U.S. patent application number 14/770714 was filed with the patent office on 2018-05-03 for sand control filter assembly with multilayer woven wire filter mesh and method for manufacture thereof.
The applicant listed for this patent is HALLIBURTON ENERGY SERVICES INC.. Invention is credited to Stephen M. Greci, Jean Marc Lopez.
Application Number | 20180119526 14/770714 |
Document ID | / |
Family ID | 54935916 |
Filed Date | 2018-05-03 |
United States Patent
Application |
20180119526 |
Kind Code |
A1 |
Lopez; Jean Marc ; et
al. |
May 3, 2018 |
SAND CONTROL FILTER ASSEMBLY WITH MULTILAYER WOVEN WIRE FILTER MESH
AND METHOD FOR MANUFACTURE THEREOF
Abstract
A sand control filter assembly and method for its manufacture.
Multiple filter layers of a woven wire mesh arc wrapped directly
onto the outer circumference of a perforated base pipe. A
perforated shroud is slid over the outermost filter layer, and the
assembly is run through a die to swage the shroud tightly over the
multiple filter layers, thereby holding the filter layers in place
and sealing their ends. In an embodiment, the woven filter mesh may
be a volumetric mesh having irregular ridges and valleys to further
enhance drainage.
Inventors: |
Lopez; Jean Marc; (Plano,
TX) ; Greci; Stephen M.; (Little Elm, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HALLIBURTON ENERGY SERVICES INC. |
Houston |
TX |
US |
|
|
Family ID: |
54935916 |
Appl. No.: |
14/770714 |
Filed: |
June 17, 2014 |
PCT Filed: |
June 17, 2014 |
PCT NO: |
PCT/US14/42781 |
371 Date: |
August 26, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 43/084
20130101 |
International
Class: |
E21B 43/08 20060101
E21B043/08 |
Claims
1. A filter assembly for downhole use, comprising: a perforated
base pipe; an inner filter layer of a woven wire mesh disposed
directly adjacent the outer circumference of said base pipe; an
outer filter layer of a woven wire mesh disposed about said inner
filter layer; and a perforated shroud disposed directly adjacent
and in intimate contact with said outer filter layer; wherein at
least one filter layer of the group consisting of said inner and
outer filter layers includes a volumetric mesh characterized by
having an irregular thickness; whereby said at least one filter
layer forms generally longitudinal drainage channels through said
filter assembly.
2. The filter assembly of claim 1 further comprising: at least one
intermediate filter layer of a woven wire mesh disposed between
said inner and outer filter layers.
3. The filter assembly of claim 1 wherein: said at least one filter
layer defines a plurality of ridges and a plurality of valleys.
4. The filter assembly of claim 1 wherein: said shroud defines
first and second ends; and said first and second ends of said
shroud are welded to said base pipe.
5. The filter assembly of claim 1 wherein: at least one filter
layer of the group consisting of said inner and outer filter layers
is helically wound about said base pipe.
6. A method for manufacturing a filter assembly for downhole use,
comprising: providing a perforated base pipe; disposing woven wire
mesh directly adjacent the outer circumference of said base pipe to
form an inner filter layer disposing woven wire mesh about said
inner filter layer to form an outer filter layer; positioning a
perforated shroud about said outer filter layer; and swaging said
shroud into intimate contact with said outer filter layer; wherein
at least one filter layer of the group consisting of said inner and
outer filter layers includes a volumetric mesh characterized by
having an irregular thickness; whereby said at least one filter
layer forms generally longitudinal drainage channels through said
filter assembly.
7. The method of claim 6 further comprising: wrapping said woven
wire mesh about said base pipe.
8. The method of claim 7 further comprising: wrapping said woven
wire mesh about said base pipe in a helical orientation.
9. The method of claim 6 further comprising: disposing woven wire
mesh disposed about said inner filter layer to form at least one
intermediate filter layer between said inner and outer filter
layers.
10. The method of claim 6 wherein: said at least one filter layer
defines a plurality of ridges and a plurality of valleys.
11. The method of claim 6 wherein: said shroud defines first and
second ends; and the method further comprises welding said first
and second ends of said shroud to said base pipe.
12. The method of claim 6 further comprising: swaging said shroud
into intimate contact with said outer filter layer by passing said
filter assembly through a die that reduces the outer diameter of
said shroud.
13. The method of claim 12 wherein: said die includes at least one
roller.
14. The method of claim 6 wherein: said inner and outer filter
layers define first and second ends; said shroud defines a first
and a second end; and the method further comprises sealing said
inner and outer filter layers and said shroud to said base pipe by
swaging said shroud.
15. A method for manufacturing a filter assembly for downhole use,
comprising: providing a perforated base pipe; disposing multiple
filter layers directly adjacent the outer circumference of said
base pipe, wherein at least one of said multiple filter layers
includes a volumetric woven wire mesh characterized by having an
irregular thickness; positioning a perforated shroud over said
multiple filter layers; and swaging said shroud on to said multiple
filter layers.
16. The method of claim 15 further comprising: wrapping woven wire
mesh directly about the outer circumference of said base pipe to
form said multiple filter layers;
17. The method of claim 16 wherein: said volumetric woven wire mesh
forms generally longitudinal drainage channels through said filter
assembly.
18. The method of claim 15 wherein: said shroud defines first and
second ends; and the method further comprises welding said first
and second ends of said shroud to said base pipe.
19. The method of claim 15 further comprising: swaging said shroud
by passing said filter assembly through a die that reduces the
outer diameter of said shroud.
Description
TECHNICAL FIELD
[0001] The present disclosure relates generally to completion
equipment utilized in conjunction with a subterranean well such as
a well for recovery of oil, gas, or minerals. More particularly,
the disclosure relates to sand control filter assemblies and
methods for their manufacture.
BACKGROUND
[0002] Oil and gas wells may be completed in a producing formation
containing fines and sand which may flow with the fluids produced
from the formation, regardless of whether the well is completed as
an open hole or as a cased hole. The fines and sand in the produced
fluids can abrade and otherwise damage completion equipment, for
example seals, pump seats, rod pumps, completion tubing, and other
completion equipment. To control and limit fines and sand
propagation into the completion equipment, filters in the form of
sand screens may be installed in the completion equipment string
and gravel may be packed around the screen, for example adjacent a
perforated casing section.
[0003] Such sand control filter assemblies are commonly constructed
by installing one or more screen jackets on a perforated base pipe.
The screen jackets typically include a coarse filter layer, which
may be formed by single wire wrapped around a plurality of
longitudinally extending ribs, for example. Once installed on the
base pipe, the ribs provide certain support to the layer and
function as a stand-off between the screen and the base pipe to
create a drainage layer for fluid travel. The filter assembly may
further include an outer protective member, such as a perforated
shroud, for protecting from abrasion and impacts. Conventionally,
screen jackets have been secured to the base pipe and sealed by
welding or crimping a ring thereabout.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Embodiments are described in detail hereinafter with
reference to the accompanying figures, in which:
[0005] FIG. 1 is an elevation view in partial cross section of a
well system according to an embodiment, including a plurality of
sand control filter assemblies located in an open wellbore
section;
[0006] FIG. 2 is an enlarged elevation view in partial cross
section of a portion of a well system according to an embodiment,
including a plurality of sand control filter assemblies located in
a cased wellbore section;
[0007] FIG. 3 is a transverse cross section of a filter assembly of
FIG. 1 or 2 according to an embodiment, showing multiple filter
layers of woven wire mesh sandwiched between a perforated base pipe
and a perforated shroud;
[0008] FIG. 4 is an axial cross section of the filter assembly of
FIG. 3;
[0009] FIG. 5 is a perspective view of a swatch of woven wire
volumetric mesh according to an embodiment for use in forming the
multiple filter layers in the filter assembly of FIGS. 3 and 4;
[0010] FIG. 6 is an elevation view of the perforated base pipe of
the filter assembly of FIGS. 3 and 4;
[0011] FIG. 7 is an elevation view of the perforated base pipe of
FIG. 6 being wrapped with woven wire mesh to form the multiple
filter layers of the filter assembly of FIGS. 3 and 4;
[0012] FIG. 8 is an exploded elevation view of the filter-wound
base pipe and the shroud of the filter assembly of FIGS. 3 and
4;
[0013] FIG. 9 is an elevation view of the filter assembly of FIG. 8
passing through a die for swaging the shroud into intimate contact
with the outer filter layer;
[0014] FIG. 10 is an elevation view of the filter assembly of FIG.
9 after swaging, showing ends of the shroud welded to the base
pipe; and
[0015] FIG. 11 is a flowchart depicting a method of manufacture as
illustrated in FIGS. 6-10, according to an embodiment.
DETAILED DESCRIPTION
[0016] The foregoing disclosure may repeat reference numerals
and/or letters in the various examples. This repetition is for the
purpose of simplicity and clarity and does not in itself dictate a
relationship between the various embodiments and/or configurations
discussed. Further, spatially relative terms, such as "beneath,"
"below," "lower," "above," "upper," "uphole," "downhole,"
"upstream," "downstream," and the like, may be used herein for ease
of description to describe one element or feature's relationship to
another element(s) or feature(s) as illustrated in the figures. The
spatially relative terms are intended to encompass different
orientations of the apparatus in use or operation in addition to
the orientation depicted in the figures.
[0017] FIG. 1 is an elevation view in cross-section of a well
system, generally designated 10, according to one embodiment. Well
system 10 may include land drilling, completion, servicing, or
workover rig 11. Although a land-based system is illustrated,
teachings of the present disclosure may also be used in association
with drilling and completion systems including offshore platforms,
semi-submersible, and drill ships as well as any other well system
satisfactory for completing a well. Rig 11 may be located proximate
well head 13. A blow out preventer, christmas tree, and/or and
other equipment associated with servicing or completing a wellbore
(not illustrated) may also be provided at well head 13. Similarly,
rig 11 may also include a rotary table and/or top drive unit (not
illustrated).
[0018] In the illustrated embodiment, a wellbore 12 extends through
the various earth strata. Wellbore 12 has a substantially vertical
section 14, the upper portion of which has cemented therein a
casing string 16 with casing cement 17. Wellbore may also have a
substantially horizontal section 18 that extends through a
hydrocarbon bearing subterranean formation 20. As illustrated,
substantially horizontal section 18 of wellbore 12 may open hole,
i.e., uncased.
[0019] Positioned within wellbore 12 and extending from the surface
is a tubing string 22. Annulus 23 is formed between the exterior of
tubing string 22 and the inside wall of wellbore 12 or casing
string 16. Tubing string 22 provides a conduit for formation fluids
recovered in a completion zone to travel from formation 20 to the
surface. Tubing string 22 is coupled to a completion string 25,
which divides the completion zone into various production intervals
15a, 15b, . . . 15.sub.i adjacent to formation 20.
[0020] The completion string includes a plurality of filter
assemblies 24, each of which is positioned between a pair of
packers 26 that provide a fluid seal between the completion string
22 and wellbore 12, thereby defining the production intervals 15.
Filter assemblies 24 function to filter sand, fines and other
particulate matter out of the production fluid stream. Filter
assemblies 24 may also be useful in controlling the flow rate of
the production fluid stream.
[0021] Although FIG. 1 illustrates completion string 22 and filter
assemblies 24 being used in an open hole environment, such are
equally well suited for use in cased wells. FIG. 2 is an enlarged
elevation view in partial cross-section of a well system of a well
system 10' according to an embodiment, in which completion string
22 and filter assemblies 24 are used in a portion of wellbore 12'
that is lined with casing 16. Prior to installation of filter
assemblies 24, the casing 16, casing cement 17, and formation 20
have been perforated, such as by a perforating gun, creating
openings 21 for flow of fluid from the formation into wellbore
12'.
[0022] Although FIGS. 1 and 2 illustrate one filter assembly 24 for
each production interval 15, any number of filter assemblies 24 may
be deployed within a production interval as appropriate.
Additionally, even though FIGS. 1 and 2 illustrate filter
assemblies 24 located in a horizontal section 18, 18' of wellbore
12, 12', respectively, filter assemblies 24 are equally well suited
for use in deviated wellbores, vertical wellbores, multilateral
wellbore and the like.
[0023] FIGS. 3 and 4 are transverse and axial cross sections,
respectively, of filter assembly 24 according to an embodiment.
Referring to both FIGS. 3 and 4, filter assembly 24 includes a
central base pipe 30. Base pipe 30 is perforated, having apertures
32 radially formed through its walls along a given filter length.
Each end of base pipe 30 (only one is illustrated) may include a
connection 31, such as a threaded pun or box, for connecting filter
assembly 24 along completion string 22 (FIG. 1).
[0024] Multiple layers 34 of a woven wire mesh 35 are positioned
directly about the outer circumference of base pipe 30 to cover the
entire filter length. Unlike typical sand control screen assemblies
of prior art, filter assembly 24 excludes the coarse conventional
filter layer formed of wire-wound longitudinal ribs that provides a
drainage layer immediately adjacent to the outer circumference of
the base. Instead, filter assembly 24 positions an inner wire-mesh
filter 34a layer directly against base pipe 30. According to a
preferred embodiment, two or more adjacent filter layers of woven
wire mesh are provided. FIGS. 3 and 4 show three adjacent filter
layers 34a, 34b, and 34c, each formed of a woven wire mesh,
although a greater number may be used.
[0025] A tubular shroud 36 covers the outer filter layer 34c along
the filter length. Shroud 36 is perforated, having apertures 38
radially formed through its walls. Shroud 36 protects filter layers
34a, 34b, and 34c from abrasion and impacts. According to an
embodiment, shroud 36 is compressed and plastically deformed into
intimate contact with filter layer 34c, thereby holding all filter
layers 34a, 34b, and 34c in place and sealing the ends of the
filter layers from sand ingress. The ends of shroud 36 may be
welded to base pipe 30 with weld beads 39.
[0026] FIG. 5 is a perspective view of a swatch of an exemplar
woven wire mesh 35 used to form filter layers 34a, 34b, 34c (FIGS.
3-4). In one embodiment, woven wire mesh 35 may be characterized by
an irregular wire weave, which creates a volumetric mesh. Such a
volumetric mesh that is suitable for filtering applications is
commercially available from GKD Solidweave, GKD-USA, Inc.,
Cambridge, Md., USA. As used herein, irregular wire weave means
that each wire does not simply repeated pass over then under
transverse wires in succession. Rather, each wire passes over and
under differing numbers of transverse wires according to a complex
pattern or randomly, thereby creating a mesh with an irregular
pattern of raised ridges and lowered valleys.
[0027] For example, as shown in FIG. 5, volumetric mesh 35 has a
plurality of longitudinally-oriented wires 40a, 40b, . . . 40.sub.n
interwoven with a plurality of transversely-oriented wires 42a,
42b, . . . 42.sub.m. A first transverse wire 42a is woven under
wire 40a, above four adjacent wires 40b-40e, and under four
adjacent wires 40f-40i. The adjacent transverse wire 42b is woven
above wire 40a, under wire 40b, above three adjacent wires 40c-40e,
under three adjacent wires 40f-40h, and above wire 40i. Following
on, the nest adjacent transverse wire 42c is woven above two wires
40a-40b, under wire 40c, above two wires 40d-40e, under two wires
40f-40g, above wire 40h, and under wire 40i. Such irregular weaving
may continue, thereby creating a mesh with an irregular pattern of
raised ridges 44 and lowered valleys 46.
[0028] Referring back to FIGS. 4 and 5, when multiple filter layers
34a, 34.sub.i, 34.sub.i+1 of volumetric mesh 35 are stacked, these
raised ridges 44 and lowered valleys 46 form a network of channels
between the layers, thereby allowing drainage so that fluid
entering the filter layers normal to the mesh can flow generally
longitudinally along filter assembly 24 and through the filter
layers 34 to reach apertures 32 in base pipe 30.
[0029] Although a volumetric mesh is illustrated and described
herein, a regular, symmetrically-woven wire mesh may also be used
to form filter layers 34. Each filter layer that is added alters
the filter micron rating. Accordingly, a filter designer can
selectively control the filtering capability by specifying both the
individual micron rating of the woven wire mesh 35 and the total
number of filter layers 34 to be used therewith. Equally, woven
wire meshes of differing micron filter rating or materials, for
example, may be used for different filter layers 34 as
appropriate.
[0030] FIGS. 6-10 are elevation views of filter assembly 24 as it
is created through the various steps of a manufacturing process
according to one embodiment, and FIG. 11 is a flowchart outlining
the steps of the manufacturing process. Referring to FIGS. 6 and
11, at step 50, a perforated base pipe 30 is provided. Base pipe 30
has apertures 32 radially formed through its walls along a given
filter length. Each end of base pipe 30 may include a connection
31, such as a threaded pin or box, for connecting filter assembly
24 along completion string 22 (FIG. 1).
[0031] Next, referring to FIGS. 7 and 11, multiple filter layers
34, such as filter layers 34a, 34b, 34c, are disposed about base
pipe 30. At step 52, woven wire mesh 35 is disposed directly
adjacent about the outer circumference of base pipe 30 to form
inner filter layer 34a. Although mesh 35 can be deployed in various
ways, in one or more embodiments mesh 35 is wound onto base pipe
30, thereby enhancing ease of manufacture. One or more intermediate
filters layers 34b of woven wire mesh may be provided. At step 54,
woven wire mesh 35 is disposed, such as by winding, about inner
filter layer 34a to form outer filter layer 34c. In one embodiment,
the filter layers are helically wound, although other suitable
methods of application may also be used.
[0032] With reference to FIGS. 8 and 11, at step 56, perforated
shroud 36 is deployed over outer filter layer 34c. Shroud 36 is
perforated, having apertures 38 radially formed through its walls.
Shroud 36 protects filter layers 34 from abrasion and impacts.
[0033] As shown in FIGS. 9 and 11, at step 58 shroud 36 is swaged
into intimate contact with the outer filter layer 34c. Shroud 36 is
compressed and plastically deformed into intimate contact with
filter layer 34c, thereby holding all filter layers 34a, 34b, and
34c in place and sealing the ends of the filter layers from sand
ingress. In one embodiment, shroud 36 is swaged by passing the
filter assembly through a die 70 that reduces the outer diameter of
the shroud. Die 70 may include one or more rollers 72a, 72b, 72c.
The swaging process compresses the multiple filter layers 34a, 34b,
34c together and holds them firmly in place. Moreover, the swaging
process may act to seal the ends of the filter layers from sand
ingress.
[0034] Finally, referring to FIGS. 10 and 11, at step 60, the ends
of shroud 36 may be welded to base pipe 30, further securing and
providing mechanical strength to filter assembly 24. Welds 39 arc
illustrated in FIG. 10.
[0035] In summary, a filter assembly for downhole use and methods
for manufacture thereof have been described. Embodiments of the
filter assembly may generally have a perforated base pipe, an inner
filter layer of a woven wire mesh disposed directly adjacent the
outer circumference of the base pipe, an outer filter layer of a
woven wire mesh disposed about the inner filter layer, and a
perforated shroud disposed directly adjacent and in intimate
contact with the outer filter layer. Embodiments of the method of
manufacture may generally include providing a perforated base pipe,
disposing woven wire mesh directly adjacent about the outer
circumference of the base pipe to form an inner filter layer,
disposing woven wire mesh about the inner filter layer to form an
outer filter layer, positioning a perforated shroud about the outer
filter layer, and swaging the shroud into intimate contact with the
outer filter layer. Embodiments of the method of manufacture may
also generally include providing a perforated base pipe, wrapping
woven wire mesh directly about the outer circumference of the base
pipe to form multiple filter layers, positioning a perforated
shroud about the wrapped woven wire mesh, and swaging the shroud
onto the wrapped woven wire mesh.
[0036] Any of the foregoing embodiments may include any one of the
following elements or characteristics, alone or in combination with
each other: At least one intermediate filter layer of a woven wire
mesh disposed between the inner and outer filter layers; at least
one filter layer of the group consisting of the inner and outer
filter layers includes a volumetric mesh characterized by having an
irregular weave; the at least one filter layer provides for
drainage through the filter assembly; the at least one filter layer
defines a plurality of ridges and a plurality of valleys; the
shroud defines first and second ends; the first and second ends of
the shroud are welded to the base pipe; at least one filter layer
of the group consisting of the inner and outer filter layers is
helically wound about the base pipe; wrapping the woven wire mesh
about the base pipe; wrapping the woven wire mesh about the base
pipe in a helical orientation; disposing woven wire mesh disposed
about the inner filter layer to form at least one intermediate
filter layer between the inner and outer filter layers; at least
one filter layer of the group consisting of the inner and outer
filter layers includes a volumetric mesh characterized by having an
irregular thickness; at least one filter layer forms generally
longitudinal drainage channels through the filter assembly; welding
the first and second ends of the shroud to the base pipe; swaging
the shroud into intimate contact with the outer filter layer by
passing the filter assembly through a die that reduces the outer
diameter of the shroud; the die includes at least one roller; the
inner and outer filter layers define first and second ends; sealing
the inner and outer filter layers and the shroud to the base pipe
by swaging the shroud; the woven wire mesh is a volumetric mesh
characterized by having an irregular thickness; and the multiple
filter layers provide for drainage through the filter assembly.
[0037] The Abstract of the disclosure is solely for providing a way
by which to determine quickly from a cursory reading the nature and
gist of technical disclosure, and it represents solely one or more
embodiments.
[0038] While various embodiments have been illustrated in detail,
the disclosure is not limited to the embodiments shown.
Modifications and adaptations of the above embodiments may occur to
those skilled in the art. Such modifications and adaptations are in
the spirit and scope of the disclosure.
* * * * *