DEHYDRATOR SCREEN FOR DOWNHOLE GRAVEL PACKING
Technical Field of the Invention
[0001] The present invention relates generally to dehydrator screens in
wellbores in subterranean formations and, more particularly (although not
necessarily exclusively), to a dehydrator screen that can direct fluid from a
gravel pack slurry to a main screen associated with a base pipe in the
well bore.
Background
[0002] Various devices can be installed in a wellbore traversing a
hydrocarbon-bearing subterranean formation. For example, screens can be
positioned with sections of base pipe in a wellbore. The screens can filter
particulate material from fluid prior to the fluid being received by an inner
section of the base pipe. Another example is gravel packs that may be
provided downhole in a slurry that includes a carrier fluid, gravel and other
material. The gravel packs may be positioned between a base pipe and
components associated with a base pipe and an inner wall of the wellbore to
provide support or other functions.
[0003] Carrier fluid is removed from the slurry for a gravel pack to form
downhole. The screens may allow the carrier fluid to drain from the slurry to
create the gravel pack. It can be difficult to create a gravel pack, however,
between screens and around a coupling between portions of a base pipe
since fluid drainage may be limited or non-existent in those areas. Drainage
tubes may be used to provide an alternate path for carrier fluid to drain from
these areas, for example. The drainage tubes include precision-cut slots and
can allow carrier fluid to drain from those areas to the screens.
[0004] Drainage tubes are made by making precise cuts using a laser to
a tubing to create slots. Precise cuts are expensive, time intensive, and may
result in a flow area of less than desirable size.
[0005] Accordingly, devices and assemblies are desirable that can filter
and direct carrier fluid from a gravel pack slurry using a more desirable flow
area and avoiding precise cuts.
Summary
[0006] Certain aspects of the present invention are directed to a
dehydrator screen that can direct fluid from a gravel pack slurry toward one or
more main screens and that are made while avoiding precise cuts.
[0007] One aspect relates to an assembly that includes a dehydrator
screen. The dehydrator screen can be positioned exterior to a base pipe in a
wellbore. The dehydrator screen can direct fluid from a gravel pack slurry
exterior to the base pipe toward a main screen that is associated with the
base pipe. The dehydrator screen includes openings and is formed from at
least one of stamped metal, wire wrap, or mesh material.
[0008] Another aspect relates to an assembly that includes a base pipe,
at least two main screens, and a dehydrator screen. The main screens can
circumferentially surround portions of the base pipe in the wellbore. The
dehydrator screen includes an elongated element, openings in the elongated
element, and at least two sealed ends. The dehydrator screen is (i)
positionable exterior to part of the base pipe and the main screens in the
wellbore and (ii) adapted for directing fluid from a gravel pack slurry exterior to
the base pipe toward at least one of the main screens.
[0009] Another aspect relates to a dehydrator screen that includes an
elongated element, openings in the surface of the elongated element, and
sealed ends. The dehydrator screen is positionable in a wellbore exterior to a
base pipe and a main screen associated with the base pipe. The dehydrator
screen is adapted for directing fluid from a gravel pack slurry exterior to the
base pipe toward the main screen.
[001 0] These illustrative aspects are mentioned not to limit or define the
invention, but to provide examples to aid understanding of the inventive
concepts disclosed herein. Other aspects, advantages, and features of the
present invention will become apparent after review of the entire document
and drawings.
Brief Description of the Drawings
[001 1] Fig. 1 is a schematic illustration of a well system having an
assembly that includes a dehydrator screen according to one example.
[00 2] Fig. 2 is a perspective view of a dehydrator screen that is a wire
wrap screen according to one example.
[001 3] Fig. 3 is a perspective view of the dehydrator screen of Fig. 2
without a capped end according to one example.
[0014] Fig. 4 is a side view of the dehydrator screen of Fig. 2 according
to one example.
[001 5] Fig. 5 is a perspective view of a dehydrator screen that includes
punched openings according to another example.
[001 6] Fig. 6 is a close-up view of the surface of the dehydrator screen
of Fig. 5 according to one example.
[001 7] Fig. 7 is a schematic side view of a punched portion of the
dehydrator screen of Fig. 5 according to one example.
[001 8] Fig. 8 is a schematic side view of a portion of the punched
dehydrator screen with direction of fluid flow according to one example.
[001 9] Fig. 9 is a perspective view of a dehydrator screen that is mesh
according to another example.
[0020] Fig. 0 is a perspective view of a dehydrator screen that is a
shroud coupled to mesh according to another example.
[0021] Fig. is a perspective view of a dehydrator screen that includes
a first shroud, mesh, and a second shroud according to another example.
Detailed Description
[0022] Certain aspects and features relate to dehydrator screens that
are inexpensively made wire, stamped metal, or mesh screens that can direct
carrier fluid from a gravel pack slurry efficiently to one or more screens
associated with a base pipe. Dehydrator screens according to some aspects
can be any shape, easy and inexpensive to manufacture, increase flow area
by twenty to thirty percent, and increase efficiency of dehydration or filtering of
carrier fluid from a gravel pack slurry.
[0023] One example of a dehydrator screen is a wire screen that may
act as a drainage tube or be used with a drainage tube. The wire screen may
be a wire wrap tube or other elongated member with two ends and openings
in an outer surface. Both ends can be sealed by welding plates to the ends,
shrink caps on the ends, or crush each end and weld any gap. Sealed ends
may help direct fluid toward one or more other screens that may be main
screens of a downhole assembly.
[0024] Another example of a dehydrator screen is a mesh screen that
includes a mesh material seam welded to form a tube or other elongated
member. The ends of the mesh screen may or may not be sealed.
[0025] Another example of a dehydrator screen is a screen formed by
stamping a strip of metal, such as by using a louvered-type stamp, to create
punched openings. The size and shape of the openings can be controlled
through stamping. The metal strip can be formed into a tube or other shaped
elongated member by helically welding the metal strip or by rolling the metal
strip longitudinally and welding the seam. The ends of the tube or other
elongated member can be sealed in ways similar to the wire screen described
above.
[0026] Certain aspects provide a dehydrator screen that can be made
anywhere, even at a wellbore site, at low cost, and can be made to a
customized length for a given application. A dehydrator screen according to
various aspects can avoid the need for precisely cut slots. Certain dehydrator
screens can allow openings in the surface of the dehydrator screens to be
adjusted, such as depending on the type or size of gravel.
[0027] These illustrative examples are given to introduce the reader to
the general subject matter discussed here and are not intended to limit the
scope of the disclosed concepts. The following sections describe various
additional aspects and examples with reference to the drawings in which like
numerals indicate like elements, and directional descriptions are used to
describe the illustrative embodiments but, like the illustrative embodiments,
should not be used to limit the present invention.
[0028] Fig. 1 depicts a well system 100 with a dehydrator screen 116
according to one aspect of the present invention. The well system 100
includes a bore that is a wellbore 102 extending through various earth strata.
The wellbore 102 has a substantially vertical section 104 and a substantially
horizontal section 106. The substantially vertical section 104 and the
substantially horizontal section 106 may include a casing string 108 cemented
at an upper portion of the substantially vertical section 104. The substantially
horizontal section 106 extends through a hydrocarbon bearing subterranean
formation 110.
[0029] A tubing string 112 that is a base pipe extends from the surface
within wellbore 102. The tubing string 112 can provide a conduit for carrier
and formation fluids to travel from the substantially horizontal section 106 to
the surface. Screens 114 are positioned circumferential to portions of the
tubing string 112 to define intervals. The dehydrator screen 116 is positioned
exterior to the tubing string 112. The dehydrator screen 116 is depicted as
being proximate to both screens 114. In other examples, the dehydrator
screen 116 is proximate to one, but not both screens 114, or otherwise
positioned with respect to one or more of the screens 114.
[0030] A gravel pack slurry may be provided down the wellbore 102 to
the screens 114. The dehydrator screen 116 can direct carrier fluid away
from the gravel pack slurry, even the slurry between the screens 114, to one
or more of the screens 114 such that the carrier fluid is substantially removed
from the gravel pack slurry.
[0031] Although Fig. 1 depicts screens 114 and the dehydrator screen
116 positioned in the substantially horizontal section 106, screens 114 and
the dehydrator screen 116 according to other examples can be located,
additionally or alternatively, in the substantially vertical section 104.
Furthermore, any number of screens 114 and dehydrator screens 116,
including one of each, can be used in the well system 100 generally. In some
embodiments, screens 114 and the dehydrator screen 116 can be positioned
in simpler wellbores, such as wellbores having only a substantially vertical
section. Screens 114 and the dehydrator screen 116 can be positioned in
open hole environments, such as is depicted in Fig. 1, or in cased wells.
[0032] Figs. 2-4 depict an example of a dehydrator screen 200 that is a
wire screen. The wire screen may be formed from a wire wrap tube 202 with
ends 204, 206 sealed by a sealing mechanism 208. The sealing mechanism
208 may include plates welded on each of the ends 204, 206 (as shown in
Figs. 2 and 4). Other examples of the sealing mechanism 208 include
shrinking caps on each of the ends 204, 206 and crushing each of the ends
204, 206 and welding any gap.
[0033] The wire wrap tube 202 includes wires 210 with openings 212
between the wires 210. Framing wires 214, shown in Fig. 3 with the sealing
mechanism removed and in the side view cross-section of Fig. 4, may be
located in an inner region of the wire wrap tube 202 to provide stability to the
dehydrator screen structure.
[0034] The openings 212 can allow carrier fluid from a gravel pack
slurry to enter the inner region of the wire wrap tube 202 and be directed
toward one or more main screens with respect to which the dehydrator screen
is positioned, as shown for example in Fig. 1.
[0035] Figs. 5-8 depict another example of a dehydrator screen 300 that
is formed from stamped metal. The dehydrator screen 300 includes punched
openings 302 formed by stamping a metal strip and forming the metal strip
into a tube 304, shroud, or other elongated structure. The ends 306, 308 can
be sealed using a sealing mechanism 310, such as those described above in
connection with Figs. 2 and 4 . In one example, the punched openings 302
can be formed using a louvered-type stamp on a metal strip that is a shroud.
The metal strip can be rolled and a seam welded to form the tube or other
elongated structure. Fig. 6 is a close-up view of a surface of the dehydrator
screen 300 that includes punched openings 302 and a welded seam 312.
[0036] Fig. 7 depicts an example of a punched opening 302. The
punched opening 302 includes two gaps 314, 316 formed after the metal strip
is punched. The gaps 314, 316 can allow fluid to enter an inner region of the
dehydrator screen, as shown in Fig. 8, and directed towards one or more
main screens.
[0037] Dehydrator screens according to other aspects may be formed
using mesh. Mesh material may be interweaved or interlaced material
forming a structure having openings. Figs. 9-1 1 depict examples of
dehydrator screens at least partially formed using mesh.
[0038] Fig. 9 depicts a dehydrator screen 400 that includes an
elongated element 402 of mesh material 404. The mesh material 404 can be
rolled and coupled using a mechanism such as a welded seam 406 to form
the elongated element. The mesh material 404 includes openings through
which carrier fluid from a gravel pack slurry can be received and directed
towards one or more main screens. The ends of dehydrator screen 400 may
or may not be sealed. If the ends are sealed, the ends can be sealed using
any suitable sealing mechanism, such as those discussed above.
[0039] Fig. 10 is a dehydrator screen 500 that includes two elongated
elements. The first elongated element 502 can be formed by stamping a strip
of metal to form punched openings 504 and rolling or otherwise coupling the
strip of metal together. The second elongated element 506 can be formed
from mesh material as in Fig. 9 and can circumferentially surround at least
part of the first elongated element 502. In other examples, the second
elongated element 506 completely surrounds the first elongated element 502.
The second elongated element 506 can be coupled to the first elongated
element 502 via a weld 508 or other suitable mechanism.
[0040] The ends of each of the first elongated element 502 and the
second elongated element 506 may or may not be sealed. In some
examples, the ends of the first elongated element 502 are not sealed and the
ends of the second elongated element 506 are sealed.
[0041] Openings in the mesh material of the second elongated element
506 can allow carrier fluid from a gravel pack slurry to flow to openings in the
first elongated element 502 and be received in an inner region of the first
elongated element 502. The dehydrator screen 500 can direct the fluid
toward one or more main screens.
[0042] Fig. 11 is a dehydrator screen 600 that includes three elongated
elements. The first elongated element 602 and the second elongated
element 604 may be similar to the first elongated element 502 and the second
elongated element 506 of Fig. 10, except that the first elongated element 502
and the second elongated element 506 are not welded together. The third
elongated element 606 partially or completely surrounds the first elongated
element 602 and the second elongated element 604. The third elongated
element 606 can be formed by stamping a strip of metal to form punched
openings 608 and rolling or otherwise coupling the strip of metal together.
[0043] The ends of each of the first elongated element 602, the second
elongated element 604, and the third elongated element 606 may or may not
be sealed.
[0044] The dehydrator screen 600 can filter carrier fluid from a gravel
pack slurry and allow the fluid to flow to an inner region defined by the first
elongated element 602, and direct the fluid toward one or more main screens.
[0045] The foregoing description of certain features, including illustrated
features, of the invention has been presented only for the purpose of
illustration and description and is not intended to be exhaustive or to limit the
invention to the precise forms disclosed. Numerous modifications,
adaptations, and uses thereof will be apparent to those skilled in the art
without departing from the scope of this invention.
Claims
What is claimed is:
1. An assembly, comprising:
a dehydrator screen (i) configured to be positioned exterior to a base
pipe in a wellbore and (ii) adapted for directing fluid from a gravel pack slurry
exterior to the base pipe toward a main screen that is associated with the
base pipe, wherein the dehydrator screen comprises a plurality of openings
and is formed from at least one of stamped metal, wire wrap or mesh
material.
2 . The assembly of claim 1, wherein the dehydrator screen comprises a
first end that is sealed and a second end that is sealed.
3 . The assembly of claim 1, wherein the dehydrator screen comprises an
elongated element formed from the stamped metal,
wherein the plurality of openings comprise a plurality of punched
openings in an outer surface of the elongated element.
4 . The assembly of claim 3, wherein the plurality of punched openings in
the outer surface of the elongated element is configured for allowing fluid to
enter and exit the dehydrator screen.
5 . The assembly of claim 3, wherein the dehydrator screen comprises a
mesh element circumferentially surrounding at least part of the elongated
element, the mesh element comprising a second plurality of openings.
6 . The assembly of claim 5, wherein the dehydrator screen comprises a
second elongated element circumferentially surrounding at least part of the
mesh element, the second elongated element comprising a third plurality of
openings that are punched openings,
wherein the plurality of punched openings, the second plurality of
openings, and the third plurality of openings are adapted to allow fluid to flow
to an inner region defined by the elongated element.
7 . The assembly of claim 1, wherein the main screen comprises at least
two main screens configured for circumferentially surrounding portions of the
base pipe in the wellbore,
wherein the dehydrator screen is positionable exterior to the at least
two main screens in the wellbore.
8 . An assembly, comprising:
a base pipe;
at least two main screens configured for circumferentially surrounding
portions of the base pipe in a wellbore; and
a dehydrator screen comprising:
an elongated element;
a plurality of openings in the elongated element; and
at least two sealed ends,
wherein the dehydrator screen is (i) positionable exterior to part of the
base pipe and the main screens in the wellbore and (ii) adapted for directing
fluid from a gravel pack slurry exterior to the base pipe toward at least one of
the main screens.
9 . The assembly of claim 8, wherein the elongated element is made from
at least one of stamped metal, wire wrap or mesh material.
10. The assembly of claim 8, wherein the elongated element comprises
stamped metal,
wherein the plurality of openings comprise a plurality of punched
openings in an outer surface of the elongated element.
11. The assembly of claim 10, wherein the dehydrator screen comprises a
mesh element circumferentially surrounding at least part of the elongated
element, the mesh element comprising a second plurality of openings.
12. The assembly of claim 11, wherein the dehydrator screen comprises a
second elongated element circumferentially surrounding at least part of the
mesh element, the second elongated element comprising a third plurality of
openings that are punched openings,
wherein the plurality of punched openings, the second plurality of
openings, and the third plurality of openings are adapted to allow fluid to flow
to an inner region defined by the elongated element.
13. A dehydrator screen comprising:
an elongated element;
a plurality of openings in a surface of the elongated element; and
sealed ends,
wherein the dehydrator screen is positionable in a wellbore exterior to a
base pipe and a main screen associated with the base pipe, wherein the
dehydrator screen is adapted for directing fluid from a gravel pack slurry
exterior to the base pipe toward the main screen.
14. The dehydrator screen of claim 13, wherein the elongated element is
made from at least one of stamped metal, wire wrap or mesh material.
15. The dehydrator screen of claim 13, wherein the elongated element
comprises stamped metal,
wherein the plurality of openings comprise a plurality of punched
openings in an outer surface of the elongated element.
16. The dehydrator screen of claim 15, wherein the stamped metal
comprises a metal strip, wherein the plurality of punched openings comprise
louvered-type stamped openings.
17. The dehydrator screen of claim 15, wherein the dehydrator screen
comprises a mesh element circumferentially surrounding at least part of the
elongated element, the mesh element comprising a second plurality of
openings.
18. The dehydrator screen of claim 17, wherein the dehydrator screen
comprises a second elongated element circumferentially surrounding at least
part of the mesh element, the second elongated element comprising a third
plurality of openings that are punched openings,
wherein the plurality of punched openings, the second plurality of
openings, and the third plurality of openings are adapted to allow fluid to flow
to an inner region defined by the elongated element.
19. The dehydrator screen of claim 13, wherein the main screen comprises
at least two main screens configured for circumferentially surrounding
portions of the base pipe in the wellbore,
wherein the dehydrator screen is positionable exterior to the at least
two main screens in the wellbore.
20. The dehydrator screen of claim 13, wherein the sealed ends comprise
plates welded on each end.