SAND SCREEN

Abstract

A sand screen including a base pipe. A plurality of individual segments having complementary perimetrically interlocking shapes configured to be nested together so as to limit relative movement among the elements and to form a tubular filtration media about the base pipe. End rings engaging the filtration media and the base pipe.

Description

BACKGROUND

In the drilling and completion industry, the formation of boreholes for the purpose of recovering hydrocarbons necessarily is accompanied by sand. Sand control therefore is a significant concern for operators and must be addressed in the downhole environment prior to its production with target fluids. This is because flowing sand is damaging to production equipment from the standpoint of erosion and further because it can adversely affect other equipment such as pumps, etc. Also notable is that the production of sand from the formation in which a borehole exists will tend to enlarge the borehole and increase the probability of cave ins, wash outs, etc., that would require remedial activity at not insignificant cost both in actual dollars and in lost production time.

The art is therefore very concerned with sand control and has developed a plethora of types of sand screen and such to mitigate the problem. In view of ever changing conditions and techniques however, the art is always in need of and receptive to alternative arrangements.

BRIEF DESCRIPTION

A sand screen includes a base pipe; a plurality of individual segments having complementary perimetrically interlocking shapes configured to be nested together so as to limit relative movement among the elements and to form a tubular filtration media about the base pipe; end rings engaging the filtration media and the base pipe.

A building component for a sand screen including a segment; a plurality of merlons and a plurality of crenels at one longitudinal end of the segment; a plurality of merlons and a plurality of crenels at an opposite longitudinal end of the segment, the merlons being configured and dimensioned to be received in a crenel of a mating segment such that adjacent side surfaces of each mated merlon will form a passageway therebetween.

A sand screen cartridge includes a plurality of individual segments having complementary perimetrically interlocking shapes configured to be nested together so as to limit relative movement among the elements and to form a tubular filtration media; end rings engaging the filtration media and the base pipe; and a shroud spanning the filtration media and affixed to the end rings.

A sand screen including a base pipe; a plurality of individual segments having complementary perimetrically interlocking shapes configured to be nested together so as to limit relative movement among the elements and to form a first tubular filtration media about the base pipe; another plurality of individual segments having complementary perimetrically interlocking shapes configured to be nested together so as to limit relative movement among the elements and to form a second tubular filtration media about the base pipe stacked adjacent the first tubular filtration media; end rings engaging the first and second filtration media and the base pipe; and a shroud spanning the first and second filtration medias.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:

FIG. 1 is a perspective view of a segment for a sand screen as disclosed herein;

FIG. 2 is a schematic view of the segment of FIG. 1 illustrating side surface angles of merlons;

FIG. 3 is another schematic view of the segment of FIG. 1 illustrating side surface angles of merlons;

FIG. 4 is a schematic view of a passageway through side surfaces of adjacent merlons;

FIG. 5 is a schematic perspective view of a sand screen as disclosed herein; and

FIG. 6 is a schematic perspective view of a sand screen having multiple sand screen cartridges thereon.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

Referring to FIG. 1, a single segment 10 is illustrated. In this embodiment, the segment is a closed annular form (e.g. a ring) but part annular forms are also contemplated. In some embodiments the segments are constructed of hard erosion resistant material and may be a ceramic material. Other hard metal or plastic is also contemplated. If indeed a ceramic material is selected, the material may comprise for example Sintered Boron Carbide, Silicon Carbide, etc.

Still referring to FIG. 1, segment 10 is castellated on both longitudinal ends 12 and 14, the axis defining longitudinal in this case. The castellation in direction 12 is a mirror image longitudinally from the castellation in direction 14. It is to be understood however, that it is not required that the castellations be mirrored end to end but to be appreciated that the castellation may be different in shape, different in register relative to castellations on the opposite end, etc. Rather what is important is that a plurality of the segments need to nest together to form a tubular structure that presents pathways for fluid to move therethrough. This can be accomplished with mirror imaged configuration as illustrated or with more complexity with other configurations. An advantage of the segments being mirror images on each end or at least mirrored shapes on both ends is that the plurality of segments may be identical to each other allowing for easy assembly into the tubular form without need to ensure the right segments are nesting with the right other segments. Rather each will nest identically with the next. It should also be appreciated that although a cylindrical shape of the segments is illustrated, other tubular shapes are also contemplated.

Still referring to FIG. 1, standoffs 16 are illustrated at an inside surface 18 of the segment 10. These may be of any number but likely not fewer than three and function to provide a drainage gap between the plurality of segments and a basepipe around which they will be positioned when the sand screen is assembled (see FIG. 4). In other words, the standoffs 16 will abut an outside surface of the basepipe and ensure that the inside surface 18 of the plurality of segments 10 will not contact the outside surface of the basepipe.

Also to be noted though relatively small in FIG. 1 (more easily seen in FIGS. 2 and 3) is a keying feature such as an offset 20, of which there are two in each crenel 22 of the segment 10 as illustrated. It is to be understood that this is but one embodiment of a configuration to ensure that the nested segments 10 (creating a filtration media 11) register properly with one another to ensure that the intended fluid passageways will be substantially uniformly distributed. Other offset or key and keyway type arrangements may be substituted while achieving the same results. Barring a configuration providing for this registration function, the segments might turn relative to one another thereby creating a larger passageway on one side of a castellation that intended and a smaller one on the other side of the same castellation. This would reduce functionality of the sand screen.

Referring to FIGS. 1, 2 and 3 together enlarged views will improve understanding of the features mentioned and facilitate description of the shape of the castellations themselves. In one embodiment of the segment 10 the castellations comprise a number of trapezoidal merlons 24 interspaced by crenels 22. In some embodiments, like the one illustrated, the merlons and crenels are sized to fit within each other or nest. Specifically, a crown surface 26 is configured to fit with crenel base surface 28, between the offsets 20. During construction of the sand screen, the crown surfaces 26 of each of the segments 10 to be used are coated with a resilient sealer such as a rubber or similar and will seal with surface 28. At the sides of the merlons however, the surfaces 30, it is intended that passageways 32 be formed, see FIG. 4. For this purpose, the side surfaces 30 are dimensioned and configured to be spaced apart from an adjacent merlon when the segments are nested together. This is accomplished in part by the offsets 20 and in part by the dimensions of the merlon itself relative to the dimensions of the crenel. The crenel 22 is slightly wider than the merlon that extends thereinto when nested. Further, in some embodiments it is desirable to have surfaces 30 when nested be parallel to each other, although it is certainly possible and in some cases could be desirable to have diverging or converging passageways simply by adjusting the angle of the surfaces 30. In order to effect a parallel result, the actual radial angle of the surface 30 relative to a radial line drawn from the axis of the segment is about 1 degree different than the radial line resulting in a narrower merlon toward the inner surface of the segment than at the outer surface of the segment. A longitudinal angle of surface 30 of the trapezoid of merlon 24 is selectable as desired and in some embodiments ranges from about 0.5 degrees to about 10 degrees. The greater the angle, the longer the particular flow passageway. For some iterations of the segments 10, the greater angle may provide for more flow area but it is also to be appreciated that a smaller angle coupled with more merlons 24 may provide an even greater total flow area even though the individual flow passageways would be shorter in length.

Referring to FIG. 5, an assembled sand screen comprising a plurality of segments nested together (the filtration media 11) is illustrated. End rings 34 are also illustrated that in some embodiments are rubbery type material and configured to mate with a last of a plurality of segments on an axial end of a stack of such segments (filtration media 11) as shown. The end rings 34 have an inside diameter that is close to an outside diameter of a base pipe 36 to which they are mated. In some embodiments there will also be a metal backup 38 that may be welded to the base pipe 36 to help retain the other components in place. And finally, an optional shroud 40 is shown radially outwardly placed of the stacked segments and welded to the metal backups 38 and/or affixed to the end rings 34 by for example swaging. In the first instance, because a base pipe 36 is included, the welding of the shroud to the backups 38 will keep it in place. In the second instance however, while the affixation to the end rings 34 may be used with a basepipe, it further facilitates the construction of a sand screen cartridge 39 comprising the plurality of segments 10 (filtration media 11), the end rings 34 and the shroud 40 but without the base pipe. Embodiments directed to cartridges may optionally also contain backups 38 welded to the shroud 40. The cartridge embodiments allow for an additional marketing opportunity as the sand screen cartridge may be sold and transported without a basepipe and thence may be installed on a base pipe at the well site or some other location that is convenient.

In another embodiment, referring to FIG. 6, the shroud 40 is a unifying component for a number of individual cartridges 39. More specifically, the filtration media 11 and end rings may be assembled in, for example only, 18 inch increments and then other of that same construction (or even other lengths) stacked adjacent each other on a base pipe, all of which are spanned by a single shroud. This would provide a more flexible sand screen and may simplify shipping since the sand screen cartridges would be small and relatively light weight when compared to a complete sand screen including the base pipe. It also would allow an operator to make a sand screen as long as is needed for the specific application by stacking cartridge segments to the desired length and cutting or extending the shroud to span them.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should further be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity).

The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc.

While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited.

Claims

1. A sand screen comprising:

a base pipe;

a plurality of individual segments having complementary perimetrically interlocking shapes configured to be nested together so as to limit relative movement among the elements and to form a tubular filtration media about the base pipe;

end rings engaging the filtration media and the base pipe.

2. A sand screen as claimed in claim 1 wherein the plurality of segments include offsets to space certain faces of the plurality of elements from mating faces of the plurality of elements to create radial fluid passageways through the filtration media.

3. A sand screen as claimed in claim 1 wherein the plurality of segments further include standoffs to space the segments from the base pipe.

3. A sand screen as claimed in claim 1 wherein the plurality of segments are rings.

4. A sand screen as claimed in claim 3 wherein the rings are castellated by merlons and crenels.

5. A sand screen as claimed in claim 4 wherein the merlons include side surfaces that are angled at about 1 degree less than an angle represented by a radial line from an axis of the rings.

6. A sand screen as claimed in claim 5 wherein the side surfaces are angled to so that mating side surfaces of adjacent merlons are parallel therewith.

7. A sand screen as claimed in claim 4 wherein the merlons include side surfaces that when nested with mating side surfaces of adjacent merlons produce one of narrowing pathways from an outer surface of the filtration media to an inner surface of the filtration media or widening pathways from an outer surface of the filtration media to an inner surface of the filtration media.

8. A sand screen as claimed in claim 4 wherein each merlon includes a side surface at an angle to a line parallel to an axis of the ring of about 0.5 to about 15 degrees.

9. A sand screen as claimed in claim 8 wherein an opposite side surface of the merlon has a mirror imaged angle.

10. A sand screen as claimed in claim 4 further comprising a sealing material disposed upon a crown of each merlon.

11. A sand screen as claimed in claim 10 wherein the sealing material creates a seal between the crown of each merlon and a base of each crenel of a mating ring.

12. A sand screen as claimed in claim 11 wherein the sealing material is a polymer.

13. A sand screen as claimed in claim 1 wherein the plurality of hard segments comprise a highly erosion resistant material.

14. A sand screen as claimed in claim 13 wherein the material comprises ceramic.

15. A sand screen as claimed in claim 14 wherein the ceramic comprises Sintered Boron Carbide and/or Silicon Carbide.

16. A building component for a sand screen comprising:

a segment;

a plurality of merlons and a plurality of crenels at one longitudinal end of the segment;

a plurality of merlons and a plurality of crenels at an opposite longitudinal end of the segment, the merlons being configured and dimensioned to be received in a crenel of a mating segment such that adjacent side surfaces of each mated merlon will form a passageway therebetween.

17. A building component for a sand screen as claimed in claim 16 wherein the segment is annular.

18. A building component for a sand screen as claimed in claim 16 wherein the segment includes a keying feature to ensure adjacent segments when stacked to form a filtration media are registered.

19. A sand screen cartridge comprising:

a plurality of individual segments having complementary perimetrically interlocking shapes configured to be nested together so as to limit relative movement among the elements and to form a tubular filtration media;

end rings engaging the filtration media and the base pipe; and

a shroud spanning the filtration media and affixed to the end rings.

20. A sand screen comprising:

a base pipe;

a plurality of individual segments having complementary perimetrically interlocking shapes configured to be nested together so as to limit relative movement among the elements and to form a first tubular filtration media about the base pipe;

another plurality of individual segments having complementary perimetrically interlocking shapes configured to be nested together so as to limit relative movement among the elements and to form a second tubular filtration media about the base pipe stacked adjacent the first tubular filtration media;

end rings engaging the first and second filtration media and the base pipe; and

a shroud spanning the first and second filtration medias.