US20220213765A1 - Elevated erosion resistant manifold - Google Patents
Elevated erosion resistant manifold Download PDFInfo
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- US20220213765A1 US20220213765A1 US17/601,110 US202017601110A US2022213765A1 US 20220213765 A1 US20220213765 A1 US 20220213765A1 US 202017601110 A US202017601110 A US 202017601110A US 2022213765 A1 US2022213765 A1 US 2022213765A1
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- manifold
- contoured
- crossover port
- tube
- packing
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- 230000003628 erosive effect Effects 0.000 title description 16
- 238000012856 packing Methods 0.000 claims abstract description 59
- 239000012530 fluid Substances 0.000 claims abstract description 20
- 238000004891 communication Methods 0.000 claims abstract description 12
- 238000000034 method Methods 0.000 claims description 19
- 239000002002 slurry Substances 0.000 claims description 19
- 239000000843 powder Substances 0.000 claims description 16
- 239000000463 material Substances 0.000 claims description 14
- 239000002184 metal Substances 0.000 claims description 13
- 238000004519 manufacturing process Methods 0.000 claims description 11
- 230000001154 acute effect Effects 0.000 claims description 9
- 230000004927 fusion Effects 0.000 claims description 6
- 239000000654 additive Substances 0.000 claims description 4
- 230000000996 additive effect Effects 0.000 claims description 4
- 238000005266 casting Methods 0.000 claims description 3
- 230000007704 transition Effects 0.000 claims description 3
- 238000005253 cladding Methods 0.000 description 5
- 230000004048 modification Effects 0.000 description 5
- 238000012986 modification Methods 0.000 description 5
- 239000002245 particle Substances 0.000 description 4
- 230000000712 assembly Effects 0.000 description 2
- 238000000429 assembly Methods 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- 239000000725 suspension Substances 0.000 description 2
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- 230000018044 dehydration Effects 0.000 description 1
- 238000006297 dehydration reaction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B23/00—Apparatus for displacing, setting, locking, releasing or removing tools, packers or the like in boreholes or wells
- E21B23/06—Apparatus for displacing, setting, locking, releasing or removing tools, packers or the like in boreholes or wells for setting packers
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/14—Obtaining from a multiple-zone well
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/12—Packers; Plugs
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/02—Subsoil filtering
- E21B43/04—Gravelling of wells
- E21B43/045—Crossover tools
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/02—Subsoil filtering
- E21B43/08—Screens or liners
Definitions
- Gravel packs are used in wells for removing particulates from inflowing hydrocarbon fluids.
- a completion having a sand screen assembly or a plurality of sand screen assemblies is deployed downhole in a wellbore and a gravel pack is formed around the completion.
- the completion may include an alternate path system to help prevent premature slurry dehydration in open hole gravel packs.
- An alternate path system utilizes transport tubes and packing tubes which provide an alternate path for gravel slurry delivery. The transport tubes deliver gravel slurry to the packing tubes via crossover ports. However, directing the gravel slurry into the packing tubes can cause erosion of the packing tubes which can sometimes lead to holes, fractures, and/or other packing tube damage.
- a system for use in a well includes a completion system having: a screen assembly; and an alternate path system disposed along the screen assembly, the alternate path system including a transport tube and a packing tube placed in fluid communication at a manifold via a contoured crossover port within the manifold, the manifold being disposed along the screen assembly, wherein the contoured crossover port comprises an acute angle.
- a manifold in one or more embodiments of the present disclosure, includes a contoured crossover port, wherein the manifold is configured to receive a transport tube extending therethrough, the transport tube configured to be in fluid communication with a packing tube at the manifold via the contoured crossover port.
- a method includes manufacturing at least a portion of a manifold using metal, the manifold including: a contoured crossover port including an acute angle, wherein the manifold is configured to receive a transport tube extending therethrough, the transport tube configured to be in fluid communication with a packing tube at the manifold via the contoured crossover port.
- a method includes transporting a gravel pack slurry in an alternate path system disposed along a screen assembly, the alternate path system including a transport tube and a packing tube placed in fluid communication at a manifold via a contoured crossover port within the manifold, the manifold being disposed along the screen assembly; diverting flow of the gravel pack slurry through the contoured crossover port in the manifold from the transport tube into the packing tube; and delivering the gravel pack slurry to a wellbore annulus via the packing tube.
- FIGS. 1 a and 1 b show a manifold according to one or more embodiments of the present disclosure
- FIGS. 2 a and 2 b show a prior art machined manifold
- FIG. 3 shows a comparison of resulting flow velocity contours between a 90 degree crossover port and a contoured crossover port in accordance with one or more embodiments of the present disclosure
- FIG. 4 shows a comparison of particle tracks between a 90 degree crossover port and a contoured crossover port in accordance with one or more embodiments of the present disclosure.
- the present disclosure generally involves a system and methodology to facilitate formation of gravel packs in wellbores and thus the subsequent production of well fluids.
- a well completion is provided with an alternate path system for carrying gravel slurry along an alternate path so as to facilitate improved gravel packing during a gravel packing operation.
- the system and methodology are very useful for facilitating formation of a gravel pack along relatively lengthy wellbores, such as extended reach open hole wells having wellbore lengths of, for example, 4000-8000 feet. However, the system and methodology may be used with wells having lengths greater or less than this range.
- pressures in the packing tubes at the heel of the completion can rise above, for example, 4000 psi and even up to 8000 psi or more.
- gravel packing operations for these types of longer wellbores can utilize substantially increased proppant volumes.
- the increased flow of proppant via gravel slurry as well as the higher pressures can potentially lead to increased erosion of the alternate path system and especially increased erosion of the packing tubes.
- a completion system includes a screen assembly and an alternate path system disposed along the screen assembly.
- the alternate path system may include a transport tube and a packing tube placed in fluid communication at a manifold via a contoured crossover port within the manifold.
- the manifold is disposed along the screen assembly.
- the manifold is about 6 inches in length according to one or more embodiments. Because the manifold includes a contoured crossover port and is about 6 inches in length, the manifold according to one or more embodiments of the present disclosure exhibits enhanced erosion resistance when compared to a manifold having a 90 degree crossover port that is only 3.5 inches in length, for example.
- the fluid flow is in the form of a gravel slurry carrying proppant through the transport tube and into the packing tube via the contoured crossover port in the manifold.
- the completion system may comprise multiple screen assemblies with multiple corresponding manifolds disposed along a wellbore.
- the manifold (or manifolds) is responsible for the functionality enabling an alternate path system so as to achieve long distance open hole gravel packs.
- the manifold delivers slurry (which is a combination of suspension fluid and proppant, e.g. gravel) to the wellbore annulus by diverting flow through a contoured crossover port in the manifold from transport tubes into packing tubes.
- the packing tubes then deliver the slurry to the annulus.
- proppant e.g. gravel
- the packed proppant/gravel in the packing tubes presents a restriction, which inhibits further flow of suspension fluid through those packing tubes.
- the restriction effectively forces the slurry to flow farther along the wellbore through the transport tubes and out through packing tubes in subsequent well zones to ensure proppant is carried to the toe of the well during lengthy gravel packs.
- a substantial portion of the open hole wellbore may be packed via flow of slurry through a relatively small number of the packing tubes. This means that the relatively small number of packing tubes could potentially be subjected to tens of thousands of pounds of proppant during the packing of extended reach wells. This can further increase the chance of packing tube erosion—at least without utilizing the system and methodology described herein.
- FIGS. 1 a and 1 b show an alternate path system 100 including a transport tube 102 and a packing tube 104 placed in fluid communication at a manifold 106 via a contoured crossover port 108 within the manifold 106 .
- the transport tube 102 and the packing tube 104 at least partially extend through the manifold 106
- a carbide liner 110 of the packing tube 104 may be at least partially inserted into a recess of the manifold 106 .
- the carbide liner 110 may provide additional erosion resistance for the alternate path system 100 .
- the contoured crossover port 108 within the manifold 106 provides for a smoothly contoured flow 112 of gravel pack slurry from the transport tube 102 and into the packing tube 104 via the contoured crossover port 108 .
- the contoured crossover port 108 is an acute angle, partial flow diversion from a main transport tube 102 within the manifold 106 into a secondary parallel flow path, i.e., the packing tube 104 .
- a transition length of the acute angle of the contoured crossover port 108 is curved to gradually “turn” and partially divert the flow from the transport tube 102 within the manifold 106 into a path of the packing tube 104 that is parallel to the path of the transport tube 102 .
- the manifold 106 measures about 6 inches in length in one or more embodiments. Other lengths of the manifold 106 are feasible and are within the scope of the present disclosure.
- metal additive manufacturing via laser powder bed fusion is utilized to produce either the entire manifold 106 or just the erosion-critical passages within the manifold 106 .
- at least one flow path of the manifold 106 e.g., the flow path corresponding to the transport tube 102 , the contoured crossover port 108 , or packing tube 104 entrance
- metal AM via laser powder bed fusion
- a casting manufacturing process may be used to produce either the entire manifold 106 or just the erosion-critical passages within the manifold 106 .
- at least one flow path of the manifold 106 e.g., the flow path corresponding to the transport tube 102 , the contoured crossover port 108 , or packing tube 104 entrance
- a casting process may be used to produce either the entire manifold 106 or just the erosion-critical passages within the manifold 106 .
- at least one flow path of the manifold 106 e.g., the flow path corresponding to the transport tube 102 , the contoured crossover port 108 , or packing tube 104 entrance
- either the at least one flow path of the manifold 106 or the entire manifold 106 may be made of casted metal in accordance with one or more embodiments of the present disclosure.
- FIG. 2 b shows an alternate path system 200 including a transport tube 202 and a packing tube 204 placed in fluid communication at a manifold 206 via a crossover port 208 within the manifold 206 .
- FIG. 2 b also shows that the packing tube 204 may include a carbide liner 210 .
- the prior art manifold 206 is machined from bar stock and milled with two 90 degree intersecting ports, creating a 90 degree crossover port 208 , as shown in FIGS. 2 a and 2 b . As shown in FIGS.
- the 90 degree crossover port 208 within the machined manifold 206 provides for a sharply angled flow 212 of gravel pack slurry from the transport tube 202 and into the packing tube 204 via the 90 degree crossover port 108 .
- the machined manifold 206 measures about 3.5 inches in length.
- FIGS. 3 and 4 a comparison of resulting flow velocity contours and particle tracks between a 90 degree crossover port ( FIGS. 2 a and 2 b ) and a contoured crossover port in accordance with one or more embodiments of the present disclosure ( FIGS. 1 a and 1 b ) are shown.
- computation fluid dynamics shows the 90 degree crossover port 208 results in the highest velocity particle impacts at the crossover port 208 and at the wall of the packing tube 204 after the crossover port 208 .
- the 90 degree crossover port 208 of FIGS. 2 a and 2 b presents a substantial erosion risk for the alternate path system 200 , especially in extended reach applications.
- the contoured crossover port 108 of FIGS. 1 a and 1 b allows for fewer particle impacts at the contoured crossover port 108 and lower velocities overall, and shifts the highest velocities away from the wall of the packing tube 104 downstream of the contoured crossover port 108 .
- the contoured crossover port 108 of FIGS. 1 a and 1 b presents a reduced erosion risk for the alternate path system 100 .
- the metal AM manifold 106 having the contoured crossover port 108 achieves at least 1.4 ⁇ the performance of the bar stock machined manifold 206 with respect to erosion resistance.
- the improved erosion resistance may be attributed to at least one of 316L metal AM via laser powder bed fusion resulting in a material structure having greater erosion resistance than annealed bar stock 316L, and an elongated and contoured crossover port 108 within a manifold 106 having a length increased from 3.5 inches to about 6 inches providing a smooth transition of erosive fluid from the transport tube 102 to the packing tube 204 .
- one or more embodiments of the present disclosure enhances the erosion resistance of the manifold, thereby increasing the open hole alternate path gravel pack system's ability to sustain erosive flow for greater amounts of proppant needed to gravel pack extended reach wells.
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Abstract
Description
- The present document is based on and claims priority to U.S. Provisional Application Ser. No. 62/830,149, filed Apr. 5, 2019, which is incorporated herein by reference in its entirety.
- Gravel packs are used in wells for removing particulates from inflowing hydrocarbon fluids. Generally, a completion having a sand screen assembly or a plurality of sand screen assemblies is deployed downhole in a wellbore and a gravel pack is formed around the completion. To facilitate the gravel pack, the completion may include an alternate path system to help prevent premature slurry dehydration in open hole gravel packs. An alternate path system utilizes transport tubes and packing tubes which provide an alternate path for gravel slurry delivery. The transport tubes deliver gravel slurry to the packing tubes via crossover ports. However, directing the gravel slurry into the packing tubes can cause erosion of the packing tubes which can sometimes lead to holes, fractures, and/or other packing tube damage.
- Attempts have been made to resist erosion by cladding an exterior of the packing tube at a location downstream of the crossover port. However, the material of the packing tube remains subject to erosive flow internally of the cladding. Once the packing tube material is thinned out sufficiently, the packing tube can lose its pressure bearing capacity and cracks can develop in the relatively brittle cladding material. As a result, the packing tube can burst under the pressures reached during packing of relatively lengthy wellbores. Additionally, some cladding processes involve inserting an end of the packing tube into the structure containing the crossover port and then welding the packing tube to the structure. Subsequently, cladding material is added, but this can result in a time-consuming and expensive manufacturing process.
- In one or more embodiments of the present disclosure, a system for use in a well includes a completion system having: a screen assembly; and an alternate path system disposed along the screen assembly, the alternate path system including a transport tube and a packing tube placed in fluid communication at a manifold via a contoured crossover port within the manifold, the manifold being disposed along the screen assembly, wherein the contoured crossover port comprises an acute angle.
- In one or more embodiments of the present disclosure, a manifold includes a contoured crossover port, wherein the manifold is configured to receive a transport tube extending therethrough, the transport tube configured to be in fluid communication with a packing tube at the manifold via the contoured crossover port.
- In one or more embodiments of the present disclosure, a method includes manufacturing at least a portion of a manifold using metal, the manifold including: a contoured crossover port including an acute angle, wherein the manifold is configured to receive a transport tube extending therethrough, the transport tube configured to be in fluid communication with a packing tube at the manifold via the contoured crossover port.
- In one or more embodiments of the present disclosure, a method includes transporting a gravel pack slurry in an alternate path system disposed along a screen assembly, the alternate path system including a transport tube and a packing tube placed in fluid communication at a manifold via a contoured crossover port within the manifold, the manifold being disposed along the screen assembly; diverting flow of the gravel pack slurry through the contoured crossover port in the manifold from the transport tube into the packing tube; and delivering the gravel pack slurry to a wellbore annulus via the packing tube.
- However, many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims.
- Certain embodiments of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood, however, that the accompanying figures illustrate the various implementations described herein and are not meant to limit the scope of various technologies described herein, and:
-
FIGS. 1a and 1b show a manifold according to one or more embodiments of the present disclosure; -
FIGS. 2a and 2b show a prior art machined manifold; -
FIG. 3 shows a comparison of resulting flow velocity contours between a 90 degree crossover port and a contoured crossover port in accordance with one or more embodiments of the present disclosure; and -
FIG. 4 shows a comparison of particle tracks between a 90 degree crossover port and a contoured crossover port in accordance with one or more embodiments of the present disclosure. - In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. However, it will be understood by those of ordinary skill in the art that the apparatus and/or method may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
- In the specification and appended claims: the terms “up” and “down,” “upper” and “lower,” “upwardly” and “downwardly,” “upstream” and “downstream,” “uphole” and “downhole,” “above” and “below,” and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the disclosure.
- The present disclosure generally involves a system and methodology to facilitate formation of gravel packs in wellbores and thus the subsequent production of well fluids. A well completion is provided with an alternate path system for carrying gravel slurry along an alternate path so as to facilitate improved gravel packing during a gravel packing operation. The system and methodology are very useful for facilitating formation of a gravel pack along relatively lengthy wellbores, such as extended reach open hole wells having wellbore lengths of, for example, 4000-8000 feet. However, the system and methodology may be used with wells having lengths greater or less than this range.
- In some of these relatively lengthy wellbore applications, pressures in the packing tubes at the heel of the completion can rise above, for example, 4000 psi and even up to 8000 psi or more. It should be noted gravel packing operations for these types of longer wellbores can utilize substantially increased proppant volumes. The increased flow of proppant via gravel slurry as well as the higher pressures can potentially lead to increased erosion of the alternate path system and especially increased erosion of the packing tubes.
- According to an embodiment of the present disclosure, a completion system includes a screen assembly and an alternate path system disposed along the screen assembly. The alternate path system may include a transport tube and a packing tube placed in fluid communication at a manifold via a contoured crossover port within the manifold. The manifold is disposed along the screen assembly. The manifold is about 6 inches in length according to one or more embodiments. Because the manifold includes a contoured crossover port and is about 6 inches in length, the manifold according to one or more embodiments of the present disclosure exhibits enhanced erosion resistance when compared to a manifold having a 90 degree crossover port that is only 3.5 inches in length, for example. During a gravel packing operation, for example, the fluid flow is in the form of a gravel slurry carrying proppant through the transport tube and into the packing tube via the contoured crossover port in the manifold. In some embodiments, the completion system may comprise multiple screen assemblies with multiple corresponding manifolds disposed along a wellbore.
- In various embodiments, the manifold (or manifolds) is responsible for the functionality enabling an alternate path system so as to achieve long distance open hole gravel packs. The manifold delivers slurry (which is a combination of suspension fluid and proppant, e.g. gravel) to the wellbore annulus by diverting flow through a contoured crossover port in the manifold from transport tubes into packing tubes. The packing tubes then deliver the slurry to the annulus. Once the wellbore annulus is packed with proppant, e.g. gravel, at a given well zone, the proppant effectively backs up through the packing tube all the way to the manifold. The packed proppant/gravel in the packing tubes presents a restriction, which inhibits further flow of suspension fluid through those packing tubes.
- The restriction effectively forces the slurry to flow farther along the wellbore through the transport tubes and out through packing tubes in subsequent well zones to ensure proppant is carried to the toe of the well during lengthy gravel packs. Sometimes a substantial portion of the open hole wellbore may be packed via flow of slurry through a relatively small number of the packing tubes. This means that the relatively small number of packing tubes could potentially be subjected to tens of thousands of pounds of proppant during the packing of extended reach wells. This can further increase the chance of packing tube erosion—at least without utilizing the system and methodology described herein.
- Referring generally to
FIGS. 1a and 1b , a manifold according to one or more embodiments of the present disclosure is shown. Specifically,FIGS. 1a and 1b show analternate path system 100 including atransport tube 102 and apacking tube 104 placed in fluid communication at amanifold 106 via acontoured crossover port 108 within themanifold 106. As shown inFIGS. 1a and 1b , in one or more embodiments, thetransport tube 102 and thepacking tube 104 at least partially extend through themanifold 106, and acarbide liner 110 of thepacking tube 104 may be at least partially inserted into a recess of themanifold 106. In one or more embodiments of the present disclosure, thecarbide liner 110 may provide additional erosion resistance for thealternate path system 100. As particularly shown in FIG. 1 a, the contouredcrossover port 108 within themanifold 106 provides for a smoothly contouredflow 112 of gravel pack slurry from thetransport tube 102 and into the packingtube 104 via the contouredcrossover port 108. As specifically shown inFIGS. 1a and 1b , the contouredcrossover port 108 is an acute angle, partial flow diversion from amain transport tube 102 within the manifold 106 into a secondary parallel flow path, i.e., the packingtube 104. In one or more embodiments of the present disclosure, a transition length of the acute angle of the contouredcrossover port 108 is curved to gradually “turn” and partially divert the flow from thetransport tube 102 within the manifold 106 into a path of thepacking tube 104 that is parallel to the path of thetransport tube 102. - Still referring to
FIGS. 1a and 1b , according to one or more embodiments of the present disclosure, the manifold 106 measures about 6 inches in length in one or more embodiments. Other lengths of the manifold 106 are feasible and are within the scope of the present disclosure. - According to one or more embodiments of the present disclosure, metal additive manufacturing (metal AM) via laser powder bed fusion is utilized to produce either the
entire manifold 106 or just the erosion-critical passages within themanifold 106. For example, at least one flow path of the manifold 106 (e.g., the flow path corresponding to thetransport tube 102, the contouredcrossover port 108, or packingtube 104 entrance) may be manufactured using metal AM via laser powder bed fusion, according to one or more embodiments of the present disclosure. In this way, either at least one flow path of the manifold 106 or theentire manifold 106 may be made of fused metal powder in accordance with one or more embodiments of the present disclosure. - In other embodiments of the present disclosure, a casting manufacturing process may be used to produce either the
entire manifold 106 or just the erosion-critical passages within themanifold 106. For example, at least one flow path of the manifold 106 (e.g., the flow path corresponding to thetransport tube 102, the contouredcrossover port 108, or packingtube 104 entrance) may be manufactured using a casting process according to one or more embodiments of the present disclosure. In this way, either the at least one flow path of the manifold 106 or theentire manifold 106 may be made of casted metal in accordance with one or more embodiments of the present disclosure. - Referring now to
FIGS. 2a and 2b for the sake of comparison, a prior art machined manifold is shown. Specifically,FIG. 2b shows analternate path system 200 including atransport tube 202 and apacking tube 204 placed in fluid communication at a manifold 206 via acrossover port 208 within themanifold 206.FIG. 2b also shows that the packingtube 204 may include acarbide liner 210. In contrast toFIGS. 1a and 1b , theprior art manifold 206 is machined from bar stock and milled with two 90 degree intersecting ports, creating a 90degree crossover port 208, as shown inFIGS. 2a and 2b . As shown inFIGS. 2a and 2b , for example, the 90degree crossover port 208 within the machinedmanifold 206 provides for a sharplyangled flow 212 of gravel pack slurry from thetransport tube 202 and into the packingtube 204 via the 90degree crossover port 108. Also in contrast toFIGS. 1a and 1b , the machinedmanifold 206 measures about 3.5 inches in length. - Referring now to
FIGS. 3 and 4 , a comparison of resulting flow velocity contours and particle tracks between a 90 degree crossover port (FIGS. 2a and 2b ) and a contoured crossover port in accordance with one or more embodiments of the present disclosure (FIGS. 1a and 1b ) are shown. In view ofFIGS. 3 and 4 , computation fluid dynamics (CFD) shows the 90degree crossover port 208 results in the highest velocity particle impacts at thecrossover port 208 and at the wall of thepacking tube 204 after thecrossover port 208. As such, the 90degree crossover port 208 ofFIGS. 2a and 2b presents a substantial erosion risk for thealternate path system 200, especially in extended reach applications. Advantageously, however, the contouredcrossover port 108 ofFIGS. 1a and 1b allows for fewer particle impacts at the contouredcrossover port 108 and lower velocities overall, and shifts the highest velocities away from the wall of thepacking tube 104 downstream of the contouredcrossover port 108. As such, the contouredcrossover port 108 ofFIGS. 1a and 1b presents a reduced erosion risk for thealternate path system 100. - The
metal AM manifold 106 having the contouredcrossover port 108 according to one or more embodiments of the present disclosure achieves at least 1.4× the performance of the bar stock machined manifold 206 with respect to erosion resistance. The improved erosion resistance may be attributed to at least one of 316L metal AM via laser powder bed fusion resulting in a material structure having greater erosion resistance than annealed bar stock 316L, and an elongated andcontoured crossover port 108 within a manifold 106 having a length increased from 3.5 inches to about 6 inches providing a smooth transition of erosive fluid from thetransport tube 102 to thepacking tube 204. Advantageously, one or more embodiments of the present disclosure enhances the erosion resistance of the manifold, thereby increasing the open hole alternate path gravel pack system's ability to sustain erosive flow for greater amounts of proppant needed to gravel pack extended reach wells. - Although a few embodiments of the disclosure have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims.
Claims (22)
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US17/601,110 US20220213765A1 (en) | 2019-04-05 | 2020-04-03 | Elevated erosion resistant manifold |
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US201962830149P | 2019-04-05 | 2019-04-05 | |
US17/601,110 US20220213765A1 (en) | 2019-04-05 | 2020-04-03 | Elevated erosion resistant manifold |
PCT/US2020/026521 WO2020206211A1 (en) | 2019-04-05 | 2020-04-03 | Elevated erosion resistant manifold |
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US11525342B2 (en) | 2018-02-26 | 2022-12-13 | Schlumberger Technology Corporation | Alternate path manifold life extension for extended reach applications |
US11753908B2 (en) | 2020-11-19 | 2023-09-12 | Schlumberger Technology Corporation | Multi-zone sand screen with alternate path functionality |
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- 2020-04-03 AU AU2020254751A patent/AU2020254751A1/en active Pending
- 2020-04-03 GB GB2114179.1A patent/GB2596706B/en active Active
- 2020-04-03 US US17/601,110 patent/US20220213765A1/en active Pending
- 2020-04-03 WO PCT/US2020/026521 patent/WO2020206211A1/en active Application Filing
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WO2020206211A1 (en) | 2020-10-08 |
AU2020254751A1 (en) | 2021-11-04 |
GB2596706A (en) | 2022-01-05 |
GB2596706B (en) | 2023-05-31 |
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