/sand screen or
screen assembly, comprising a pipe 725 comprising at least one
port/perforation/hole 740, the or each port 740 having a respective
seal 787.
[0156] The pipe 725 can be referred to as a base pipe or production
tubing. The pipe 725 comprises a plurality of ports 740.
[0157] In a closed disposition the respective plug 787 is received
or be provided within or adjacent to the respective port 740. In an
open disposition the respective plug 787 is provided distal the
respective port 740. The plug(s) 787 are carried by a sleeve 785a,
i.e. on an outer surface of a shifting/sliding sleeve provided
within the pipe 725.
[0158] Referring to FIGS. 17(a)-(c) there is shown a modification
to the screen 708 of FIGS. 12(a)-(f). In the modified screen 708'
shown in FIGS. 17(a)-(c) like parts are identified by like numerals
but suffixed `'`.
[0159] In the screen 708' the seal 787' has plastic back-ups
788'.
[0160] Referring to FIG. 17(a), with the seal 787' in place, the
seal 787' is compressed against the hole 740' in the base pipe
725'. A pressure differential from either direction will energise
the seal 787' and act to ensure pressure integrity. Referring to
FIG. 17(b), sliding the inner sleeve 785b' de-supports the finger
sleeve 785a' and relaxes compression in the seal 787'. Referring to
FIG. 17(c), the finger sleeve 785' can now be slid to expose the
hole 740'.
[0161] According to the present invention there is also provided a
screen assembly, such as a downhole/sand screen assembly,
comprising a first screen 105; 205; 305; 305'; 305''; 405; 505;
605; 705; 405'; 505' 705' according to any preceding embodiment of
the present invention and a second screen 5c.
[0162] The first screen 705 and second screen 5c are longitudinally
disposed relative to one another. The first screen can be selected
to be provided in high(er) flow areas, i.e. production and/or
particularly injection fluid flow areas. The second screen 5c can
be selected to be provided in low(er) flow areas, i.e. production
and/or injection fluid flow areas. The second screen can comprise
wire having a cross-section comprising a triangular shape (see
FIGS. 3(a)-(c)).
[0163] Referring to FIG. 18 there is shown a screen assembly 1000,
such as a downhole/sand screen assembly, comprising a first screen
1005a and a second screen 1005b. The pipe 1025 is non-perforated.
The first screen 1005a has a higher erosion resistance than the
screen 1005b. The first screen 1005a is a screen according to an
embodiment of the present invention, e.g. comprising ceramic discs.
The second screen 1005b can be a screen according to the prior
art.
[0164] FIGS. 18(a) and 18 (b) show injection and production fluid
flow respectively. The pipe 1025 comprises a port 1040
longitudinally distal the screens 1005a, 1005b.
[0165] For sand screen configurations where production or injection
flow enters or exits the base pipe 1025 from a single point at one
or either end of the sand screen 1025, the flow will tend to take
the path of least resistance and the majority of the flow will
enter or exit a section of sleeve 1031a or filter media closest to
that point. By incorporating a highly erosion resistant portion of
the screen 1005a closest to the flow port/s 1040, the erosion
effect of the high volume, high velocity flow in this area can be
mitigated. The screen 1005a can comprise ceramic discs. The
remainder of the screen 1005b area will be less susceptible to
erosion due to the reduced flow rates and velocities, therefore,
can be made up of a more conventional filter media type such as
metal mesh or wire wrap, e.g. of triangular cross-section.
[0166] Referring now to FIGS. 16(a)-(i) there is shown a screen or
screen assembly 305', such as a downhole/sand screen or screen
assembly, comprising a pipe 325' and a sleeve 331', wherein the
pipe 305' comprises a port(s) 362', and where the sleeve 331'
comprises a solid or wall portion(s) 390' at or near the port(s)
362'.
[0167] The solid or wall portions 390' are provided radially
outwardly of the ports 362'.
[0168] The pipe 325' can be referred to as a base pipe or
production tubing.
[0169] The port(s) 362' are provided on the pipe 325' and/or at
each end of the pipe, in the latter case the pipe optionally having
a solid wall. The solid or wall portion(s) 390' are provided
radially adjacent the port(s), i.e. radially outward of the
port(s).
[0170] This arrangement can provide that injection flow, i.e. high
rate injection flow may meet or hit a solid or wall portion, change
direction and flow axially along an annulus between the pipe 325'
and the sleeve 331'. In this way an area of highest erosion is
deflected to an area of pipe 305' having a solid outer wall.
[0171] Referring next to FIGS. 13(a) and (b) and FIGS. 13(c) and
(d), there is shown a screen assembly 890a; 890b, such as a
downhole/sand screen assembly, comprising first and second screens
805a; 805b longitudinally coupled together, wherein there is
provided a fluid flow path 891a; 891b between the first and second
screens 805a; 805b.
[0172] The first screen 805a; 805b comprises a first pipe 825a;
825b and a first sleeve 831a; 831b. The second screen 805a; 805b
comprises a second pipe 825a; 825b and a second sleeve 831a; 831b.
The first and second pipes 825a; 825b are coupled by a coupling,
i.e. a threaded coupling 892a; 892b.
[0173] The first and second sleeves are coupled, i.e. by first and
second support rings 893a; 894a; 893b; 894b and a centraliser or
further sleeve or screen 895a; 895b.
[0174] The fluid flow path is annular.
[0175] Referring to FIGS. 13(a) and (b), there is shown a screen
assembly 890a, such as a downhole/sand screen assembly, comprising
first and second screens 805a longitudinally disposed relative to
one another, wherein a centraliser 895a is provided between
adjacent ends of the first and second screens 805a.
[0176] A first support ring 893a is provided between an end of a
sleeve 831a of the first screen and a first end of the centraliser
895a. A second support ring 894a is provided between an end of a
sleeve 831a of the second screen and a second end of the
centraliser 895a.
[0177] Referring to FIGS. 13(c) and (d), there is shown a screen
assembly 890b, such as a downhole/sand screen assembly, comprising
first and second screens longitudinally disposed relative to one
another, wherein a further screen 895b or screen portion is
provided between adjacent ends of the first and second screens
805b.
[0178] A first support ring 893b is provided between an end of a
sleeve 851b of the first screen and a first end of the further
screen 895b. A second support ring 894b is provided between an end
of a sleeve 831b of the second screen and a second end of the
further screen 895b.
[0179] Referring to FIGS. 19(a)-(d), there is shown a screen or
screen assembly 405'', such as a downhole or sand screen or screen
assembly, comprising a pipe 425'' and a plurality of ceramic discs
470'' around the pipe 425''.
[0180] The ceramic discs 470'' are stacked on each other. Gaps
between discs 470'' determine a size of particulate to be filtered,
and can be modified to suit a well and specification of an
operator.
[0181] At least one spacer 499'' is provided between at least two
adjacent discs 470'', wherein the/each at least spacer 499'' is
aligned with a respective hole 440'' or slot or perforation in the
pipe 425''.
[0182] Such provides enhanced erosion resistance.
[0183] The pipe 425'' can be referred to as a base pipe or
production tubing.
[0184] The/each spacer 499'' is shaped to diffuse fluid flow
exiting a hole 440'' or slot of perforation in the pipe 425''. The
spacer 499'' comprises first and second surfaces 499''a, 499''b.
The first and second surfaces 499''a, 499''b are concave and face
in opposing directions. Each of the first and second surface
499''a, 499''b is radially diverging.
[0185] The discs 470'' are provided around the pipe 425''.
Beneficially each spacer 499'' is integrally formed with a disc
470''. Beneficially each disc 470'' and/or each spacer 499'' is
made from a ceramic material.
[0186] As shown in FIG. 19(c), in this implementation, a plurality
of longitudinally adjacent discs 470'' provide a plurality of
circumferentially adjacent spacers 499''. Such are rotationally
aligned with a hole/slot/perforation 440'' in the pipe 425''.
[0187] The discs 470'' provide a filter media. Adjacent discs 470''
are spaced from one another, e.g. by the spacer(s) 499''. The
spacer(s) 499'' are provided on a surface or face of the/each disc
470''. Spacer(s) 499'' are provided around the surface or face of
the/each disc 470''. As can be seen from FIG. 19(a) an outer sleeve
is provided around the discs 470''. The outer sleeve which can be
metallic protects the discs 470'' during run-in.
[0188] Referring to FIG. 20 there is shown a screen or screen
assembly, such as a downhole screen or screen assembly 2005.
[0189] `X` shows the distance between the inner diameter (ID) of
the borehole and the outer diameter (OD) of a sand screen (dashed
line). Within the (outer) sand screen (dashed line) is a pipe or
base pipe A. In or on the base pipe A is a joint B. The joint B is
a threaded connection between two sections of base pipe (`C`
indicates threads). The joint B has an additional function--it
protrudes into throughbore D and presents an incline E to act as a
kick down shoulder. Sleeve F provides ports G. The ports G can be
aligned with ports H in the base pipe when the sleeve F is moved.
The sleeve F has a recess I on the inner surface (on the left hand
side) to accept keys that lock the sleeve F to a shifting tool (not
shown).
[0190] In operation, keys on a shifting tool are biased outwardly,
and as the shifting tool is pulled up the throughbore D, the keys
engage with the profile on the inner surface of the sleeve F. Once
the shifting tool keys are locked into the sleeve F, the shifting
tool is pulled to align the ports G in the sleeve F and the base
pipe ports H. Once the sleeve F has reached its full extent of
travel, the joint B provides a shoulder stop for the shifting
sleeve F and the keys on the shifting tool B. This releases the
keys and disengages the shifting tool from the sleeve F. The
process can be repeated for the next sleeve etc.
[0191] This arrangement provides for "bottom-up opening" of
shifting sleeves.
[0192] Referring now to FIG. 21, there is shown a downhole assembly
or screen or screen assembly 3005. Pipe A provides lateral ports H.
A pin J is in the first of these ports H. The pin J can run in a
groove to ensure axial alignment of the sleeve F and restrict
rotation. Once the sleeve F has reached the full extent of travel,
the pin J can drop into a groove to lock the sleeve F in place. The
pin J acts as an anti-rotation key.
[0193] It will be appreciated that the embodiments of the present
invention may be combined. It will also be appreciated that any
feature or features of one embodiment of the invention may be
adopted or used in another embodiment of the invention. Any
feature(s) described or referenced herein may be combined with any
feature(s) of any other embodiment. Thus feature(s) defined in
relation to one embodiment may be provided in combination with
feature(s) of any other embodiment.
[0194] It will be appreciated that in the disclosed embodiments the
pipe (or tubular) and/or the sleeve each comprise a hollow
cylindrical shape, and are disposed substantially co-axially, the
sleeve typically surrounding the pipe. Further: [0195] the wire can
comprise wire mesh or wire wrap; [0196] the screen or screen
assembly can be configurable for one or more of fluid injection,
stimulation, fracturing and/or production; [0197] the pipe
comprises production tubing; [0198] the screen or sleeve comprises
a second tubular; [0199] the screen or sleeve can be permeable;
[0200] the pipe can comprise a perforated tubular member or tubular
member having a plurality of ports or can comprise a solid tubular
member; [0201] the pipe can comprise a first tubular; [0202] the
pipe can be permeable or impermeable; [0203] the pipe can be
disposed within the sleeve; [0204] the pipe can define an axial
through-bore; [0205] an annulus can be provided between the pipe
and the sleeve; [0206] the sleeve, i.e. sliding sleeves can
comprise further tubulars and/or; [0207] the wire is
circumferentially disposed or wound or wrapped.
[0208] It will be appreciated that the embodiments hereinbefore
described are given by way of example only and are not meant to be
limiting of the scope of the invention in any way. It will be
appreciated that the embodiments may be combined. It will be
appreciated that one or more features of one embodiment may be
adapted or used in another embodiment. Thus any feature(s) of one
embodiment may be combined with any feature(s) of any other general
solution or aspect.
[0209] The aspects/embodiments of the present invention herebefore
described provide one or more of: [0210] (i) Axial screen support
rods having `diamond` cross-section (i.e. one `pointy` end welded
to the base pipe and opposing `pointy` end welded to
circumferential screen). This wire shape is in intended to give
enhanced erosion resistance. (See FIG. 4). [0211] (ii)
Circumferential wire wrap having `diamond` cross-section. (i.e. one
`pointy` end welded to the axial support rod and opposing `pointy`
end facing the formation). This wire shape is in intended to give
enhanced erosion resistance. (See FIG. 6). [0212] (iii) Axial
screen support rods having a cross-section of square/rectangular
core with triangular ends (i.e. one `pointy` end welded to the base
pipe and opposing `pointy` end welded to outer circumferential
screen with square/rectangular middle section therebetween). This
wire shape is in intended to give enhanced erosion resistance. (See
FIG. 5). [0213] (iv) Circumferential wire wrap using wire having a
cross-section of square/rectangular core with triangular ends (i.e.
one `pointy` end welded to the axial support rod and the opposing
`pointy` end facing the formation with square/rectangular middle
section therebetween). This wire shape is in intended to give
enhanced erosion resistance. (See FIG. 7). [0214] (v) Wire wrap
screen or axial support rods having square cross-section. In this
case, the lack of `pointy` end may result in less turbulence and
therefore lower erosion rates. This wire shape is in intended to
give enhanced erosion resistance. (See FIGS. 8(a) and (b)). [0215]
(vi) Any combination of screen construction using axial supports
and circumferential screen from (i)-(v). [0216] (vii) Coated
wire/hardened wire. Can be used with any wire screen arrangement.
One example of the hardening process is hardide tungsten carbide
chemical vapour deposition (CVD). CVD can be applied to steel. The
wire would need to be coated in shorter lengths then made
up/assembled into longer continuous lengths of screened pipe. (See
FIGS. 3(a) and (b) or FIG. 6, FIG. 7 or FIGS. 8(a) and (b)). [0217]
(viii) Stacks of ceramic disks overlaid on the base pipe (either
slotted or solid). This provides screen with enhanced erosion
resistance. (See FIGS. 9(a)-(e) and FIGS. 14(a) and (b)). [0218]
(ix) Microporous sand screen made from foamed metal or ceramic over
slotted or solid base pipe (again the solid base pipe would need
opening(s) at the end to deliver injection fluid to the annulus).
Pore size can be adjusted to suit the requirements of the client.
This provides screen with enhanced erosion resistance. (See FIGS.
10(a)-(e)). [0219] (x) Foamed screen made from metal or ceramic
that is bonded with the exterior of the base pipe, but with axial
opening or slots (daisy passages) running along the exterior of the
base pipe to deliver fluid to the foamed screen. This provides
screen with enhanced erosion resistance on solid base pipe, but
allowing for even distribution of injection fluids. (See FIGS.
10(a)-(c)). [0220] (xi) Perforated base pipe, each perforation
having an associated check valve. The check valve is initially
provided to isolate the ID and the OD of the base pipe, but the
presence of multiple holes in the base pipe allows more even
distribution of the injection fluid. This can be used with any of
the enhanced erosion screen concepts or conventional screen. (See
FIGS. 10(a)-(c) or FIGS. 11(a)-(i)). [0221] (xii) Perforated base
pipe with internal shift sleeve. Shift sleeves can have holes that
align with the closest portion of pipe when open, but which are
misaligned over the pipe in the closed position. The presence of
multiple holes in the base pipe allows more even distribution of
the injection fluid. This can be used with any of the enhanced
erosion screen concepts or conventional screen. (See FIGS.
12(a)-(f)). [0222] (xiii) Perforated base pipe with multiple shift
sleeves, each sleeve ranging between around 1 to 30 foot. The
screens can be linked by flexible sections and glide rings provided
to reduce friction. The shifting sleeves can make use of
O-rings/bonded seals/reed valves/check valves. Screens are
initially closed, then opened before injection operations commence
to spread the flow. (See FIGS. 12(a)-(f)). [0223] (xiv)
Perforations in the base pipe sealed by thin steel flaps (reed
valves). The presence of multiple holes in the base pipe allows
more even distribution of the injection fluid. This can be used
with any of the enhanced erosion screen concepts or conventional
screen. (See FIGS. 9(a)-(e) and FIGS. 12(a)-(f)). [0224] (xv)
Perforations sealed by `knock-out` plugs. The presence of multiple
holes in the base pipe allows more even distribution of the
injection fluid. This can be used with any of the enhanced erosion
screen concepts or conventional screen. (See FIGS. 12(a)-(f)).
[0225] (xvi) Solid base pipe with split screen, i.e. a length of
high erosion resistant screen in high flow areas (i.e. a certain
distance range from the openings)--any of concepts (i) to (ix),
followed by a longer length of normal triangular section wire wrap
over the remaining area that experiences lower flow rates. (See
FIGS. 18(a)-(b)). [0226] (xvii) Screen (any known type or (i) to
(vii) that has solid areas near injection flow openings, (such as
at ends of solid base pipe and over holes in perforated base pipe).
This allows the high rate injection flow to hit a solid section,
change direction and flow axially along the annulus between base
pipe and screen so that the potential area of highest erosion is at
a portion of solid pipe rather than screen. The solid part can be a
ring wrapped over the top of the screen or joined to adjacent
sections of screen. (See FIGS. 16(a)-(d)). [0227] (xviii) Coupling
between adjacent screen joints provides a flow path and is also a
centraliser (dual function). (See FIGS. 13(a) and (b)). [0228]
(xix) Coupling between adjacent screen joints provides a flow path
and is also screen. (See FIGS. 13(c) and (d)).
* * * * *