WO2020005382A1 - Well screen systems, hydrocarbon wells that include the well screen systems, and methods of injecting fluid into the hydrocarbon wells - Google Patents

Well screen systems, hydrocarbon wells that include the well screen systems, and methods of injecting fluid into the hydrocarbon wells Download PDF

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Publication number
WO2020005382A1
WO2020005382A1 PCT/US2019/029837 US2019029837W WO2020005382A1 WO 2020005382 A1 WO2020005382 A1 WO 2020005382A1 US 2019029837 W US2019029837 W US 2019029837W WO 2020005382 A1 WO2020005382 A1 WO 2020005382A1
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WO
WIPO (PCT)
Prior art keywords
screen
aperture
shroud
wire
trajectory
Prior art date
Application number
PCT/US2019/029837
Other languages
French (fr)
Inventor
Jason Y. WANG
James S. BROWN III
Federico G. GALLO
Matthew J. TENNY
Original Assignee
Exxonmobil Upstream Research Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Exxonmobil Upstream Research Company filed Critical Exxonmobil Upstream Research Company
Publication of WO2020005382A1 publication Critical patent/WO2020005382A1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E21EARTH DRILLING; MINING
    • E21BEARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02Subsoil filtering
    • E21B43/08Screens or liners
    • E21B43/088Wire screens
    • EFIXED CONSTRUCTIONS
    • E21EARTH DRILLING; MINING
    • E21BEARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02Subsoil filtering
    • E21B43/08Screens or liners
    • EFIXED CONSTRUCTIONS
    • E21EARTH DRILLING; MINING
    • E21BEARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/16Enhanced recovery methods for obtaining hydrocarbons
    • EFIXED CONSTRUCTIONS
    • E21EARTH DRILLING; MINING
    • E21BEARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/25Methods for stimulating production

Definitions

  • the present disclosure relates generally to well screen systems, to hydrocarbon wells that include the well screen systems, and to methods of injecting fluid into hydrocarbon wells that include the well screen systems.
  • Hydrocarbon wells may be utilized to flow, or to produce, hydrocarbon fluids from a subterranean formation that extends within a subsurface region.
  • it may be desirable to inject fluid into the subterranean formation via the hydrocarbon well.
  • the injection may be performed to stimulate the subterranean formation, and such stimulation may be utilized to increase a production rate of the hydrocarbon fluids from the subterranean formation.
  • fluid may be injected into the subterranean formation, via the hydrocarbon well, at high pressures in a process that may be referred to herein as hydraulic fracturing.
  • This high-pressure fluid injection creates cracks, or fractures, within the subterranean formation, thereby improving, or increasing, a fluid permeability of the subterranean formation.
  • acids may be injected into the subterranean formation to dissolve a portion of the subterranean formation, which also may increase the fluid permeability of the subterranean formation.
  • a proppant may be injected into the subterranean formation to prop open any created cracks and/or fractures.
  • the injection may be performed to provide pressure support to the subterranean formation and/or to sweep hydrocarbons from the reservoir.
  • Such injection may be performed below a fracture pressure of the subterranean formation and/or above the fracture pressure.
  • the injection may maintain injectivity of the subterranean formation and/or may create new fractures and/or extend existing fractures within the subterranean formation.
  • Such injection operations often may be performed at relatively high flow rates for the injected fluid, and these high flow rates may cause wear, erosion, and/or damage to various structures of the hydrocarbon well.
  • a well screen system may be positioned within a wellbore of the hydrocarbon well.
  • the well screen system may be utilized to screen and/or filter flow of the hydrocarbon fluids into a wellbore tubular that extends within the wellbore, such as to restrict and/or prevent flow of sand, gravel, and/or other solids into a tubular conduit defined by the wellbore tubular.
  • the injected fluid also may flow through the well screen system during stimulation of the subterranean formation, leading to wear to, damage to, and/or failure of conventional well screen systems.
  • the well screen systems include a screen-supporting tubular, a screen structure, a screen spacer, and a shroud structure.
  • the screen-supporting tubular includes an inner surface, an outer surface, and a plurality of spaced-apart apertures extending within an aperture-defining region of the screen supporting tubular. Each aperture extends along an aperture trajectory from the inner surface to the outer surface.
  • the screen structure encircles the outer surface of the aperture-defining region of the screen-supporting tubular.
  • the screen spacer extends between the screen supporting tubular and the screen structure and maintains a spaced-apart relationship between at least a majority of the screen structure and at least a majority of the aperture-defining region.
  • the shroud structure is positioned at least along the aperture trajectory of each aperture and restricts fluid flow therethrough along the aperture trajectory.
  • the hydrocarbon wells include a wellbore, a wellbore tubular extending within the wellbore, and the well screen system.
  • the wellbore extends within a subterranean formation.
  • the wellbore tubular defines a tubular conduit and has a downhole end.
  • the well screen system is operatively attached to the downhole end of the wellbore tubular.
  • the methods include methods of injecting fluid into a subterranean formation utilizing the hydrocarbon wells.
  • the methods including providing the fluid to the tubular conduit and flowing the fluid along the tubular conduit to the downhole end.
  • the methods also include flowing a respective fraction of the fluid along a respective aperture trajectory that extends through each aperture and re-directing the respective fraction from the respective aperture trajectory to a respective modified trajectory.
  • the methods further include flowing at least a majority of the respective fraction of the fluid through a region of the screen structure that is spaced-apart from the aperture trajectory and flowing the respective fraction of the fluid into the subterranean formation.
  • FIG. 1 is a schematic illustration of examples of hydrocarbon wells including well screen systems, according to the present disclosure.
  • FIG. 2 is a schematic longitudinal cross-sectional illustration of examples of well screen systems according to the present disclosure.
  • Fig. 3 is a less schematic transverse cross-sectional illustration of examples of well screen systems, according to the present disclosure, such as may be taken along line A-A of Fig. 1.
  • Fig. 4 is a cross-sectional view of the well screen systems of Fig. 3 taken along line 4- 4 of Fig. 3.
  • Fig. 5 is another less schematic transverse cross-sectional illustration of an example of a well screen system, according to the present disclosure, such as may be taken along line A- A of Fig. 1.
  • Fig. 6 is a cross-sectional view of the well screen system of Fig. 5 taken along line 6-6 of Fig. 5.
  • Fig. 7 is another less schematic transverse cross-sectional illustration of an example of a well screen system, according to the present disclosure, such as may be taken along line A- A of Fig. 1.
  • Fig. 8 is a cross-sectional view of the well screen system of Fig. 7 taken along line 8-8 of Fig. 7.
  • Fig. 9 is a less schematic side view of an example of a well screen system, according to the present disclosure.
  • Fig. 10 is a less schematic transverse cross-sectional illustration of the well screen system of Fig. 9, such as may be taken along line 10-10 of Fig. 9 and/or along line A-A of Fig. 1
  • Fig. 11 is a cross-sectional view of the well screen system of Fig. 10 taken along line
  • Fig. 12 is another less schematic transverse cross-sectional illustration of an example of a well screen system, according to the present disclosure, such as may be taken along line A-A of Fig. 1.
  • Fig. 13 is a cross-sectional view of the well screen system of Fig. 12 taken along line 13-13 of Fig. 12.
  • Fig. 14 is another less schematic transverse cross-sectional illustration of an example of a well screen system, according to the present disclosure, such as may be taken along line A-A of Fig. 1.
  • Fig. 15 is a cross-sectional view of the well screen system of Fig. 14 taken along line 15-15 of Fig. 14.
  • Fig. 16 is a schematic bottom view of a shroud structure of Figs. 15-16.
  • Figs. 1-16 provide examples of well screen systems 100 and of hydrocarbon wells 10 that include well screen systems 100 and/or may be utilized with methods, according to the present disclosure, of injecting fluid into hydrocarbon wells 10. Elements that serve a similar, or at least substantially similar, purpose are labeled with like numbers in each of Figs. 1-16, and these elements may not be discussed in detail herein with reference to each of Figs. 1-16. Similarly, all elements may not be labeled in each of Figs. 1-16, but reference numerals associated therewith may be utilized herein for consistency. Elements, components, and/or features that are discussed herein with reference to one or more of Figs. 1-16 may be included in and/or utilized with any of Figs. 1-16 without departing from the scope of the present disclosure. In general, elements that are likely to be included in a particular embodiment are illustrated in solid lines, while elements that are optional are illustrated in dashed lines.
  • Fig. 1 is a schematic illustration of examples of hydrocarbon wells 10 including well screen systems 100, according to the present disclosure.
  • hydrocarbon wells 10 include a wellbore 20 extending within a subterranean formation 8.
  • Wellbore 20 also may be referred to herein as extending within a subsurface region 6 that includes subterranean formation 8 and/or as extending between a surface region 4 and the subterranean formation.
  • Hydrocarbon wells 10 also include a wellbore tubular 30 extending within wellbore 20.
  • Wellbore tubular has and/or defines a tubular conduit 32 and/or a downhole end 34.
  • Downhole end 34 also may be referred to herein as and/or may be a downhole region and/or an end region of the wellbore tubular, and thus may include more than the terminal downhole edge of the wellbore tubular.
  • Hydrocarbon wells 10 further include well screen system 100.
  • Well screen system 100 is operatively attached to downhole end 34 of wellbore tubular 30, and more specific and/or detailed examples of well screen system 100 are illustrated Figs. 2-15 and discussed herein with reference thereto.
  • Well screen system 100 is configured to filter fluid flow 40 between subterranean formation 8 and tubular conduit 32. This may include filtering fluid flow 40 from the subterranean formation and into the tubular conduit via downhole end 34, such as during production of hydrocarbon fluid from the subterranean formation. Additionally or alternatively, this also may include filtering fluid flow 40, via downhole end 34, from the tubular conduit and into the subterranean formation, such as during stimulation of the subterranean formation via the hydrocarbon well. As discussed in more detail herein, well screen system 100 includes a screen structure 130, and the well screen system permits fluid communication between wellbore 20 and tubular conduit 32 through and/or via the screen structure.
  • hydrocarbon well 10 may include a gravel pack 50.
  • Gravel pack 50 when present, may extend between wellbore 20 and well screen system 100 and/or may be or function as a gravel filter, or as a coarse filter, within hydrocarbon well 10.
  • well screen system 100 and/or screen structure 130 thereof may be configured to resist flow and/or conveyance of gravel from the gravel pack into tubular conduit 32.
  • hydrocarbon well 10 may include one or more packers 60.
  • Packers 60 when present, may be associated with wellbore tubular 30 and/or with well screen system 100. Stated another way, and as illustrated by the uppermost packer in Fig. 1, packers 60 may extend between the wellbore tubular and wellbore 20. Additionally or alternatively, and as illustrated by the lowermost packer in Fig. 1, packers 60 may extend between well screen system 100, or a central region of well screen system 100, and wellbore 20.
  • Packers 60 that are associated with well screen system 100 may cause fluid flow 40 to be concentrated at and/or near the packers. This concentration of fluid flow contributed to increased erosion of prior art well screen systems, thereby demonstrating the need for well screen systems 100, according to the present disclosure.
  • Hydrocarbon well 10 also may include one or more additional/optional structures that may be known in the art and/or that may be common to conventional hydrocarbon wells.
  • hydrocarbon well 10 may include one or more casings, casing collars, downhole tubes, production tubes, tubing collars, pumps, valves, sensors, detectors, and/or controllers. It should be understood that these conventional structures have not been illustrated in the schematic wellbore of Fig. 1 so as not to detract from the discussion and presentation of well screen systems 100.
  • Figs. 2-16 provide more specific and/or detailed examples of well screen systems 100. It is within the scope of the present disclosure that well screen systems 100 of Figs. 2-16 may include and/or be more detailed illustrations and/or examples of well screen system 100 of Fig. 1. As such, any of the structures, functions, and/or features of well screen systems 100 of Figs. 2-16 may be included in and/or utilized with hydrocarbon well 10 of Fig. 1 without departing from the scope of the present disclosure. Similarly, any of the structures, functions, and/or features of hydrocarbon well 10 of Fig. 1 may be included in and/or utilized with well screen systems 100 of Figs. 2-16 without departing from the scope of the present disclosure.
  • Fig. 2 is a schematic illustration of examples of well screen systems 100 according to the present disclosure.
  • Fig. 3 is a less schematic illustration of examples of a transverse cross- section of well screen systems 100, according to the present disclosure, such as may be taken along line A-A of Fig. 1, while Fig. 4 is a cross-sectional view of the well screen systems of Fig. 3 taken along line 4-4 of Fig. 3.
  • Fig. 5 is another less schematic illustration of an example of a transverse cross-section of well screen system 100, according to the present disclosure, such as may be taken along line A-A of Fig. 1, while Fig. 6 is a cross-sectional view of the well screen system of Fig. 5 taken along line 6-6 of Fig. 5.
  • Fig. 3 is a less schematic illustration of examples of a transverse cross- section of well screen systems 100, according to the present disclosure, such as may be taken along line A-A of Fig. 1, while Fig. 6 is a cross-sectional view of the well screen system of
  • FIG. 7 is another less schematic illustration of an example of a transverse cross-section of well screen system 100, according to the present disclosure, such as may be taken along line A-A of Fig. 1, while Fig. 8 is a cross- sectional view of the well screen system of Fig. 7 taken along line 8-8 of Fig. 7.
  • Fig. 9 is a less schematic side view of an example of well screen system 100, according to the present disclosure
  • Fig. 10 is a less schematic illustration of a transverse cross-section of the well screen system of Fig. 9, such as may be taken along line 10-10 of Fig. 9 and/or along line A-A of Fig. 1
  • Fig. 11 is a cross-sectional view of the well screen system of Fig. 10 taken along line 11-11 of Fig. 10.
  • Fig. 12 is another less schematic illustration of atransverse cross-section of an example of well screen system 100, according to the present disclosure, such as may be taken along line A-A of Fig. 1, while Fig. 13 is a cross-sectional view of the well screen system of Fig. 12 taken along line 13-13 of Fig. 12.
  • Fig. 14 is another less schematic illustration of a transverse cross-section of an example of well screen system 100, according to the present disclosure, such as may be taken along line A-A of Fig. 1, while Fig. 15 is a cross-sectional view of the well screen system of Fig. 14 taken along line 15-15 of Fig. 14, and Fig. 16 is a schematic bottom view of a shroud structure 170 of Figs. 15-16.
  • well screen systems 100 include a screen-supporting tubular 110, a screen structure 130, a screen spacer 150, and a shroud structure 170.
  • Screen supporting tubular 110 also may be referred to herein as a screen- wrapped tubular 110, as a screen tubular 110, as a system tubular 110, as an underlying tubular 110, and/or as a central tubular 110.
  • the screen-supporting tubular includes an outer surface 112, an inner surface 114, and a plurality of spaced-apart apertures 118. Apertures 118 extend within an aperture-defining region 116 of the screen-supporting tubular.
  • each aperture 118 extends along an aperture trajectory 120 from inner surface 114 to and beyond outer surface 112.
  • the term“aperture traj ectory” refers to a collection of all lines, or traj ectories, that extend, along a length 119 of a given aperture, from inner surface 114 toward and/or past outer surface 112.
  • aperture trajectory 120 of a given aperture 118 extends across an entirety of a transverse cross-section of the given aperture, extends from the given aperture 118, and extends along a direction that is parallel, or at least substantially parallel, to the length of the aperture.
  • aperture trajectories 120 of apertures 118 may be considered to extend away from, and/or described as extending away from, inner surface 114, past outer surface 112, and/or away from screen-supporting tubular 110. Stated another way, aperture trajectories 120 of apertures 118 may illustrate and/or define a flow path, an entirety of a flow path, an unobstructed flow path, and/or an entirety of an unobstructed flow path for fluid flow 40 that flows from screen-supporting tubular conduit 122 of screen- supporting tubular 110 via apertures 118.
  • aperture trajectories 120 of apertures 118 may be three-dimensional (e.g., each having a length, a width, and a height) and each may be illustrated by a trajectory shape that conforms to the shape of corresponding aperture 118 and projects from the aperture and away from screen-supporting tubular 110, as illustrated in dash-dot lines in Fig. 2.
  • aperture trajectories 120 also may be referred to herein as and/or may be an aperture projection 120, and aperture extending volume, and/or an extending volume 120.
  • screen structure 130 encircles, or surrounds, outer surface 112 of at least aperture-defining region 116 of screen-supporting tubular 110.
  • Screen spacer 150 extends between screen-supporting tubular 110 and screen structure 130. As such, the screen spacer maintains a spaced-apart relationship between at least a majority, or even an entirety, of screen structure 130 and at least a majority, or even an entirety, of aperture- defining region 116.
  • Screen spacers 150 also may be referred to herein as ribs 150, as screen supporting ribs 150, as screen-spacing ribs 150, as elongate ribs 150, and/or as elongate ribs 150 that extend along a length of the screen-supporting tubular.
  • Shroud structure 170 is positioned at least along aperture trajectory 120 of each aperture 118. Stated another way, shroud structure 170 may intersect each aperture trajectory 120, may completely intersect each aperture trajectory 120, and/or may be at least partially coextensive with each aperture trajectory 120, and/or may be completely coextensive with each aperture trajectory 120.
  • a fluid flow 40 may be injected into subterranean formation 8 via the hydrocarbon well.
  • the fluid may be supplied to tubular conduit 32 of wellbore tubular 30 and may flow, along the length of the tubular conduit, to downhole end 34.
  • the fluid then may flow into well screen system 100 and a respective fraction of the fluid may flow along a respective aperture trajectory 120 that extends through each aperture 118 of the well screen system.
  • shroud structure 170 is positioned along the aperture trajectory of each aperture.
  • shroud structure 170 may re-direct the respective fraction of the fluid, from aperture trajectory 120, to a modified trajectory 124 that differs from the aperture trajectory, as illustrated schematically in Fig. 2.
  • a majority, or even an entirety, of the respective fraction of the fluid may flow through a region of screen structure 130 that is spaced-apart from aperture trajectory 120 before exiting well screen system 100, such as to flow into and/or to enter subterranean formation 8.
  • prior art and/or conventional well screen systems which may include a conventional screen-supporting tubular, a conventional screen structure, and/or a conventional screen spacer but that may not include shroud structures 170 according to the present disclosure
  • a majority of the fluid flow through the conventional well screen systems is along corresponding aperture trajectories.
  • a portion of the conventional screen structure that is proximal to and/or that extends across the corresponding aperture trajectories wears (i.e., is eroded) significantly more quickly than a remainder of the conventional screen structure. This may produce premature failure of the conventional well screen systems.
  • well screen systems 100 distribute fluid flow 40 away from aperture trajectories 120 and/or across a greater area of screen structure 130, thereby decreasing a rate at which screen structure 130 of well screen systems 100 wears when compared to the conventional well screen systems.
  • the above-described operation of hydrocarbon wells 10 also may be referred to herein as a method of injecting fluid into a subterranean formation.
  • Such a method may include the steps of providing the fluid to the tubular conduit, flowing the fluid along the tubular conduit, flowing the respective fraction of the fluid along the respective aperture trajectory, re-directing the respective fraction of the fluid, and flowing at least a majority of the respective fraction of the fluid through a region of the screen structure that is spaced-apart from the respective aperture trajectory, as discussed herein.
  • the fluid may include and/or be any suitable fluid, examples of which include water, sea water, and/or water that previously was produced from the hydrocarbon well.
  • the fluid may be provided to the tubular conduit for any suitable purpose, examples of which include to support a pressure within the subterranean formation, to maintain the pressure within the subterranean formation, to sweep a reservoir fluid from the subterranean formation, and/or for disposal of the fluid within the subterranean formation.
  • the fluid also may be provided at any suitable flow rate and/or volumetric flow rate.
  • the volumetric flow rate include flow rates of at least 0.01 cubic meter per second, at least 0.02 cubic meters per second, at least 0.03 cubic meters per second, at least 0.04 cubic meters per second, at least 0.05 cubic meters per second, at least 0.06 cubic meters per second, at least 0.07 cubic meters per second, at least 0.08 cubic meters per second, at least 0.09 cubic meters per second, at least 0.10 cubic meters per second, at least 0.12 cubic meters per second, at least 0.14 cubic meters per second, at least 0.16 cubic meters per second, at least 0.18 cubic meters per second, and/or at least 0.20 cubic meters per second.
  • the fluid additionally or alternatively may be provided such that the respective fraction of the fluid flows along the respective aperture trajectory of each aperture at any suitable flow rate, flow velocity, and/or flow speed.
  • the flow speed include flow speeds through the aperture include flow speeds of at least 1 meter per second (m/s), at least 2 m/s, at least 3 m/s, at least 4 m/s, at least 5 m/s, at least 6 m/s, at least 7 m/s, at least 8 m/s, at least 9 m/s, and/or at least 10 m/s.
  • shroud structure 170 is positioned at least along aperture trajectory 120 of each aperture 118 of the plurality of apertures 118 defined by screen-supporting tubular 110.
  • shroud structure 170 may include a wire 172, or a plurality of wires 172, that may be wrapped, such as helically wrapped, around screen-supporting tubular 110 such that the shroud structure restricts fluid flow 40 therethrough and along the aperture trajectory.
  • Wire 172 also may be referred to herein as a shroud wire 172 and may have and/or define any suitable length, width, height, shape, and/or transverse cross-sectional shape.
  • wire 172 may have a trapezoidal, or an isosceles trapezoidal, transverse cross-sectional shape. Under these conditions, and as illustrated, the wire may have a wide side of the trapezoid and a narrow side of the trapezoid, which is parallel to the wide side of the trapezoid. The wide side of the trapezoid may face away from screen-supporting tubular 110.
  • wire 172 may include and/or be a flat strip of wire, as discussed in more detail herein. As additional examples, wire 172 may have a square, rectangular, a pentagonal, or other geometric cross-sectional shape.
  • a single length of wire 172 may define an entirety of shroud structure 170. Additionally or alternatively, it is also within the scope of the present disclosure that the plurality of wires 172, when utilized, may be wrapped around screen-supporting tubular 110 in parallel and/or in series to define the shroud structure.
  • screen structure 130 separates shroud structure 170 from screen-supporting tubular 110, screen structure 130 extends between shroud structure 170 and screen-supporting tubular 110, and/or screen structure 130 is between shroud structure 170 and screen-supporting tubular 110.
  • wire 172 is helically wrapped around an outer surface 134 of screen structure 130. This may include a plurality of wraps of wire 172, as perhaps best illustrated in solid lines in Fig. 4, or a flat strip of wire 172, as illustrated in dashed lines in Fig. 4.
  • the presence of shroud structure 170 causes fluid flow 40 from screen supporting tubular 110 via apertures 118 to be redirected from aperture trajectory 120 to modified trajectory 124 that differs from the aperture trajectory.
  • shroud structure 170 includes the plurality of wraps of wire 172
  • the wire may be tight- wrapped and/or each wrap of wire may be in contact with an adjacent wrap of wire, thereby defining a shroud structure 170 that resists fluid flow 40 therethrough. Additionally or alternatively, the wraps of wire may be spaced such that wire 172 extends across gaps 136 in screen structure 130, thereby resisting fluid flow 40 through the screen structure.
  • shroud structure 170 includes a flat strip of wire 172
  • the flat strip of wire may define a strip width 176 that is greater than a diameter, or an effective diameter, of each aperture 118.
  • a wrap of the flat strip of wire 172 may extend across aperture trajectory 120 of each aperture 118.
  • screen structure 130 also may be defined by wire 172.
  • both screen structure 130 and shroud structure 170 may be defined by a single layer, or even by a single strand, of wire 172.
  • wire 172 may define a flow-occluding wire spacing, or a flow-occluding periodicity, when the wire intersects aperture trajectory 120 and/or in a flow-occluding region 178 of the screen structure.
  • Wire 172 also may define a flow-permitting wire spacing, or a flow-permitting periodicity, when the wire is spaced-apart from the aperture trajectory and/or in a flow-permitting region 179 of the screen structure.
  • the flow-occluding wire spacing may be less than the flow-permitting wire spacing.
  • Flow-occluding region 178 and flow-permitting region 179 may be spaced-apart from one another, and the flow-permitting wire spacing and the flow-occluding wire spacing may be selected such that less than a threshold fraction of the fluid flows through flow-occluding region 178.
  • the threshold fraction include threshold fractions of less than 20%, less than 15%, less than 10%, less than 5%, less than 1%, less than 0.5%, less than 0.25%, and 0%.
  • fluid flow 40 from screen-supporting tubular 110 via apertures 118 may be redirected from aperture trajectory 120 to modified trajectory 124 that differs from the aperture trajectory.
  • the flow-occluding wire spacing and/or the flow-permitting wire spacing may be measured and/or defined between adjacent wraps of wire 172. Stated another way, spacing between adjacent wire wraps may be selectively varied, with this selective variation being utilized to provide both the flow-occluding wire spacing (e.g., a relatively closer wire spacing that blocks, restricts, and/or occludes fluid flow past the wire wraps) and the flow-permitting wire spacing (e.g., a relatively wider and/or larger wire spacing that provides gaps, or larger gaps, between adjacent wire wraps and provides relatively less resistance to fluid flow past the wire wraps, as compared to the flow-occluding wire spacing).
  • the flow-occluding wire spacing e.g., a relatively closer wire spacing that blocks, restricts, and/or occludes fluid flow past the wire wraps
  • the flow-permitting wire spacing e.g., a relatively wider and/or larger wire spacing that provides gaps, or larger gaps, between adjacent wire
  • the flow-occluding wire spacing may maintain constant, or at least substantially constant, contact between each wrap of wire and each adjacent wrap of wire.
  • the flow-permitting wire spacing may maintain a spaced-apart relationship between each wrap of wire and each adjacent wrap of wire and/or may maintain a nonzero average distance between each wrap of wire and each adjacent wrap of wire.
  • the flow-occluding wire spacing and/or the flow- permitting wire spacing may be defined relative to screen structure 130.
  • the flow-occluding wire spacing may be such that wire 172 blocks, obstructs, and/or extends across gaps within screen structure 130 that otherwise would permit fluid flow therethrough.
  • the flow-permitting wire spacing may be such that wire 172 does not block, or only minimally obstructs, the gaps within the screen structure.
  • screen structure 130 separates shroud structure 170 from screen-supporting tubular 110, screen structure 130 extends between shroud structure 170 and screen-supporting tubular 110, and/or screen structure 130 is between shroud structure 170 and screen-supporting tubular 110.
  • screen structure 130 is defined by a screen wire 132 that is helically wrapped around screen-supporting tubular 110, wire 172 is helically wrapped around outer surface 134 of screen structure 130, and the well screen system further includes a shroud spacer 174 that extends between wire 172 and screen structure 130.
  • the shroud spacer maintains a spaced-apart relationship between at least a majority of wire 172 and at least a majority of screen structure 130.
  • wire 172 defines a flow-occluding shroud wire spacing when wire 172 is spaced-apart from aperture trajectory 120 and a flow-permitting shroud wire spacing when wire 172 intersects the aperture trajectory.
  • the flow-occluding shroud wire spacing may be present within a flow-occluding region 178 of the shroud structure, and the flow-permitting shroud wire spacing may be present within a flow-permitting region 179 of the shroud structure.
  • screen wire 132 defines a flow-occluding screen wire spacing when the screen wire intersects the aperture trajectory and a flow-permitting screen wire spacing when the screen wire is spaced-apart from the aperture trajectory.
  • the flow-occluding screen wire spacing may be present within a flow-occluding region 138 of the screen wire, and the flow- permitting screen wire spacing may be present within a flow-permitting region 139 of the screen wire.
  • flow-permitting region 179 of shroud structure 170 intersects aperture trajectory 120 of each aperture of the plurality of apertures, while flow-permitting region 139 of screen structure 130 is spaced-apart from aperture trajectory 120 of each aperture of the plurality of apertures.
  • fluid flow from screen supporting tubular 110 via apertures 118 may be directed, by the combination of screen structure 130 and shroud structure 170, along modified trajectory 124 that differs from aperture trajectory 120.
  • modified trajectory 124 that differs from aperture trajectory 120. Examples of flow-permitting and flow-occluding wire spacings of both wire 172 are screen wire 132 are discussed herein with reference to wire 172 of Figs. 5-6.
  • shroud structure 170 may include a perforated sleeve 180 that includes a plurality of sleeve perforations 182.
  • Perforated sleeve 180 additionally or alternatively may be referred to herein as including a flow-occluding region 184 that spatially separates the plurality of sleeve perforations.
  • the flow-occluding region may be configured to restrict, to block, and/or to occlude fluid flow 40 therethrough, to direct fluid that flows toward apertures 118 and/or toward sleeve perforations 182, and/or to deflect fluid flow from aperture trajectory 120 and/or to modified trajectory 124.
  • screen structure 130 may extend between shroud structure 170 and screen-supporting tubular 110, and each sleeve perforation 182 may be offset from aperture trajectory 120 of each aperture 118.
  • each sleeve perforation 182 may be spaced apart from the aperture trajectory of each aperture 118, may not intersect the aperture trajectory of each aperture 118, and/or may not be coextensive with the aperture trajectory of each aperture 118.
  • perforated sleeve 180 may restrict fluid flow therepast along the aperture trajectory of each aperture 118 and instead may redirect the fluid flow to modified trajectory 124, as illustrated in Fig. 11.
  • Sleeve perforations 182 may have any suitable shape and/or structure.
  • sleeve perforations 182 may include a plurality of circular sleeve perforations, a plurality of slots, a plurality of holes, a plurality of angled holes, and/or a plurality of profiled holes.
  • the plurality of sleeve perforations may define a perforation relative orientation
  • the plurality of apertures may define an aperture relative orientation.
  • the aperture relative orientation may correspond to the perforation relative orientation.
  • the aperture relative orientation may be offset from, translated relative to, and/or rotated relative to the sleeve relative orientation, thereby causing the fluid flow to be redirected along modified trajectory 124.
  • the plurality of sleeve perforations may define a total, or a cumulative, perforation cross-sectional area.
  • the plurality of apertures may define a total, or a cumulative, aperture cross-sectional area.
  • the total perforation cross-sectional area and the total aperture cross-sectional area may be measured in a direction that is transverse to an axis of radial symmetry of screen-supporting tubular 110, transverse to a radius of screen-supporting tubular 110, and/or transverse to aperture trajectory 120.
  • the total perforation cross-sectional area and the total aperture cross-sectional area may have and/or define any suitable relative magnitude.
  • the total perforation cross-sectional area may be equal, or at least substantially equal, to the total aperture cross-sectional area.
  • the total perforation cross- sectional area may be at least 0.25, at least 0.5, at least 0.75, at least 1, at least 1.25, at least 1.5, at least 2, at least 3, at least 4, and/or at least 5 times larger than the total aperture cross-sectional area.
  • the total perforation cross-sectional area may be at most 0.25, at most 0.5, at most 0.75, at most 1, at most 1.5, at most 2, at most 2.5, at most 3, at most 3.5, at most 4, at most 4.5, and/or at most 5 times the total aperture cross-sectional area.
  • shroud structure 170 may separate screen structure 130 from screen-supporting tubular 110 and may restrict fluid flow 40 along aperture trajectory 120 and through and/or into contact with the screen structure. Stated another way, and prior to contact between fluid that flows from screen supporting tubular 110 via apertures 118 and screen structure 130, shroud structure 170 may interact with and/or redirect the fluid flow such that the fluid flow contacts and/or flows through the screen structure along modified trajectory 124 that differs from the aperture trajectory.
  • shroud structure 170 and screen spacer 150 may be defined by the same structure and/or structures. Stated another way, shroud structure 170 may include and/or may function as screen spacer 150. Stated yet another way, screen spacer 150 may include and/or may function as shroud structure 170.
  • shroud structure 170 may include an elongate shroud body 190 that extends along a longitudinal axis of screen-supporting tubular 110.
  • the elongate shroud body may include a closed side 192, and open side 194, and a pair of spaced-apart side walls that extends between the open side and the closed side to define and/or bound an elongate channel 198.
  • Open side 194 may face toward screen-supporting tubular 110 and may be oriented, relative to the screen-supporting tubular, such that aperture trajectory 120 of at least a subset of apertures 118 extends into the elongate channel.
  • Closed side 192 may face toward and/or may contact screen structure 130, and elongate shroud body 190 further may define a plurality of cross-flow ports 199 that extend through spaced-apart side walls 196. As such, fluid flow 40 exiting screen-supporting tubular 110 via apertures 118 is re-directed, by elongate shroud body 190 and/or by closed side 192 thereof, from aperture trajectory 120 and to modified trajectory 124.
  • shroud structure 170 may include a plurality of elongate shroud bodies 190, with each elongate shroud body of the plurality of elongate shroud bodies being associated with a respective subset of apertures 118.
  • shroud structure 170 may be distinct and/or spaced- apart from screen spacer 150.
  • shroud structure 170 may include a plurality of shrouds 186, with each shroud in the plurality of shrouds being associated with a corresponding aperture 118 and/or extending at least partially within the corresponding aperture.
  • each shroud 186 may include and/or define an aperture-internal region 202, which extends within the corresponding aperture, and an aperture-external region 200, which is external to the corresponding aperture.
  • An internal cross-sectional area of aperture-internal region 202 may be less than an external cross-sectional area of aperture-external region 200, also as measured in the direction that is perpendicular to the aperture trajectory.
  • fluid flow 40 from screen-supporting tubular 110 via apertures 118 may be re-directed, by shrouds 186 and/or by aperture-external region 200 thereof, from aperture trajectory 120 to modified trajectory 124.
  • Aperture-external region 200 and aperture-internal region 202 may have and/or define any suitable shape, relative shape, size, relative size, and/or relative cross-sectional area.
  • the internal cross-sectional area may be less than 80%, less than 70%, less than 60%, less than 50%, less than 40%, less than 30%, less than 20%, at least 10%, at least 20%, at least 40%, and/or at least 60% of the external cross-sectional area.
  • the internal cross-sectional shape may be a plus-shape.
  • the external cross- sectional area may be circular.
  • the internal cross-sectional area of aperture-internal region 202 may be less than an aperture cross-sectional area of a corresponding aperture 118.
  • the internal cross- sectional area may be less than 80%, less than 70%, less than 60%, less than 50%, less than 40%, less than 30%, less than 20%, at least 10%, at least 20%, at least 40%, and/or at least 60% of the aperture cross-sectional area.
  • a relative orientation of at least one, or even each, shroud 186, relative to screen-supporting tubular 110 may be fixed, or at least substantially fixed. Additionally or alternatively, it is also within the scope of the present disclosure that at least one, or even each, shroud 186 may be configured to translate, or move, relative to the screen-supporting tubular. This may include translation between an open orientation 204 and a closed orientation 206. When in open orientation 204, shrouds 186 may be configured to permit fluid flow through corresponding aperture 118. When in closed orientation 206, shrouds 186 may be configured to resist and/or to restrict fluid flow through the corresponding aperture.
  • shrouds 186 may function as individual check valves that, in the example that is illustrated in Figs. 14-15, may permit outflow from screen supporting tubular 110 via apertures 118 and may resist inflow into the screen-supporting tubular via the apertures.
  • Screen-supporting tubular 110 may include any suitable structure that may include and/or define outer surface 112, inner surface 114, aperture-defining region 116, and/or apertures 118.
  • screen-supporting tubular 110 may include and/or be a pipe and/or a base pipe that may be formed from a steel and/or from a carbon steel.
  • screen-supporting tubular 110 may include and/or be a section of pipe that may be similar, or at least substantially similar, to wellbore tubular 30 of Fig. 1.
  • Screen structure 130 may include any suitable structure that may be at least partially fluid permeable and/or that may surround outer surface 112 of aperture-defining region 116 of screen-supporting tubular 110.
  • screen structure 130 may include and/or be a wire 132, or a screen wire 132, that may be wrapped (such as helically wrapped) around screen-supporting tubular 110 and/or around screen spacer 150.
  • This may include a single screen wire 132 and/or a plurality of distinct screen wires 132 that may be wrapped in parallel and/or in series around the screen-supporting tubular to provide at least regions of fluid permeability, such as via spacing between adjacent wraps of wire 132.
  • screen structure 130 may extend around screen-supporting tubular 110, may encircle screen-supporting tubular 110, and/or may surround at least a portion, such as aperture-defining region 116, of the screen-supporting tubular.
  • screen structure 130 may contact, may directly contact, may be attached to, and/or may be welded to screen spacer 150.
  • a relative orientation between screen structure 130 and screen-supporting tubular 110 and/or between screen structure 130 and screen space 150 may be fixed, or at least substantially fixed.
  • screen structure 130 may be formed from and/or may include any suitable material and/or materials.
  • screen structure 130 may include one or more of a steel, a steel alloy, a stainless steel, 316 stainless steel, a nickel-chromium-iron (Inconel®) alloy, and/or a corrosion-resistant alloy.
  • Screen spacer 150 may include any suitable structure that may extend between screen supporting tubular 110 and screen structure 130 and/or that may maintain the spaced-apart relationship between the screen-supporting tubular and the screen structure.
  • screen spacer 150 may include a plurality of elongate spacers. Under these conditions, a longitudinal axis of each of the elongate spacers may extend along, at least substantially along, parallel to, and/or at least substantially parallel to a longitudinal axis of screen-supporting tubular 110.
  • the plurality of elongate spaces may be spaced-apart, or circumferentially spaced- apart about a perimeter, or about a transverse cross-section, of outer surface 112 of screen- supporting tubular 110.
  • screen spacer 150 may establish, define, and/or maintain an at least partially annular space that extends between screen-supporting tubular 110 and screen structure 130.
  • a relative orientation between screen spacer 150 and screen-supporting tubular 110 and/or screen structure 130 may be fixed, or at least substantially fixed.
  • Shroud structure 170 may include any suitable structure that may be positioned at least along aperture trajectory 120 of each aperture 118 and/or that may restrict fluid flow 40 therethrough and along the aperture trajectory.
  • shroud structure 170 may be configured to direct a fluid stream, which flows through each aperture 118, along a tortuous flow path, direct the fluid stream away from the aperture trajectory, direct the fluid stream along an elongate axis of the screen-supporting tubular, divert the fluid stream, and/or divert the fluid stream from the aperture trajectory.
  • shroud structure 170 may be configured to permit fluid flow 40 though regions of the screen structure that are spaced-apart from the aperture trajectory. Such a configuration may facilitate fluid flow 40 over a larger surface area of screen structure 130 than otherwise would occur if shroud structure 170 were not present in well screen system 100, thereby decreasing wear of screen structure 130 when compared to an otherwise identical well screen system that does not include shroud structure 170.
  • Shroud structure 170 may be formed from and/or may include any suitable material and/or materials. As examples, shroud structure 170 may be formed from a shroud material that has a greater hardness than a screen material of screen structure 130, is a nickel-chromium- iron (Inconel®) alloy, is a resilient material, and/or is an abrasion-resistant material.
  • a shroud material that has a greater hardness than a screen material of screen structure 130, is a nickel-chromium- iron (Inconel®) alloy, is a resilient material, and/or is an abrasion-resistant material.
  • the term“and/or” placed between a first entity and a second entity means one of (1) the first entity, (2) the second entity, and (3) the first entity and the second entity.
  • Multiple entities listed with“and/or” should be construed in the same manner, i.e.,“one or more” of the entities so conjoined.
  • Other entities may optionally be present other than the entities specifically identified by the“and/or” clause, whether related or unrelated to those entities specifically identified.
  • a reference to“A and/or B,” when used in conjunction with open-ended language such as“comprising” may refer, in one embodiment, to A only (optionally including entities other than B); in another embodiment, to B only (optionally including entities other than A); in yet another embodiment, to both A and B (optionally including other entities).
  • These entities may refer to elements, actions, structures, steps, operations, values, and the like.
  • the phrase“at least one,” in reference to a list of one or more entities should be understood to mean at least one entity selected from any one or more of the entities in the list of entities, but not necessarily including at least one of each and every entity specifically listed within the list of entities and not excluding any combinations of entities in the list of entities.
  • This definition also allows that entities may optionally be present other than the entities specifically identified within the list of entities to which the phrase“at least one” refers, whether related or unrelated to those entities specifically identified.
  • “at least one of A and B” may refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including entities other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including entities other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other entities).
  • the phrases“at least one,”“one or more,” and“and/or” are open-ended expressions that are both conjunctive and disjunctive in operation.
  • each of the expressions“at least one of A, B, and C,” “at least one of A, B, or C,”“one or more of A, B, and C,”“one or more of A, B, or C,” and “A, B, and/or C” may mean A alone, B alone, C alone, A and B together, A and C together, B and C together, A, B, and C together, and optionally any of the above in combination with at least one other entity.
  • adapted and “configured” mean that the element, component, or other subject matter is designed and/or intended to perform a given function.
  • the use of the terms“adapted” and“configured” should not be construed to mean that a given element, component, or other subject matter is simply“capable of’ performing a given function but that the element, component, and/or other subject matter is specifically selected, created, implemented, utilized, programmed, and/or designed for the purpose of performing the function.
  • elements, components, and/or other recited subject matter that is recited as being adapted to perform a particular function may additionally or alternatively be described as being configured to perform that function, and vice versa.
  • the phrase,“for example,” the phrase,“as an example,” and/or simply the term“example,” when used with reference to one or more components, features, details, structures, embodiments, and/or methods according to the present disclosure, are intended to convey that the described component, feature, detail, structure, embodiment, and/or method is an illustrative, non-exclusive example of components, features, details, structures, embodiments, and/or methods according to the present disclosure.

Abstract

Well screen systems (100), hydrocarbon wells (10) that include the well screen systems, and methods of injecting fluid into the hydrocarbon wells are disclosed herein. The well screen systems (100) include a screen-supporting tubular (110), a screen structure (130), a screen spacer (150) and a shroud structure (170). The screen-supporting tubular includes a plurality of apertures (118) and each aperture extends along an aperture trajectory (120). The screen structure encircles an aperture-defining region (116) of the screen-supporting tubular. The screen spacer extends between the screen-supporting tubular and the screen structure. The shroud structure restricts fluid flow therethrough and along the aperture trajectory. The hydrocarbon wells (10) include a wellbore (20), a wellbore tubular (30) extending within the wellbore and having a downhole end (34), and the well screen systems (100), which is operatively attached to the downhole end of the wellbore tubular. The methods include methods of injecting fluid into a subterranean formation (8) utilizing the hydrocarbon wells.

Description

WELL SCREEN SYSTEMS, HYDROCARBON WELLS THAT INCLUDE THE WELL SCREEN SYSTEMS, AND METHODS OF INJECTING FLUID INTO THE
HYDROCARBON WELLS
Cross-Reference to Related Applications
[0001] This application claims the benefits of U.S. Provisional Application 62/691,382, filed June 28, 2018, the entirety of which is incorporated by reference herein.
Field of the Disclosure
[0002] The present disclosure relates generally to well screen systems, to hydrocarbon wells that include the well screen systems, and to methods of injecting fluid into hydrocarbon wells that include the well screen systems.
Background of the Disclosure
[0003] Hydrocarbon wells may be utilized to flow, or to produce, hydrocarbon fluids from a subterranean formation that extends within a subsurface region. In certain circumstances, it may be desirable to inject fluid into the subterranean formation via the hydrocarbon well. The injection may be performed to stimulate the subterranean formation, and such stimulation may be utilized to increase a production rate of the hydrocarbon fluids from the subterranean formation. As an example, fluid may be injected into the subterranean formation, via the hydrocarbon well, at high pressures in a process that may be referred to herein as hydraulic fracturing. This high-pressure fluid injection creates cracks, or fractures, within the subterranean formation, thereby improving, or increasing, a fluid permeability of the subterranean formation. As another example, acids may be injected into the subterranean formation to dissolve a portion of the subterranean formation, which also may increase the fluid permeability of the subterranean formation. As yet another example, a proppant may be injected into the subterranean formation to prop open any created cracks and/or fractures.
[0004] Additionally or alternatively, the injection may be performed to provide pressure support to the subterranean formation and/or to sweep hydrocarbons from the reservoir. Such injection may be performed below a fracture pressure of the subterranean formation and/or above the fracture pressure. When performed above the fracture pressure, the injection may maintain injectivity of the subterranean formation and/or may create new fractures and/or extend existing fractures within the subterranean formation. [0005] Such injection operations often may be performed at relatively high flow rates for the injected fluid, and these high flow rates may cause wear, erosion, and/or damage to various structures of the hydrocarbon well. As an example, a well screen system may be positioned within a wellbore of the hydrocarbon well. During production operations, the well screen system may be utilized to screen and/or filter flow of the hydrocarbon fluids into a wellbore tubular that extends within the wellbore, such as to restrict and/or prevent flow of sand, gravel, and/or other solids into a tubular conduit defined by the wellbore tubular. In such a configuration, the injected fluid also may flow through the well screen system during stimulation of the subterranean formation, leading to wear to, damage to, and/or failure of conventional well screen systems. Thus, there exists a need for improved well screen systems, for hydrocarbon wells that include the well screen systems, and/or for methods of injecting fluid into hydrocarbon wells that include the well screen systems.
Summary of the Disclosure
[0006] Well screen systems, hydrocarbon wells that include the well screen systems, and methods of injecting fluid into the hydrocarbon wells are disclosed herein. The well screen systems include a screen-supporting tubular, a screen structure, a screen spacer, and a shroud structure. The screen-supporting tubular includes an inner surface, an outer surface, and a plurality of spaced-apart apertures extending within an aperture-defining region of the screen supporting tubular. Each aperture extends along an aperture trajectory from the inner surface to the outer surface. The screen structure encircles the outer surface of the aperture-defining region of the screen-supporting tubular. The screen spacer extends between the screen supporting tubular and the screen structure and maintains a spaced-apart relationship between at least a majority of the screen structure and at least a majority of the aperture-defining region. The shroud structure is positioned at least along the aperture trajectory of each aperture and restricts fluid flow therethrough along the aperture trajectory.
[0007] The hydrocarbon wells include a wellbore, a wellbore tubular extending within the wellbore, and the well screen system. The wellbore extends within a subterranean formation. The wellbore tubular defines a tubular conduit and has a downhole end. The well screen system is operatively attached to the downhole end of the wellbore tubular.
[0008] The methods include methods of injecting fluid into a subterranean formation utilizing the hydrocarbon wells. The methods including providing the fluid to the tubular conduit and flowing the fluid along the tubular conduit to the downhole end. The methods also include flowing a respective fraction of the fluid along a respective aperture trajectory that extends through each aperture and re-directing the respective fraction from the respective aperture trajectory to a respective modified trajectory. The methods further include flowing at least a majority of the respective fraction of the fluid through a region of the screen structure that is spaced-apart from the aperture trajectory and flowing the respective fraction of the fluid into the subterranean formation.
Brief Description of the Drawings
[0009] Fig. 1 is a schematic illustration of examples of hydrocarbon wells including well screen systems, according to the present disclosure.
[0010] Fig. 2 is a schematic longitudinal cross-sectional illustration of examples of well screen systems according to the present disclosure.
[0011] Fig. 3 is a less schematic transverse cross-sectional illustration of examples of well screen systems, according to the present disclosure, such as may be taken along line A-A of Fig. 1.
[0012] Fig. 4 is a cross-sectional view of the well screen systems of Fig. 3 taken along line 4- 4 of Fig. 3.
[0013] Fig. 5 is another less schematic transverse cross-sectional illustration of an example of a well screen system, according to the present disclosure, such as may be taken along line A- A of Fig. 1.
[0014] Fig. 6 is a cross-sectional view of the well screen system of Fig. 5 taken along line 6-6 of Fig. 5.
[0015] Fig. 7 is another less schematic transverse cross-sectional illustration of an example of a well screen system, according to the present disclosure, such as may be taken along line A- A of Fig. 1.
[0016] Fig. 8 is a cross-sectional view of the well screen system of Fig. 7 taken along line 8-8 of Fig. 7.
[0017] Fig. 9 is a less schematic side view of an example of a well screen system, according to the present disclosure.
[0018] Fig. 10 is a less schematic transverse cross-sectional illustration of the well screen system of Fig. 9, such as may be taken along line 10-10 of Fig. 9 and/or along line A-A of Fig. 1
[0019] Fig. 11 is a cross-sectional view of the well screen system of Fig. 10 taken along line
11-11 of Fig. 10.
[0020] Fig. 12 is another less schematic transverse cross-sectional illustration of an example of a well screen system, according to the present disclosure, such as may be taken along line A-A of Fig. 1. [0021] Fig. 13 is a cross-sectional view of the well screen system of Fig. 12 taken along line 13-13 of Fig. 12.
[0022] Fig. 14 is another less schematic transverse cross-sectional illustration of an example of a well screen system, according to the present disclosure, such as may be taken along line A-A of Fig. 1.
[0023] Fig. 15 is a cross-sectional view of the well screen system of Fig. 14 taken along line 15-15 of Fig. 14.
[0024] Fig. 16 is a schematic bottom view of a shroud structure of Figs. 15-16.
Detailed Description and Best Mode of the Disclosure
[0025] Figs. 1-16 provide examples of well screen systems 100 and of hydrocarbon wells 10 that include well screen systems 100 and/or may be utilized with methods, according to the present disclosure, of injecting fluid into hydrocarbon wells 10. Elements that serve a similar, or at least substantially similar, purpose are labeled with like numbers in each of Figs. 1-16, and these elements may not be discussed in detail herein with reference to each of Figs. 1-16. Similarly, all elements may not be labeled in each of Figs. 1-16, but reference numerals associated therewith may be utilized herein for consistency. Elements, components, and/or features that are discussed herein with reference to one or more of Figs. 1-16 may be included in and/or utilized with any of Figs. 1-16 without departing from the scope of the present disclosure. In general, elements that are likely to be included in a particular embodiment are illustrated in solid lines, while elements that are optional are illustrated in dashed lines.
However, elements that are shown in solid lines may not be essential and, in some embodiments, may be omitted without departing from the scope of the present disclosure.
[0026] Fig. 1 is a schematic illustration of examples of hydrocarbon wells 10 including well screen systems 100, according to the present disclosure. As illustrated in solid lines in Fig. 1, hydrocarbon wells 10 include a wellbore 20 extending within a subterranean formation 8. Wellbore 20 also may be referred to herein as extending within a subsurface region 6 that includes subterranean formation 8 and/or as extending between a surface region 4 and the subterranean formation.
[0027] Hydrocarbon wells 10 also include a wellbore tubular 30 extending within wellbore 20. Wellbore tubular has and/or defines a tubular conduit 32 and/or a downhole end 34. Downhole end 34 also may be referred to herein as and/or may be a downhole region and/or an end region of the wellbore tubular, and thus may include more than the terminal downhole edge of the wellbore tubular. [0028] Hydrocarbon wells 10 further include well screen system 100. Well screen system 100 is operatively attached to downhole end 34 of wellbore tubular 30, and more specific and/or detailed examples of well screen system 100 are illustrated Figs. 2-15 and discussed herein with reference thereto. Well screen system 100 is configured to filter fluid flow 40 between subterranean formation 8 and tubular conduit 32. This may include filtering fluid flow 40 from the subterranean formation and into the tubular conduit via downhole end 34, such as during production of hydrocarbon fluid from the subterranean formation. Additionally or alternatively, this also may include filtering fluid flow 40, via downhole end 34, from the tubular conduit and into the subterranean formation, such as during stimulation of the subterranean formation via the hydrocarbon well. As discussed in more detail herein, well screen system 100 includes a screen structure 130, and the well screen system permits fluid communication between wellbore 20 and tubular conduit 32 through and/or via the screen structure.
[0029] As illustrated in dashed lines in Fig. 1, and while not required of all embodiments, hydrocarbon well 10 may include a gravel pack 50. Gravel pack 50, when present, may extend between wellbore 20 and well screen system 100 and/or may be or function as a gravel filter, or as a coarse filter, within hydrocarbon well 10. When hydrocarbon well 10 includes gravel pack 50, well screen system 100 and/or screen structure 130 thereof may be configured to resist flow and/or conveyance of gravel from the gravel pack into tubular conduit 32.
[0030] As also illustrated in dashed lines in Fig. 1, and while not required of all embodiments, hydrocarbon well 10 may include one or more packers 60. Packers 60, when present, may be associated with wellbore tubular 30 and/or with well screen system 100. Stated another way, and as illustrated by the uppermost packer in Fig. 1, packers 60 may extend between the wellbore tubular and wellbore 20. Additionally or alternatively, and as illustrated by the lowermost packer in Fig. 1, packers 60 may extend between well screen system 100, or a central region of well screen system 100, and wellbore 20. Packers 60 that are associated with well screen system 100 may cause fluid flow 40 to be concentrated at and/or near the packers. This concentration of fluid flow contributed to increased erosion of prior art well screen systems, thereby demonstrating the need for well screen systems 100, according to the present disclosure.
[0031] Hydrocarbon well 10 also may include one or more additional/optional structures that may be known in the art and/or that may be common to conventional hydrocarbon wells. As examples, hydrocarbon well 10 may include one or more casings, casing collars, downhole tubes, production tubes, tubing collars, pumps, valves, sensors, detectors, and/or controllers. It should be understood that these conventional structures have not been illustrated in the schematic wellbore of Fig. 1 so as not to detract from the discussion and presentation of well screen systems 100.
[0032] Figs. 2-16 provide more specific and/or detailed examples of well screen systems 100. It is within the scope of the present disclosure that well screen systems 100 of Figs. 2-16 may include and/or be more detailed illustrations and/or examples of well screen system 100 of Fig. 1. As such, any of the structures, functions, and/or features of well screen systems 100 of Figs. 2-16 may be included in and/or utilized with hydrocarbon well 10 of Fig. 1 without departing from the scope of the present disclosure. Similarly, any of the structures, functions, and/or features of hydrocarbon well 10 of Fig. 1 may be included in and/or utilized with well screen systems 100 of Figs. 2-16 without departing from the scope of the present disclosure.
[0033] Fig. 2 is a schematic illustration of examples of well screen systems 100 according to the present disclosure. Fig. 3 is a less schematic illustration of examples of a transverse cross- section of well screen systems 100, according to the present disclosure, such as may be taken along line A-A of Fig. 1, while Fig. 4 is a cross-sectional view of the well screen systems of Fig. 3 taken along line 4-4 of Fig. 3. Fig. 5 is another less schematic illustration of an example of a transverse cross-section of well screen system 100, according to the present disclosure, such as may be taken along line A-A of Fig. 1, while Fig. 6 is a cross-sectional view of the well screen system of Fig. 5 taken along line 6-6 of Fig. 5. Fig. 7 is another less schematic illustration of an example of a transverse cross-section of well screen system 100, according to the present disclosure, such as may be taken along line A-A of Fig. 1, while Fig. 8 is a cross- sectional view of the well screen system of Fig. 7 taken along line 8-8 of Fig. 7. Fig. 9 is a less schematic side view of an example of well screen system 100, according to the present disclosure, while Fig. 10 is a less schematic illustration of a transverse cross-section of the well screen system of Fig. 9, such as may be taken along line 10-10 of Fig. 9 and/or along line A-A of Fig. 1 and Fig. 11 is a cross-sectional view of the well screen system of Fig. 10 taken along line 11-11 of Fig. 10. Fig. 12 is another less schematic illustration of atransverse cross-section of an example of well screen system 100, according to the present disclosure, such as may be taken along line A-A of Fig. 1, while Fig. 13 is a cross-sectional view of the well screen system of Fig. 12 taken along line 13-13 of Fig. 12. Fig. 14 is another less schematic illustration of a transverse cross-section of an example of well screen system 100, according to the present disclosure, such as may be taken along line A-A of Fig. 1, while Fig. 15 is a cross-sectional view of the well screen system of Fig. 14 taken along line 15-15 of Fig. 14, and Fig. 16 is a schematic bottom view of a shroud structure 170 of Figs. 15-16. [0034] As illustrated in Figs. 2-16, well screen systems 100 include a screen-supporting tubular 110, a screen structure 130, a screen spacer 150, and a shroud structure 170. Screen supporting tubular 110 also may be referred to herein as a screen- wrapped tubular 110, as a screen tubular 110, as a system tubular 110, as an underlying tubular 110, and/or as a central tubular 110. The screen-supporting tubular includes an outer surface 112, an inner surface 114, and a plurality of spaced-apart apertures 118. Apertures 118 extend within an aperture-defining region 116 of the screen-supporting tubular.
[0035] As illustrated in Figs. 2, 4, 6, 8, 11, 13, and 15, each aperture 118 extends along an aperture trajectory 120 from inner surface 114 to and beyond outer surface 112. As used herein, the term“aperture traj ectory” refers to a collection of all lines, or traj ectories, that extend, along a length 119 of a given aperture, from inner surface 114 toward and/or past outer surface 112. Stated another way, aperture trajectory 120 of a given aperture 118 extends across an entirety of a transverse cross-section of the given aperture, extends from the given aperture 118, and extends along a direction that is parallel, or at least substantially parallel, to the length of the aperture. This is in contrast to a single line, or ray, that might, for example, be central to an aperture 118, might extend along the length of an aperture 118, and/or might define a flow direction, or an average flow direction, for fluid flow 40 that exits screen-supporting tubular conduit 122 via an aperture 118.
[0036] As illustrated in dash-dot lines in Fig. 2, aperture trajectories 120 of apertures 118 may be considered to extend away from, and/or described as extending away from, inner surface 114, past outer surface 112, and/or away from screen-supporting tubular 110. Stated another way, aperture trajectories 120 of apertures 118 may illustrate and/or define a flow path, an entirety of a flow path, an unobstructed flow path, and/or an entirety of an unobstructed flow path for fluid flow 40 that flows from screen-supporting tubular conduit 122 of screen- supporting tubular 110 via apertures 118. Stated yet another way, aperture trajectories 120 of apertures 118 may be three-dimensional (e.g., each having a length, a width, and a height) and each may be illustrated by a trajectory shape that conforms to the shape of corresponding aperture 118 and projects from the aperture and away from screen-supporting tubular 110, as illustrated in dash-dot lines in Fig. 2. With the above in mind, aperture trajectories 120 also may be referred to herein as and/or may be an aperture projection 120, and aperture extending volume, and/or an extending volume 120.
[0037] Returning more generally to Figs. 2-16, screen structure 130 encircles, or surrounds, outer surface 112 of at least aperture-defining region 116 of screen-supporting tubular 110. Screen spacer 150 extends between screen-supporting tubular 110 and screen structure 130. As such, the screen spacer maintains a spaced-apart relationship between at least a majority, or even an entirety, of screen structure 130 and at least a majority, or even an entirety, of aperture- defining region 116. Screen spacers 150 also may be referred to herein as ribs 150, as screen supporting ribs 150, as screen-spacing ribs 150, as elongate ribs 150, and/or as elongate ribs 150 that extend along a length of the screen-supporting tubular.
[0038] Shroud structure 170 is positioned at least along aperture trajectory 120 of each aperture 118. Stated another way, shroud structure 170 may intersect each aperture trajectory 120, may completely intersect each aperture trajectory 120, and/or may be at least partially coextensive with each aperture trajectory 120, and/or may be completely coextensive with each aperture trajectory 120.
[0039] During operation of hydrocarbon wells 10 that include well screen systems 100, a fluid flow 40, as illustrated schematically in Figs. 1-2, may be injected into subterranean formation 8 via the hydrocarbon well. As an example, the fluid may be supplied to tubular conduit 32 of wellbore tubular 30 and may flow, along the length of the tubular conduit, to downhole end 34. The fluid then may flow into well screen system 100 and a respective fraction of the fluid may flow along a respective aperture trajectory 120 that extends through each aperture 118 of the well screen system. As discussed, shroud structure 170 is positioned along the aperture trajectory of each aperture. As such, shroud structure 170 may re-direct the respective fraction of the fluid, from aperture trajectory 120, to a modified trajectory 124 that differs from the aperture trajectory, as illustrated schematically in Fig. 2. Thus, at least a majority, or even an entirety, of the respective fraction of the fluid may flow through a region of screen structure 130 that is spaced-apart from aperture trajectory 120 before exiting well screen system 100, such as to flow into and/or to enter subterranean formation 8.
[0040] In prior art and/or conventional well screen systems, which may include a conventional screen-supporting tubular, a conventional screen structure, and/or a conventional screen spacer but that may not include shroud structures 170 according to the present disclosure, a majority of the fluid flow through the conventional well screen systems is along corresponding aperture trajectories. As such, a portion of the conventional screen structure that is proximal to and/or that extends across the corresponding aperture trajectories wears (i.e., is eroded) significantly more quickly than a remainder of the conventional screen structure. This may produce premature failure of the conventional well screen systems. In contrast, well screen systems 100, according to the present disclosure, distribute fluid flow 40 away from aperture trajectories 120 and/or across a greater area of screen structure 130, thereby decreasing a rate at which screen structure 130 of well screen systems 100 wears when compared to the conventional well screen systems.
[0041] The above-described operation of hydrocarbon wells 10 also may be referred to herein as a method of injecting fluid into a subterranean formation. Such a method may include the steps of providing the fluid to the tubular conduit, flowing the fluid along the tubular conduit, flowing the respective fraction of the fluid along the respective aperture trajectory, re-directing the respective fraction of the fluid, and flowing at least a majority of the respective fraction of the fluid through a region of the screen structure that is spaced-apart from the respective aperture trajectory, as discussed herein.
[0042] In hydrocarbon wells 10, the fluid may include and/or be any suitable fluid, examples of which include water, sea water, and/or water that previously was produced from the hydrocarbon well. The fluid may be provided to the tubular conduit for any suitable purpose, examples of which include to support a pressure within the subterranean formation, to maintain the pressure within the subterranean formation, to sweep a reservoir fluid from the subterranean formation, and/or for disposal of the fluid within the subterranean formation.
[0043] The fluid also may be provided at any suitable flow rate and/or volumetric flow rate. Examples of the volumetric flow rate include flow rates of at least 0.01 cubic meter per second, at least 0.02 cubic meters per second, at least 0.03 cubic meters per second, at least 0.04 cubic meters per second, at least 0.05 cubic meters per second, at least 0.06 cubic meters per second, at least 0.07 cubic meters per second, at least 0.08 cubic meters per second, at least 0.09 cubic meters per second, at least 0.10 cubic meters per second, at least 0.12 cubic meters per second, at least 0.14 cubic meters per second, at least 0.16 cubic meters per second, at least 0.18 cubic meters per second, and/or at least 0.20 cubic meters per second.
[0044] The fluid additionally or alternatively may be provided such that the respective fraction of the fluid flows along the respective aperture trajectory of each aperture at any suitable flow rate, flow velocity, and/or flow speed. Examples of the flow speed include flow speeds through the aperture include flow speeds of at least 1 meter per second (m/s), at least 2 m/s, at least 3 m/s, at least 4 m/s, at least 5 m/s, at least 6 m/s, at least 7 m/s, at least 8 m/s, at least 9 m/s, and/or at least 10 m/s.
[0045] As discussed, shroud structure 170 is positioned at least along aperture trajectory 120 of each aperture 118 of the plurality of apertures 118 defined by screen-supporting tubular 110. As illustrated schematically in Fig. 2 and less schematically in Figs. 3-8, shroud structure 170 may include a wire 172, or a plurality of wires 172, that may be wrapped, such as helically wrapped, around screen-supporting tubular 110 such that the shroud structure restricts fluid flow 40 therethrough and along the aperture trajectory. Wire 172 also may be referred to herein as a shroud wire 172 and may have and/or define any suitable length, width, height, shape, and/or transverse cross-sectional shape. As an example, and as illustrated in solid lines in Figs. 4, 6, 8, 11, 13, and 15, wire 172 may have a trapezoidal, or an isosceles trapezoidal, transverse cross-sectional shape. Under these conditions, and as illustrated, the wire may have a wide side of the trapezoid and a narrow side of the trapezoid, which is parallel to the wide side of the trapezoid. The wide side of the trapezoid may face away from screen-supporting tubular 110. As another example, and as illustrated in dashed lines in Fig. 4, wire 172 may include and/or be a flat strip of wire, as discussed in more detail herein. As additional examples, wire 172 may have a square, rectangular, a pentagonal, or other geometric cross-sectional shape.
[0046] It is within the scope of the present disclosure that a single length of wire 172 may define an entirety of shroud structure 170. Additionally or alternatively, it is also within the scope of the present disclosure that the plurality of wires 172, when utilized, may be wrapped around screen-supporting tubular 110 in parallel and/or in series to define the shroud structure.
[0047] In one example of well screen system 100, which is illustrated schematically in Fig. 2 and less schematically in Figs. 3-4, screen structure 130 separates shroud structure 170 from screen-supporting tubular 110, screen structure 130 extends between shroud structure 170 and screen-supporting tubular 110, and/or screen structure 130 is between shroud structure 170 and screen-supporting tubular 110. In this example, wire 172 is helically wrapped around an outer surface 134 of screen structure 130. This may include a plurality of wraps of wire 172, as perhaps best illustrated in solid lines in Fig. 4, or a flat strip of wire 172, as illustrated in dashed lines in Fig. 4. The presence of shroud structure 170 causes fluid flow 40 from screen supporting tubular 110 via apertures 118 to be redirected from aperture trajectory 120 to modified trajectory 124 that differs from the aperture trajectory.
[0048] When shroud structure 170 includes the plurality of wraps of wire 172, the wire may be tight- wrapped and/or each wrap of wire may be in contact with an adjacent wrap of wire, thereby defining a shroud structure 170 that resists fluid flow 40 therethrough. Additionally or alternatively, the wraps of wire may be spaced such that wire 172 extends across gaps 136 in screen structure 130, thereby resisting fluid flow 40 through the screen structure.
[0049] When shroud structure 170 includes a flat strip of wire 172, the flat strip of wire may define a strip width 176 that is greater than a diameter, or an effective diameter, of each aperture 118. As such, and as illustrated in Fig. 4, a wrap of the flat strip of wire 172 may extend across aperture trajectory 120 of each aperture 118. [0050] In another example of well screen system 100, which is illustrated schematically in Fig. 2 and less schematically in Figs. 5-6, screen structure 130 also may be defined by wire 172. Stated another way, both screen structure 130 and shroud structure 170 may be defined by a single layer, or even by a single strand, of wire 172. In this example, wire 172 may define a flow-occluding wire spacing, or a flow-occluding periodicity, when the wire intersects aperture trajectory 120 and/or in a flow-occluding region 178 of the screen structure. Wire 172 also may define a flow-permitting wire spacing, or a flow-permitting periodicity, when the wire is spaced-apart from the aperture trajectory and/or in a flow-permitting region 179 of the screen structure. The flow-occluding wire spacing may be less than the flow-permitting wire spacing.
[0051] Flow-occluding region 178 and flow-permitting region 179 may be spaced-apart from one another, and the flow-permitting wire spacing and the flow-occluding wire spacing may be selected such that less than a threshold fraction of the fluid flows through flow-occluding region 178. Examples of the threshold fraction include threshold fractions of less than 20%, less than 15%, less than 10%, less than 5%, less than 1%, less than 0.5%, less than 0.25%, and 0%. As such, fluid flow 40 from screen-supporting tubular 110 via apertures 118 may be redirected from aperture trajectory 120 to modified trajectory 124 that differs from the aperture trajectory.
[0052] The flow-occluding wire spacing and/or the flow-permitting wire spacing may be measured and/or defined between adjacent wraps of wire 172. Stated another way, spacing between adjacent wire wraps may be selectively varied, with this selective variation being utilized to provide both the flow-occluding wire spacing (e.g., a relatively closer wire spacing that blocks, restricts, and/or occludes fluid flow past the wire wraps) and the flow-permitting wire spacing (e.g., a relatively wider and/or larger wire spacing that provides gaps, or larger gaps, between adjacent wire wraps and provides relatively less resistance to fluid flow past the wire wraps, as compared to the flow-occluding wire spacing).
[0053] As an example, the flow-occluding wire spacing may maintain constant, or at least substantially constant, contact between each wrap of wire and each adjacent wrap of wire. In contrast, the flow-permitting wire spacing may maintain a spaced-apart relationship between each wrap of wire and each adjacent wrap of wire and/or may maintain a nonzero average distance between each wrap of wire and each adjacent wrap of wire.
[0054] Additionally or alternatively, the flow-occluding wire spacing and/or the flow- permitting wire spacing may be defined relative to screen structure 130. As an example, the flow-occluding wire spacing may be such that wire 172 blocks, obstructs, and/or extends across gaps within screen structure 130 that otherwise would permit fluid flow therethrough. In contrast, the flow-permitting wire spacing may be such that wire 172 does not block, or only minimally obstructs, the gaps within the screen structure.
[0055] In another example of well screen system 100, which is illustrated schematically in Fig. 2 and less schematically in Figs. 7-8, screen structure 130 separates shroud structure 170 from screen-supporting tubular 110, screen structure 130 extends between shroud structure 170 and screen-supporting tubular 110, and/or screen structure 130 is between shroud structure 170 and screen-supporting tubular 110. In this example, screen structure 130 is defined by a screen wire 132 that is helically wrapped around screen-supporting tubular 110, wire 172 is helically wrapped around outer surface 134 of screen structure 130, and the well screen system further includes a shroud spacer 174 that extends between wire 172 and screen structure 130. The shroud spacer maintains a spaced-apart relationship between at least a majority of wire 172 and at least a majority of screen structure 130.
[0056] As perhaps best illustrated in Fig. 8, wire 172 defines a flow-occluding shroud wire spacing when wire 172 is spaced-apart from aperture trajectory 120 and a flow-permitting shroud wire spacing when wire 172 intersects the aperture trajectory. The flow-occluding shroud wire spacing may be present within a flow-occluding region 178 of the shroud structure, and the flow-permitting shroud wire spacing may be present within a flow-permitting region 179 of the shroud structure.
[0057] In contrast, screen wire 132 defines a flow-occluding screen wire spacing when the screen wire intersects the aperture trajectory and a flow-permitting screen wire spacing when the screen wire is spaced-apart from the aperture trajectory. The flow-occluding screen wire spacing may be present within a flow-occluding region 138 of the screen wire, and the flow- permitting screen wire spacing may be present within a flow-permitting region 139 of the screen wire. As perhaps best illustrated in Fig. 8, flow-permitting region 179 of shroud structure 170 intersects aperture trajectory 120 of each aperture of the plurality of apertures, while flow-permitting region 139 of screen structure 130 is spaced-apart from aperture trajectory 120 of each aperture of the plurality of apertures. As such, fluid flow from screen supporting tubular 110 via apertures 118 may be directed, by the combination of screen structure 130 and shroud structure 170, along modified trajectory 124 that differs from aperture trajectory 120. Examples of flow-permitting and flow-occluding wire spacings of both wire 172 are screen wire 132 are discussed herein with reference to wire 172 of Figs. 5-6.
[0058] As illustrated schematically in Fig. 2 and less schematically in Figs. 9-11, shroud structure 170 may include a perforated sleeve 180 that includes a plurality of sleeve perforations 182. Perforated sleeve 180 additionally or alternatively may be referred to herein as including a flow-occluding region 184 that spatially separates the plurality of sleeve perforations. The flow-occluding region may be configured to restrict, to block, and/or to occlude fluid flow 40 therethrough, to direct fluid that flows toward apertures 118 and/or toward sleeve perforations 182, and/or to deflect fluid flow from aperture trajectory 120 and/or to modified trajectory 124.
[0059] In this example, screen structure 130 may extend between shroud structure 170 and screen-supporting tubular 110, and each sleeve perforation 182 may be offset from aperture trajectory 120 of each aperture 118. Stated another way, each sleeve perforation 182 may be spaced apart from the aperture trajectory of each aperture 118, may not intersect the aperture trajectory of each aperture 118, and/or may not be coextensive with the aperture trajectory of each aperture 118. As such, perforated sleeve 180 may restrict fluid flow therepast along the aperture trajectory of each aperture 118 and instead may redirect the fluid flow to modified trajectory 124, as illustrated in Fig. 11.
[0060] Sleeve perforations 182 may have any suitable shape and/or structure. As examples, sleeve perforations 182 may include a plurality of circular sleeve perforations, a plurality of slots, a plurality of holes, a plurality of angled holes, and/or a plurality of profiled holes.
[0061] As illustrated in Fig. 9, and while not required of all embodiments, the plurality of sleeve perforations may define a perforation relative orientation, and the plurality of apertures may define an aperture relative orientation. The aperture relative orientation may correspond to the perforation relative orientation. However, the aperture relative orientation may be offset from, translated relative to, and/or rotated relative to the sleeve relative orientation, thereby causing the fluid flow to be redirected along modified trajectory 124.
[0062] The plurality of sleeve perforations may define a total, or a cumulative, perforation cross-sectional area. Similarly, the plurality of apertures may define a total, or a cumulative, aperture cross-sectional area. The total perforation cross-sectional area and the total aperture cross-sectional area may be measured in a direction that is transverse to an axis of radial symmetry of screen-supporting tubular 110, transverse to a radius of screen-supporting tubular 110, and/or transverse to aperture trajectory 120. The total perforation cross-sectional area and the total aperture cross-sectional area may have and/or define any suitable relative magnitude. As an example, the total perforation cross-sectional area may be equal, or at least substantially equal, to the total aperture cross-sectional area. As another example, the total perforation cross- sectional area may be at least 0.25, at least 0.5, at least 0.75, at least 1, at least 1.25, at least 1.5, at least 2, at least 3, at least 4, and/or at least 5 times larger than the total aperture cross-sectional area. As yet another example, the total perforation cross-sectional area may be at most 0.25, at most 0.5, at most 0.75, at most 1, at most 1.5, at most 2, at most 2.5, at most 3, at most 3.5, at most 4, at most 4.5, and/or at most 5 times the total aperture cross-sectional area.
[0063] As illustrated schematically in Fig. 2 and less schematically in Figs. 12-16, shroud structure 170 may separate screen structure 130 from screen-supporting tubular 110 and may restrict fluid flow 40 along aperture trajectory 120 and through and/or into contact with the screen structure. Stated another way, and prior to contact between fluid that flows from screen supporting tubular 110 via apertures 118 and screen structure 130, shroud structure 170 may interact with and/or redirect the fluid flow such that the fluid flow contacts and/or flows through the screen structure along modified trajectory 124 that differs from the aperture trajectory.
[0064] In one example of well screen system 100, which is illustrated schematically in Fig. 2 and less schematically in Figs. 12-13, shroud structure 170 and screen spacer 150 may be defined by the same structure and/or structures. Stated another way, shroud structure 170 may include and/or may function as screen spacer 150. Stated yet another way, screen spacer 150 may include and/or may function as shroud structure 170.
[0065] In this example, shroud structure 170 may include an elongate shroud body 190 that extends along a longitudinal axis of screen-supporting tubular 110. The elongate shroud body may include a closed side 192, and open side 194, and a pair of spaced-apart side walls that extends between the open side and the closed side to define and/or bound an elongate channel 198. Open side 194 may face toward screen-supporting tubular 110 and may be oriented, relative to the screen-supporting tubular, such that aperture trajectory 120 of at least a subset of apertures 118 extends into the elongate channel. Closed side 192 may face toward and/or may contact screen structure 130, and elongate shroud body 190 further may define a plurality of cross-flow ports 199 that extend through spaced-apart side walls 196. As such, fluid flow 40 exiting screen-supporting tubular 110 via apertures 118 is re-directed, by elongate shroud body 190 and/or by closed side 192 thereof, from aperture trajectory 120 and to modified trajectory 124.
[0066] As illustrated in Fig. 12, shroud structure 170 may include a plurality of elongate shroud bodies 190, with each elongate shroud body of the plurality of elongate shroud bodies being associated with a respective subset of apertures 118.
[0067] In another example of well screen system 100, which is illustrated schematically in Fig.
2 and less schematically in Figs. 14-16, shroud structure 170 may be distinct and/or spaced- apart from screen spacer 150. In this example, shroud structure 170 may include a plurality of shrouds 186, with each shroud in the plurality of shrouds being associated with a corresponding aperture 118 and/or extending at least partially within the corresponding aperture. [0068] As an example, each shroud 186 may include and/or define an aperture-internal region 202, which extends within the corresponding aperture, and an aperture-external region 200, which is external to the corresponding aperture. An internal cross-sectional area of aperture-internal region 202, as measured in a direction that is perpendicular to aperture trajectory 120, may be less than an external cross-sectional area of aperture-external region 200, also as measured in the direction that is perpendicular to the aperture trajectory. As such, and as illustrated in Figs. 14-15, fluid flow 40 from screen-supporting tubular 110 via apertures 118 may be re-directed, by shrouds 186 and/or by aperture-external region 200 thereof, from aperture trajectory 120 to modified trajectory 124.
[0069] Aperture-external region 200 and aperture-internal region 202 may have and/or define any suitable shape, relative shape, size, relative size, and/or relative cross-sectional area. As an example, the internal cross-sectional area may be less than 80%, less than 70%, less than 60%, less than 50%, less than 40%, less than 30%, less than 20%, at least 10%, at least 20%, at least 40%, and/or at least 60% of the external cross-sectional area. As another example, and as perhaps best illustrated in Fig. 16, the internal cross-sectional shape may be a plus-shape. As yet another example, and also as perhaps best illustrated in Fig. 16, the external cross- sectional area may be circular.
[0070] The internal cross-sectional area of aperture-internal region 202 may be less than an aperture cross-sectional area of a corresponding aperture 118. As examples, the internal cross- sectional area may be less than 80%, less than 70%, less than 60%, less than 50%, less than 40%, less than 30%, less than 20%, at least 10%, at least 20%, at least 40%, and/or at least 60% of the aperture cross-sectional area.
[0071] It is within the scope of the present disclosure that a relative orientation of at least one, or even each, shroud 186, relative to screen-supporting tubular 110, may be fixed, or at least substantially fixed. Additionally or alternatively, it is also within the scope of the present disclosure that at least one, or even each, shroud 186 may be configured to translate, or move, relative to the screen-supporting tubular. This may include translation between an open orientation 204 and a closed orientation 206. When in open orientation 204, shrouds 186 may be configured to permit fluid flow through corresponding aperture 118. When in closed orientation 206, shrouds 186 may be configured to resist and/or to restrict fluid flow through the corresponding aperture. As an example, shrouds 186 may function as individual check valves that, in the example that is illustrated in Figs. 14-15, may permit outflow from screen supporting tubular 110 via apertures 118 and may resist inflow into the screen-supporting tubular via the apertures. [0072] Screen-supporting tubular 110 may include any suitable structure that may include and/or define outer surface 112, inner surface 114, aperture-defining region 116, and/or apertures 118. As examples, screen-supporting tubular 110 may include and/or be a pipe and/or a base pipe that may be formed from a steel and/or from a carbon steel. As another example, screen-supporting tubular 110 may include and/or be a section of pipe that may be similar, or at least substantially similar, to wellbore tubular 30 of Fig. 1.
[0073] Screen structure 130 may include any suitable structure that may be at least partially fluid permeable and/or that may surround outer surface 112 of aperture-defining region 116 of screen-supporting tubular 110. As an example, and as discussed herein, screen structure 130 may include and/or be a wire 132, or a screen wire 132, that may be wrapped (such as helically wrapped) around screen-supporting tubular 110 and/or around screen spacer 150. This may include a single screen wire 132 and/or a plurality of distinct screen wires 132 that may be wrapped in parallel and/or in series around the screen-supporting tubular to provide at least regions of fluid permeability, such as via spacing between adjacent wraps of wire 132.
[0074] As another example, screen structure 130 may extend around screen-supporting tubular 110, may encircle screen-supporting tubular 110, and/or may surround at least a portion, such as aperture-defining region 116, of the screen-supporting tubular. As yet another example, screen structure 130 may contact, may directly contact, may be attached to, and/or may be welded to screen spacer 150. As another example, a relative orientation between screen structure 130 and screen-supporting tubular 110 and/or between screen structure 130 and screen space 150 may be fixed, or at least substantially fixed.
[0075] It is within the scope of the present disclosure that screen structure 130 may be formed from and/or may include any suitable material and/or materials. As examples, screen structure 130 may include one or more of a steel, a steel alloy, a stainless steel, 316 stainless steel, a nickel-chromium-iron (Inconel®) alloy, and/or a corrosion-resistant alloy.
[0076] Screen spacer 150 may include any suitable structure that may extend between screen supporting tubular 110 and screen structure 130 and/or that may maintain the spaced-apart relationship between the screen-supporting tubular and the screen structure. As an example, screen spacer 150 may include a plurality of elongate spacers. Under these conditions, a longitudinal axis of each of the elongate spacers may extend along, at least substantially along, parallel to, and/or at least substantially parallel to a longitudinal axis of screen-supporting tubular 110. The plurality of elongate spaces may be spaced-apart, or circumferentially spaced- apart about a perimeter, or about a transverse cross-section, of outer surface 112 of screen- supporting tubular 110. [0077] As another example, screen spacer 150 may establish, define, and/or maintain an at least partially annular space that extends between screen-supporting tubular 110 and screen structure 130. As yet another example, a relative orientation between screen spacer 150 and screen-supporting tubular 110 and/or screen structure 130 may be fixed, or at least substantially fixed.
[0078] Shroud structure 170 may include any suitable structure that may be positioned at least along aperture trajectory 120 of each aperture 118 and/or that may restrict fluid flow 40 therethrough and along the aperture trajectory. As examples, shroud structure 170 may be configured to direct a fluid stream, which flows through each aperture 118, along a tortuous flow path, direct the fluid stream away from the aperture trajectory, direct the fluid stream along an elongate axis of the screen-supporting tubular, divert the fluid stream, and/or divert the fluid stream from the aperture trajectory.
[0079] Additionally or alternatively, shroud structure 170 may be configured to permit fluid flow 40 though regions of the screen structure that are spaced-apart from the aperture trajectory. Such a configuration may facilitate fluid flow 40 over a larger surface area of screen structure 130 than otherwise would occur if shroud structure 170 were not present in well screen system 100, thereby decreasing wear of screen structure 130 when compared to an otherwise identical well screen system that does not include shroud structure 170.
[0080] Shroud structure 170 may be formed from and/or may include any suitable material and/or materials. As examples, shroud structure 170 may be formed from a shroud material that has a greater hardness than a screen material of screen structure 130, is a nickel-chromium- iron (Inconel®) alloy, is a resilient material, and/or is an abrasion-resistant material.
[0081] As used herein, the term“and/or” placed between a first entity and a second entity means one of (1) the first entity, (2) the second entity, and (3) the first entity and the second entity. Multiple entities listed with“and/or” should be construed in the same manner, i.e.,“one or more” of the entities so conjoined. Other entities may optionally be present other than the entities specifically identified by the“and/or” clause, whether related or unrelated to those entities specifically identified. Thus, as a non-limiting example, a reference to“A and/or B,” when used in conjunction with open-ended language such as“comprising” may refer, in one embodiment, to A only (optionally including entities other than B); in another embodiment, to B only (optionally including entities other than A); in yet another embodiment, to both A and B (optionally including other entities). These entities may refer to elements, actions, structures, steps, operations, values, and the like. [0082] As used herein, the phrase“at least one,” in reference to a list of one or more entities should be understood to mean at least one entity selected from any one or more of the entities in the list of entities, but not necessarily including at least one of each and every entity specifically listed within the list of entities and not excluding any combinations of entities in the list of entities. This definition also allows that entities may optionally be present other than the entities specifically identified within the list of entities to which the phrase“at least one” refers, whether related or unrelated to those entities specifically identified. Thus, as a non- limiting example,“at least one of A and B” (or, equivalently,“at least one of A or B,” or, equivalently“at least one of A and/or B”) may refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including entities other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including entities other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other entities). In other words, the phrases“at least one,”“one or more,” and“and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions“at least one of A, B, and C,” “at least one of A, B, or C,”“one or more of A, B, and C,”“one or more of A, B, or C,” and “A, B, and/or C” may mean A alone, B alone, C alone, A and B together, A and C together, B and C together, A, B, and C together, and optionally any of the above in combination with at least one other entity.
[0083] In the event that any patents, patent applications, or other references are incorporated by reference herein and (1) define a term in a manner that is inconsistent with and/or (2) are otherwise inconsistent with, either the non-incorporated portion of the present disclosure or any of the other incorporated references, the non-incorporated portion of the present disclosure shall control, and the term or incorporated disclosure therein shall only control with respect to the reference in which the term is defined and/or the incorporated disclosure was present originally.
[0084] As used herein the terms “adapted” and “configured” mean that the element, component, or other subject matter is designed and/or intended to perform a given function. Thus, the use of the terms“adapted” and“configured” should not be construed to mean that a given element, component, or other subject matter is simply“capable of’ performing a given function but that the element, component, and/or other subject matter is specifically selected, created, implemented, utilized, programmed, and/or designed for the purpose of performing the function. It is also within the scope of the present disclosure that elements, components, and/or other recited subject matter that is recited as being adapted to perform a particular function may additionally or alternatively be described as being configured to perform that function, and vice versa.
[0085] As used herein, the phrase,“for example,” the phrase,“as an example,” and/or simply the term“example,” when used with reference to one or more components, features, details, structures, embodiments, and/or methods according to the present disclosure, are intended to convey that the described component, feature, detail, structure, embodiment, and/or method is an illustrative, non-exclusive example of components, features, details, structures, embodiments, and/or methods according to the present disclosure. Thus, the described component, feature, detail, structure, embodiment, and/or method is not intended to be limiting, required, or exclusive/exhaustive; and other components, features, details, structures, embodiments, and/or methods, including structurally and/or functionally similar and/or equivalent components, features, details, structures, embodiments, and/or methods, are also within the scope of the present disclosure.
Industrial Applicability
[0086] The systems and methods disclosed herein are applicable to the oil and gas industries.
[0087] It is believed that the disclosure set forth above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions, and/or properties disclosed herein. Similarly, where the claims recite“a” or“a first” element or the equivalent thereof, such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements.
[0088] It is believed that the following claims particularly point out certain combinations and subcombinations that are directed to one of the disclosed inventions and are novel and non- obvious. Inventions embodied in other combinations and subcombinations of features, functions, elements and/or properties may be claimed through amendment of the present claims or presentation of new claims in this or a related application. Such amended or new claims, whether they are directed to a different invention or directed to the same invention, whether different, broader, narrower, or equal in scope to the original claims, are also regarded as included within the subject matter of the inventions of the present disclosure.

Claims

1. A well screen system, comprising:
a screen-supporting tubular including an outer surface and an inner surface, wherein the screen-supporting tubular includes a plurality of spaced-apart apertures extending within an aperture-defining region of the screen-supporting tubular, and further wherein each aperture of the plurality of spaced-apart apertures extends along an aperture trajectory from the inner surface to the outer surface;
a screen structure that encircles the outer surface of the aperture-defining region of the screen-supporting tubular;
a screen spacer that extends between the screen-supporting tubular and the screen structure, wherein the screen spacer maintains a spaced-apart relationship between at least a majority of the screen structure and at least a majority of the aperture-defining region of the screen-supporting tubular; and
a shroud structure positioned at least along the aperture trajectory of each aperture of the plurality of apertures, wherein the shroud structure separates the screen structure from the screen-supporting tubular, and further wherein the shroud structure restricts fluid flow along the aperture trajectory and through the screen structure.
2. The well screen system of claim 1, wherein the shroud structure includes an elongate shroud body that extends along a longitudinal axis of the screen-supporting tubular, wherein the elongate shroud body includes a closed side, an open side, and a pair of spaced-apart sidewalls that extends between the open side and the closed side to define an elongate channel, wherein the open side faces toward the screen-supporting tubular and is oriented, relative to the screen-supporting tubular, such that the aperture trajectory of at least a subset of the plurality of apertures extends into the elongate channel, wherein the closed side faces toward the screen structure, and further wherein the elongate shroud body defines a plurality of cross- flow ports extending through the pair of spaced-apart sidewalls.
3. The well screen system of claim 2, wherein the shroud structure includes a plurality of elongate shroud bodies, wherein each elongate shroud body of the plurality of elongate shroud bodies is associated with a respective subset of the plurality of apertures.
4. The well screen system of claim 1, wherein the shroud structure is distinct from the screen spacer.
5. The well screen system of claim 1, wherein the shroud structure includes a plurality of shrouds, wherein each shroud of the plurality of shrouds is associated with a corresponding aperture of the plurality of apertures.
6. The well screen system of claim 5, wherein each shroud includes an aperture-internal region, which extends within the corresponding aperture, and an aperture-external region, which is external to the corresponding aperture.
7. The well screen system of any of claims 5-6, wherein a relative orientation of each shroud, relative to the screen-supporting tubular, is at least substantially fixed.
8. The well screen system of any of claims 5-6, wherein each shroud is configured to translate, relative to the screen-supporting tubular, between an open orientation and a closed orientation, wherein, when in the open orientation, each shroud permits the fluid flow through the corresponding aperture, and further wherein, when in the closed orientation, each shroud restricts fluid flow through the corresponding aperture.
9. The well screen according to any of the preceding claims, used in a hydrocarbon well further comprising:
a wellbore extending within a subterranean formation;
a wellbore tubular defining a tubular conduit, wherein the wellbore tubular extends within the wellbore and has a downhole end; and
the well screen system of any of the preceding claims operatively attached to the downhole end of the wellbore tubular.
10. The well screen according to any of the preceding claims, used in conjunction with a method of injecting fluid into the subterranean formation utilizing the hydrocarbon well of any of the preceding claims, the method comprising:
providing the fluid to the tubular conduit of the wellbore tubular;
flowing the fluid, along the tubular conduit, to the downhole end of the wellbore tubular and into the well screen system;
flowing a respective fraction of the fluid along a respective aperture trajectory that extends through each aperture of the plurality of apertures;
re-directing the respective fraction of the fluid, from the respective aperture trajectory, to a respective modified trajectory that differs from the respective aperture trajectory;
flowing at least a majority of the respective fraction of the fluid through a region of the screen structure that is spaced-apart from the respective aperture trajectory; and
flowing the respective fraction of the fluid into the subterranean formation.
11. The well screen according to any of the preceding claims used in a well screen system comprising:
a screen-supporting tubular including an outer surface and an inner surface, wherein the screen-supporting tubular includes a plurality of spaced-apart apertures extending within an aperture-defming region of the screen-supporting tubular, and further wherein each aperture of the plurality of spaced-apart apertures extends along an aperture trajectory from the inner surface toward the outer surface;
a screen structure that encircles the outer surface of the aperture-defining region of the screen-supporting tubular;
a screen spacer that extends between the screen-supporting tubular and the screen structure, wherein the screen spacer maintains a spaced-apart relationship between at least a majority of the screen structure and at least a majority of the aperture-defining region of the screen-supporting tubular; and
a shroud structure positioned at least along the aperture trajectory of each aperture of the plurality of apertures, wherein the shroud structure includes wire helically wrapped around the screen-supporting tubular such that the shroud structure restricts fluid flow therethrough and along the aperture trajectory.
12. The well screen system of claim 11, wherein the screen structure is defined by the wire, wherein the wire defines a flow-occluding wire spacing when the wire intersects the aperture trajectory and a flow-permitting wire spacing when the wire is spaced-apart from the aperture trajectory, wherein a flow-permitting region of the screen structure has the flow-permitting wire spacing, and further wherein a flow-occluding region of the screen structure has the flow- occluding wire spacing.
13. The well screen system of claim 11, wherein:
(i) the wire is a shroud wire;
(ii) the screen structure is defined by a screen wire helically wrapped around the screen-supporting tubular;
(iii) the well screen system includes a shroud spacer that extends between the shroud wire and the screen wire and maintains a spaced-apart relationship between at least a majority of the shroud wire and at least a majority of the screen wire;
(iv) the shroud wire defines a flow-occluding shroud wire spacing when the shroud wire is spaced-apart from the aperture trajectory and a flow-permitting shroud wire spacing when the shroud wire intersects the aperture trajectory; and
(iv) the screen wire defines a flow-occluding screen wire spacing when the screen wire intersects the aperture trajectory and a flow-permitting screen wire spacing when the screen wire is spaced-apart from the aperture trajectory.
14. A well screen system, comprising: a screen-supporting tubular including an outer surface and an inner surface, wherein the screen supporting tubular includes a plurality of spaced-apart apertures extending within an aperture defining region of the screen-supporting tubular, and further wherein each aperture of the plurality of spaced-apart apertures extends along an aperture trajectory from the inner surface to the outer surface;
a screen structure that encircles the outer surface of the aperture-defining region of the screen-supporting tubular;
a screen spacer that extends between the screen-supporting tubular and the screen structure, wherein the screen spacer maintains a spaced-apart relationship between at least a majority of the screen structure and at least a majority of the aperture-defining region of the screen-supporting tubular; and
a shroud structure positioned at least along the aperture trajectory of each aperture of the plurality of apertures, wherein the shroud structure includes a perforated sleeve including a plurality of sleeve perforations, wherein the screen structure extends between the shroud structure and the screen-supporting tubular, and further wherein each sleeve perforation of the plurality of sleeve perforations is offset from the aperture trajectory of each aperture of the plurality of apertures.
15. The well screen system of claim 14, wherein the plurality of sleeve perforations defines a perforation relative orientation, wherein the plurality of apertures defines an aperture relative orientation, and further wherein the perforation relative orientation corresponds to, and is offset from, the aperture relative orientation.
PCT/US2019/029837 2018-06-28 2019-04-30 Well screen systems, hydrocarbon wells that include the well screen systems, and methods of injecting fluid into the hydrocarbon wells WO2020005382A1 (en)

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US62/691,382 2018-06-28

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