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.

Claims

1. A downhole screen assembly for use in production of fluids, the downhole screen assembly comprising: at least one tubular having a first pipe, a second pipe, and a coupling that couples the first and second pipes, the first pipe being permeable and having at least one port or perforation or hole, the at least one port or perforation or hole having a valve associated therewith, the second pipe being impermeable; and at least one flow control element extending circumferentially around the at least one tubular, wherein the at least one flow control element comprises: first and second portions longitudinally coupled together, the first portion comprising a first screen disposed around the first pipe of the at least one tubular, the second portion comprising a second screen disposed around the second pipe of the at least one tubular; and a third portion comprising a centralizer or a third screen coupling the first and second screens longitudinally together, the centralizer or third screen extending circumferentially around the first pipe, the second pipe and the coupling, the centralizer or third screen being configured to provide a fluid flow path between the first and second screens.

2. The downhole screen assembly of claim 1, wherein the coupling comprises a threaded coupling between first and second pipes, wherein the fluid flow path is annular, and/or wherein the third portion further comprises first and second support rings.

3. The downhole screen assembly of claim 1, wherein the first and second screens are longitudinally disposed relative to one another; and wherein the third portion comprises the third screen provided between adjacent ends of the first and second screens.

4. The downhole screen assembly of claim 1, wherein the third portion of the at least one flow control element comprises the third screen; wherein the assembly comprises at least one support provided between each of the first and second pipes and the third screen; and wherein the at least one support has a cross-section comprising first and second points, vertices, surface discontinuities and/or corners.

5. The downhole screen assembly of claim 1, wherein the third portion of the at least one flow control element comprises the third screen; and wherein the third screen comprises wire: (i) having a cross-section comprising first and second points, vertices, surface discontinuities, and/or corners, or (ii) comprising a rectilinear shape or parallelogram.

6. The downhole screen assembly of claim 1, wherein each of the first and second screens of the at least one flow control element comprises coated and/or hardened wire.

7. The downhole screen assembly of claim 1, wherein the at least one port or perforation or hole comprises a plurality of slotted ports or longitudinally extending ports on the first pipe.

8. The downhole screen assembly according to claim 1, wherein each of the first and second screens of the at least one flow control element comprises an erosion resistant microporous sleeve.

9. The downhole screen assembly according to claim 8, wherein the microporous sleeve comprises a material selected from the group consisting of: a metal foam, a ceramic foam microporous polymeric foams, microporous metal foams, microporous carbide monoliths, silicon carbide, tungsten carbide, titanium carbide monoliths, microporous nitride monoliths, and boron nitride.

10. The downhole screen assembly according to claim 8, wherein the microporous sleeve intimately contacts and/or is bonded to an outer surface of the at least one tubular.

11. The downhole screen assembly of claim 1, wherein the first and second screens each comprises a foam or a microporous material being bonded with or to an exterior surface of the first and second pipe.

12. The downhole screen assembly of claim 1, wherein the associated valve comprises at least one sleeve provided within the first 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 first pipe but which in an open position is alignable or aligned with the at least one port or perforation or hole in the first pipe.

13. The downhole screen assembly of claim 1, wherein the at least one flow control element comprises a plurality of sleeves provided within the first and second pipes.

14. The downhole screen assembly of claim 1, wherein the first and second screens are longitudinally disposed relative to one another; and wherein the third portion comprises the centralizer provided between adjacent ends of the first and second screens.

15. The downhole screen assembly of claim 1, wherein the first screen of 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; and wherein each at least one spacer is aligned with a respective one of the at least one port or perforation or hole in the first pipe.

16. The downhole screen assembly of claim 1, wherein the first screen of 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; and wherein each of the at least one spacer is shaped to diffuse fluid flow exiting the at least one port or perforation or hole in the first pipe.

17. The downhole screen assembly of claim 1, wherein the first and second screens each comprise a shifting sleeve; and wherein the assembly is arranged such that the shifting sleeves are capable of being opened and/or closed sequentially.

18. The downhole screen assembly of claim 1, wherein at least one of the first and second screens comprises a plurality of ceramic discs around at least one of the first and second pipes.

19. The downhole screen assembly of claim 18, wherein the ceramic discs are stacked on each other.

20. The downhole screen assembly of claim 18, wherein one or more of the ceramic discs are arranged so as to provide one or more circumferential/annular spaces between the at least one of the first and second pipes and the respective ceramic disc.

21. The downhole screen assembly of claim 20, wherein between adjacent circumferential/annular spaces, the one or more ceramic discs are arranged such that there is no gap between the at least one of the first and second pipes and the ceramic disc; wherein portions of the one or more ceramic discs have reduced internal diameter such that the at least one of the first and second pipes and the one or more ceramic discs radially abut or contact one another at said portions; wherein the one or more spaces extend longitudinally between adjacent ceramic discs; or wherein the one or more spaces are aligned with at least one port in the at least one of the first and second pipes.

22. The downhole screen assembly of claim 20, wherein the associated valve is provided between a port and a respective space.

23. The downhole screen assembly of claim 22, wherein the associated valve comprises a slideable member or a longitudinally slideable member; wherein associated valve comprises at least one further port and/or at least one reed valve that is selectively alignable with or out of alignment with the at least one port or perforation or hole of the first pipe; wherein the associated valve is biased into a closed position; wherein the associated valve comprises a spherical member, a biased spherical member, or a spherical member movably provided within a space provided by the at least one port or perforation or hole in the first pipe and a recessed portion in a sleeve; or wherein the associated valve comprises a flap, a thin metallic flap, a steel flap, a reed valve, and/or one or more sliding sleeves.

24. The downhole screen assembly of claim 1, wherein at least one of: the associated valve is a check valve; the associated valve, in use, is initially provided to isolate an inner diameter of the first pipe from an outer diameter of the first pipe; upon opening the associated valve, the provision of multiple of the at least one port or perforation or hole in the first pipe provide improved distribution of injection fluid; and/or the associated valve is deployable by or comprises a sliding sleeve and/or is deployable by pressure of fluid flow, in use.

25. The downhole screen assembly of claim 24, wherein the sliding sleeve slides relative to an inner surface of the first pipe; and/or wherein the sliding sleeve comprises second port(s) which is controllably aligned or alignable with the at least one port or perforation or hole of the first pipe.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0065] Embodiments of the present invention will now be described by way of example only and with reference to accompanying drawings which are:

[0066] FIG. 1 is a cross-sectional view of a sand screen operatively positioned in a subterranean well-bore;

[0067] FIG. 2 is a cross-sectioned view of another sand screen operatively positioned in a subterranean well-bore;

[0068] FIG. 3(a) is a transverse cross-sectional view of a screen according to the prior art;

[0069] FIGS. 3(b)-(c) are partial longitudinal cross-sectional views of the screen of FIG. 3(a);

[0070] FIG. 4 is a transverse cross-sectional view of a screen according to an embodiment of the present invention;

[0071] FIG. 5 is a transverse cross-sectional view of a screen according to an embodiment of the present invention;

[0072] FIG. 6 is a partial longitudinal cross-sectional view of a screen according to an embodiment of the present invention;

[0073] FIG. 7 is a partial longitudinal cross-sectional view of a screen according to an embodiment of the present invention;

[0074] FIGS. 8(a)-(b) are partial longitudinal cross-sectional views of a screen according to an embodiment of the present invention;

[0075] FIG. 8(c) is a partial longitudinal cross-sectional view of a screen according to an embodiment of the present invention;

[0076] FIG. 8(d) is a partial longitudinal cross-sectional view of a screen according to an embodiment of the present invention;

[0077] FIG. 9(a) is a transverse cross-sectional view of a screen according to an embodiment of the present invention;

[0078] FIGS. 9(b)-(e) are a series of longitudinal views of the screen of FIG. 9(a) in closed and opened dispositions;

[0079] FIGS. 10(a)-(c) are a series of longitudinal cross-sectional views of a screen according to an embodiment of the present invention;

[0080] 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;

[0081] 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;

[0082] 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;

[0083] FIGS. 12(d)-(f) are a sequence of longitudinal cross-sectional views illustrating closing of the screen of FIGS. 12(a)-(c);

[0084] FIGS. 13(a)-(b) is longitudinal cross-sectional views of a screen assembly according to an embodiment of the present invention;

[0085] FIGS. 13(c)-(d) are longitudinal cross-sectional views of a screen assembly according to an embodiment of the present invention;

[0086] FIG. 14(a) is a transverse cross-sectional view of a screen according to an embodiment of the present invention;

[0087] FIG. 14(b) is a longitudinal view of the screen of FIG. 14(a);

[0088] FIGS. 15(a)-(c) are a series of longitudinal cross-sectional views of a screen according to an embodiment of the present invention;

[0089] FIG. 15(d) is a perspective view of a sliding sleeve of the screen of FIGS. 15(a)-(c);

[0090] FIG. 16(a) is a transverse cross-sectional view of screen according to an embodiment of the present invention;

[0091] 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);

[0092] 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;

[0093] FIG. 18(a)-(b) partial longitudinal cross-sectional views of a screen assembly according to an embodiment of the present invention;

[0094] FIG. 19(a) is a perspective longitudinal view of a screen according to an embodiment of the present invention;

[0095] FIG. 19(b) is a partial longitudinal cross-sectional view of the screen of FIG. 19(a) to an enlarged scale;

[0096] FIG. 19(c) is a stack of discs of the screen of FIG. 19(a);

[0097] FIG. 19(d) is a partial perspective view of a ceramic disc of the stack of ceramic discs of FIG. 19(c);

[0098] FIG. 20 is a cross-sectional side view of a screen according to an embodiment of the present invention; and

[0099] 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

[0100] 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.

[0101] 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.

[0102] 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.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] 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.

[0107] 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.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] The support(s) is/are typically made from steel.

[0114] 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.

[0115] 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.

[0116] The screen 205 comprises a pipe 225 and a sleeve 231 (the sleeve 231 comprising the wire233/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.

[0117] 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.

[0118] 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.

[0119] 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.

[0120] The wire 233; 233′ is typically made from steel.

[0121] 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.

[0122] 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.

[0123] 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.

[0124] 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′″.

[0125] 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.

[0126] 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″.

[0127] 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.

[0128] 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.

[0129] 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.

[0130] The screen comprises a pipe and a sleeve, the sleeve comprising the wire, and optionally at least one support.

[0131] 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.

[0132] 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.

[0133] 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.

[0134] 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.

[0135] 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.

[0136] The pipe 425 comprises a plurality of ports 440, e.g. slots, e.g. circumferentially and axially spaced thereupon.

[0137] 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′.

[0138] 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.

[0139] 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′.

[0140] 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.

[0141] 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.

[0142] 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.

[0143] 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.

[0144] 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.

[0145] 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.

[0146] 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).

[0147] The following optional features apply to any disclosed embodiments.

[0148] The pipe is typically referred to as base pipe or production tubing.

[0149] 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′.

[0150] 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′.

[0151] 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.

[0152] 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′.

[0153] 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.

[0154] 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.

[0155] 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′.

[0156] The valve member(s) 573; 673; 573′ may be biased into a closed position, e.g. by biasing means 582; 682; 582′.

[0157] 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.

[0158] 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.

[0159] 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.

[0160] 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.

[0161] 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.

[0162] 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′″.

[0163] 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.

[0164] In another implementation the valve member(s) comprise a flap, i.e. thin metallic or steel flap, or reed valve.

[0165] 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.

[0166] 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.

[0167] 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.

[0168] 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.

[0169] The pipe 725 can be referred to as a base pipe or production tubing.

[0170] 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.

[0171] 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.

[0172] 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.

[0173] The pipe 725 can be referred to as a base pipe or production tubing. The pipe 725 comprises a plurality of ports 740.

[0174] 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.

[0175] 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′″.

[0176] In the screen 708′ the seal 787′ has plastic back-ups 788′.

[0177] 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′.

[0178] 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.

[0179] 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)).

[0180] 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.

[0181] 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.

[0182] 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.

[0183] 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′.

[0184] The solid or wall portions 390′ are provided radially outwardly of the ports 362′.

[0185] The pipe 325′ can be referred to as a base pipe or production tubing.

[0186] 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).

[0187] 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.

[0188] 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.

[0189] 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.

[0190] 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.

[0191] The fluid flow path is annular.

[0192] 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.

[0193] 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.

[0194] 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.

[0195] 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.

[0196] 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″.

[0197] 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.

[0198] 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″.

[0199] Such provides enhanced erosion resistance.

[0200] The pipe 425″ can be referred to as a base pipe or production tubing.

[0201] 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.

[0202] 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.

[0203] 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″.

[0204] 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.

[0205] Referring to FIG. 20 there is shown a screen or screen assembly, such as a downhole screen or screen assembly 2005.

[0206] ‘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).

[0207] 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.

[0208] This arrangement provides for “bottom-up opening” of shifting sleeves.

[0209] 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.

[0210] 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.

[0211] 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: [0212] the wire can comprise wire mesh or wire wrap; [0213] the screen or screen assembly can be configurable for one or more of fluid injection, stimulation, fracturing and/or production; [0214] the pipe comprises production tubing; [0215] the screen or sleeve comprises a second tubular; [0216] the screen or sleeve can be permeable; [0217] the pipe can comprise a perforated tubular member or tubular member having a plurality of ports or can comprise a solid tubular member; [0218] the pipe can comprise a first tubular; [0219] the pipe can be permeable or impermeable; [0220] the pipe can be disposed within the sleeve; [0221] the pipe can define an axial through-bore; [0222] an annulus can be provided between the pipe and the sleeve; [0223] the sleeve, i.e. sliding sleeves can comprise further tubulars and/or; [0224] the wire is circumferentially disposed or wound or wrapped.

[0225] 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.

[0226] The aspects/embodiments of the present invention herebefore described provide one or more of: [0227] (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). [0228] (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). [0229] (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). [0230] (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). [0231] (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)). [0232] (vi) Any combination of screen construction using axial supports and circumferential screen from (i)-(v). [0233] (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)). [0234] (viii) Stacks of ceramic disks overlaid on the base pipe (either slotted or solid).

[0235] This provides screen with enhanced erosion resistance. (See FIGS. 9(a)-(e) and FIGS. 14(a) and (b)). [0236] (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)). [0237] (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)). [0238] (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)). [0239] (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)). [0240] (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)). [0241] (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)). [0242] (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)). [0243] (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)). [0244] (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)). [0245] (xviii) Coupling between adjacent screen joints provides a flow path and is also a centraliser (dual function). (See FIGS. 13(a) and (b)). [0246] (xix) Coupling between adjacent screen joints provides a flow path and is also screen. (See FIGS. 13(c) and (d)).