Screen for sand control in a wellbore

Abstract

A sand screen for a wellbore that employs a seamless tube shaped filter member covering perforations in a length of perforated tubular is disclosed. The filter member includes a monofilament or multifilament wire that is precisely wound to control angle and spacing of the wire. Configuration of a wind pattern and the amount of wire wound controls aperture size for filtering particles, flow characteristics through the filter member, and overall strength of the filter member. Seals at each end of the filter member can secure and circumferentially seal the filter member on the perforated tubular.

1 . A sand screen for use in a wellbore, comprising: 
 a length of tubular having perforations therethrough; and    a filtering member disposed around an outer wall of the tubular and covering at least some of the perforations, the filtering member comprising a wire wound around the outer wall to form a substantially seamless tubular shape.    
   
   
       2 . The sand screen of  claim 1 , wherein the wire has offset overlapping portions.  
   
   
       3 . The sand screen of  claim 1 , wherein overlapping portions of the wire are substantially non-offset.  
   
   
       4 . The sand screen of  claim 1 , wherein the filtering member further comprises a mandrel that the wire is wound around.  
   
   
       5 . The sand screen of  claim 1 , wherein the filtering member further comprises a mandrel that the wire is wound around, the mandrel having end rings separated by longitudinal members.  
   
   
       6 . The sand screen of  claim 1 , wherein the wire is a multifilament wire.  
   
   
       7 . The sand screen of  claim 1 , further comprising a seal at each end of the filtering member.  
   
   
       8 . The sand screen of  claim 1 , wherein the filtering member is sintered.  
   
   
       9 . The sand screen of  claim 1 , wherein the filtering member further comprises sized particles packed in an annular area between the substantially seamless tubular shape and a second tubular member having apertures therethrough.  
   
   
       10 . The sand screen of  claim 9 , wherein the second tubular member is wound wire.  
   
   
       11 . A method for assembling a sand screen, comprising: 
 rotating a mandrel; and    winding a wire around the mandrel into a tubular shape having a wall defined by overlapping sections of the wire.    
   
   
       12 . The method of  claim 11 , wherein the mandrel is a perforated tubular.  
   
   
       13 . The method of  claim 11 , further comprising removing the mandrel from the tubular shape.  
   
   
       14 . The method of  claim 11 , further comprising positioning the mandrel around an outer wall of a tubular having perforations therethrough, thereby covering at least some of the perforations.  
   
   
       15 . The method of  claim 11 , wherein the winding the wire offsets overlapping portions of the wire.  
   
   
       16 . A method for assembling a sand screen, comprising: 
 winding a wire into a substantially seamless tubular shape to provide a filtering member;    positioning the filtering member around an outer wall of a tubular having perforations therethrough thereby covering at least some of the perforations; and    circumferentially sealing the filtering member to the tubular at each end of the filtering member.    
   
   
       17 . The method of  claim 16 , further comprising sintering the filtering member thereby diffusion bonding contact points of the wire.  
   
   
       18 . The sand screen of  claim 16 , wherein the winding the wire offsets overlapping portions of the wire.  
   
   
       19 . A method for assembling a sand screen, comprising: 
 winding a wire to form a coil in a substantially seamless tubular shape;    positioning the coil relative to a first tubular having a different diameter than the coil to provide an annular area between the coil and the first tubular;    packing the annular area with sized particles to provide a packing;    sealing ends of the annular area thereby retaining the packing to provide a filtering member;    positioning the filtering member around an outer wall of a second tubular having perforations therethrough thereby covering at least some of the perforations; and    circumferentially sealing the filtering member to the tubular at each end of the filtering member.    
   
   
       20 . The method of  claim 19 , wherein the first tubular is wound wire.  
   
   
       21 . The method of  claim 19 , wherein the first tubular is selected from the group consisting of slotted tubing, wire wrapped screen, wire mesh, and premium screen.