This description relates to filtration apparatus for use in subterranean wellbores.
For centuries, wells have been drilled to extract oil, natural gas, water, and other fluids from subterranean formations. In extracting the fluids, a production string is provided in a wellbore, both reinforcing the structural integrity of the wellbore, as well as assisting in extraction of fluids from the well. To allow fluids to flow into production string, apertures are often provided in the tubing string in the section of the string corresponding with production zones of the well. Although perforations allow for ingress of the desired fluids from the formation, these perforations can also allow unwanted materials to flow into the well from the surrounding foundations during production. Debris, such as formation sand and other particulate, can fall or be swept into the tubing together with formation fluid, contaminating the recovered fluid. Not only do sand and other particulates contaminate the recovered fluid, this particulate can cause many additional problems for the well operator. For example, as the particulate flows through production equipment, it gradually erodes the equipment, accumulate in chambers, and block flow passages. Repairing and replacing production equipment damaged by particulate in-flow can be costly and time-consuming, particularly for downhole equipment sometimes located several thousand feet below the Earth's surface. Consequently, to guard against particulate from entering production equipment, while at the same time preserving sufficient fluid flow pathways, various production filters and filtration methods have been developed and employed including gravel packs and well screen assemblies.
A number of well screen filtration designs have been employed. A well screen assembly is a screen of one or more layers installed in the well, capable of filtering against passage of particulate of a specified size and larger, such as sand, rock fragments and gravel from surrounding gravel packing. The specific design of the well screen can take into account the type of subterranean formation likely to be encountered, as well as the well-type.
This description relates to filtration apparatus for use in subterranean wellbores, for example, well screen assemblies.
In certain aspects, a well screen assembly has an elongate tubular base pipe defining apertures extending between the interior and exterior of the base pipe. A screen layer is carried on the base pipe and includes a wire that has been wrapped helically around the exterior of the base pipe. A crimp ring is affixed to the base pipe and encircles the base pipe and an end of the screen layer. The crimp ring is plastically deformed about an outer surface of the screen layer.
In certain aspects, a method for constructing a well screen assembly includes positioning a crimp ring encircling and over an end of a wrapped-on-pipe screen layer on a tubular base pipe. The crimp ring is plastically deformed about an outer surface of the screen layer. Weld is applied to affix the crimp ring to the base pipe.
In certain aspects, a method includes wrapping a wire helically around a base pipe to define a screen layer. A crimp ring is introduced over an end of the screen layer. The crimp ring is plastically deformed around the screen layer and securing the screen layer to the base pipe.
One or more of the aspects include some, none or all of the following features. In certain instances, an end ring is affixed to the base pipe and encircles the base pipe. The crimp ring is plastically deformed about an outer surface of the end ring. The crimp ring is welded to the end ring, and the end ring is welded to the base pipe. The end ring is continuous or split. In certain instances, the split end ring includes a plurality of arcuate ring segments assembled about the base pipe. In certain instances, the end ring is omitted and the crimp ring is welded to the base pipe. The crimp ring is deformed into contact with the outer surface of the screen layer. In certain instances, the material of the screen layer and the material of the base pipe are incompatible for welding. In certain instances, a second crimp ring is affixed to the base pipe and encircles the base pipe and a second end of the screen layer, the second crimp ring plastically deformed about the outer surface of the screen layer.
The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.
Like reference symbols in the various drawings indicate like elements.
Although shown in the context of a horizontal well system 10, well screen assemblies 12 can be provided in other well configurations, including vertical well systems having a vertical or substantial vertical wellbore, multi-lateral well systems having multiple wellbores deviating from a common wellbore and/or other well systems. Also, although described in a production context, well screen assemblies 12 can be used in other contexts, including injection, well treatment and/or other applications.
The screen assembly 200 is formed by wrapping the wire 214 helically around the exterior of the base pipe 210. Then, a end ring 216 is placed on the base pipe 210, encircling the base pipe 210 and adjacent, and in some instances adjacent and contacting, the end of the screen layer 220. In certain instances, the end ring 216 can be a continuous ring. In certain instances the end ring 216 can be split such that the end ring can be opened and placed laterally over the base pipe 210, rather than requiring the end ring to be introduced over the end of the base pipe 210 and passed over the base pipe 210 into position. In certain instances, the end ring 216, when split, need not account for irregularities (e.g., ovality, thickness and diameter variations, and other irregularities) over the entire or other length of the base pipe 210, because it need not pass over the length of the base pipe 210. Furthermore, in certain instances, it can be more convenient to place the end ring 216 laterally over the base pipe 210 when, for example, the screen layer 220 terminates intermediate a length of the base pipe 210 rather than adjacent an end.
The split end ring 216 can be two or more arcuate, C-shaped ring segments 216a, 216b as in
The end ring 216 is secured to the base pipe and/or the screen layer 220. In certain instances, the end ring 216 is tack welded to the base pipe 210 and/or the screen layer 220. Tack welding is a technique where short segments or points of weld are applied at spaced out intervals, rather than a continuous or a long stitch weld. In other instances, the end ring 216 can be clamped, secured by fasteners, secured with adhesive, and/or secured another manner. The end ring 216 need not be permanently and strongly secured to the base pipe 210, because as is discussed below, the end ring 216 will be further secured to the base pipe in a later construction step. In certain instances, the end ring 216 is provided with a weld bevel 217 opposite the surface facing the screen layer 220 to facilitate formation of a weld bead between the end ring 216 and the outer surface of the base pipe 210.
A crimp ring 218 (
Thereafter, the crimp ring 218, end ring 216 and base pipe 210 are welded together by forming one or more beads of weld 222 circumferentially around and contacting the interface between the crimp ring 218 and the end ring 216 and the interface between the end ring 216 and the base pipe 210 as shown in
Because the base pipe 210 and crimp ring 218 need not be welded to the screen layer 220, the screen layer 220 can be made of materials that cannot be welded or readily welded with the materials of the base pipe 210 and crimp ring 218.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other implementations are within the scope of the following claims.
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