Systems And Methods To Reduce Erosion In Wire Wrap Screen On Perforated Base Pipe

Abstract

A well screen system having enhanced resistance to erosion, including a tubular defined by a circumferential wall having an outer surface and a first plurality of apertures circumferentially disposed longitudinally along at least a portion thereof, the first plurality of apertures extending radially through the circumferential wall; a series of circumferential channels positioned about the outer surface of the circumferential wall; a plurality of longitudinal ribs positioned adjacent the series of circumferential channels and extending radially therefrom, the plurality of longitudinal ribs forming a series of longitudinal channels; and a wire helically disposed around the tubular, substantially enclosing the series of circumferential channels and the series of longitudinal channels, wherein the series of circumferential channels is structured and arranged to permit fluid communication with the series of longitudinal channels. A method for producing a well screen having enhanced resistance to erosion is also provided.

1 . A well screen system having enhanced resistance to erosion, the well screen system comprising:
 a tubular defined by a circumferential wall having an outer surface and a first plurality of apertures circumferentially disposed longitudinally along at least a portion thereof, the first plurality of apertures extending radially through the circumferential wall;   a series of circumferential channels positioned about the outer surface of the circumferential wall;   a plurality of longitudinal ribs positioned adjacent the series of circumferential channels and extending radially therefrom, the plurality of longitudinal ribs forming a series of longitudinal channels; and   a wire helically disposed around the tubular, substantially enclosing the series of circumferential channels and the series of longitudinal channels,   wherein the series of circumferential channels is structured and arranged to permit fluid communication with the series of longitudinal channels.   
     
     
         2 . The system of  claim 1 , wherein the series of circumferential channels is defined by a plurality of circumferential ribs. 
     
     
         3 . The system of  claim 2 , wherein the plurality of circumferential ribs is affixed to the outer surface of the circumferential wall and the plurality of longitudinal ribs is affixed to the plurality of circumferential ribs. 
     
     
         4 . The system of  claim 3 , wherein the plurality of circumferential ribs is normal to the plurality of longitudinal ribs. 
     
     
         5 . The system of  claim 4 , wherein the plurality of longitudinal ribs extend axially along the outer surface of the circumferential wall. 
     
     
         6 . The system of  claim 1 , wherein the series of circumferential channels is defined by a plurality of grooves formed within the outer surface of the circumferential wall. 
     
     
         7 . The system of  claim 6 , wherein the plurality of longitudinal ribs is affixed to the outer surface of the circumferential wall. 
     
     
         8 . The system of  claim 7 , wherein the plurality of grooves is normal to the plurality of longitudinal ribs. 
     
     
         9 . The system of  claim 8 , wherein the plurality of longitudinal ribs extend axially along the outer surface of the circumferential wall. 
     
     
         10 . The system of  claim 1 , wherein the plurality of longitudinal ribs is affixed to the outer surface of the circumferential wall. 
     
     
         11 . The system of  claim 10 , wherein the series of circumferential channels is defined by a second plurality of apertures, the second plurality of apertures formed along each of the plurality of longitudinal ribs. 
     
     
         12 . The system of  claim 11 , wherein each of the second plurality of apertures is substantially circular. 
     
     
         13 . The system of  claim 11 , wherein each of the plurality of longitudinal ribs include a series of scallops on one edge thereof, the scallops facing the outer surface of the circumferential wall and therewith forming the second plurality of apertures. 
     
     
         14 . The system of  claim 11 , wherein each of the plurality of longitudinal ribs include a series of scallops on one edge thereof, the scallops facing the helically disposed wire and therewith forming the plurality of second apertures. 
     
     
         15 . A method for producing a well screen having enhanced resistance to erosion, the method comprising:
 obtaining a tubular having a first plurality of apertures extending radially;   forming a series of circumferential channels about the outer surface of the tubular;   positioning a plurality of longitudinal ribs adjacent the series of circumferential channels so as to form a series of longitudinal channels; and   helically wrapping a wire around the tubular and substantially enclosing the series of circumferential channels and the series of longitudinal channels,   wherein the series of circumferential channels is structured and arranged to permit fluid communication with the series of longitudinal channels.   
     
     
         16 . The method of  claim 15 , further comprising affixing a plurality of circumferential ribs to the outer surface of the tubular to form the series of circumferential channels. 
     
     
         17 . The method of  claim 15 , further comprising forming a plurality of grooves within the outer surface of the tubular to form the series of circumferential channels. 
     
     
         18 . The method of  claim 15 , further comprising affixing the plurality of longitudinal ribs to the outer surface of the tubular. 
     
     
         19 . The method of  claim 18 , further comprising forming a second plurality of apertures along each of the plurality of longitudinal ribs to form the series of circumferential channels. 
     
     
         20 . The method of  claim 19 , wherein each of the plurality of longitudinal ribs include a series of scallops on one edge thereof, the scallops facing the outer surface of the tubular and therewith forming the second plurality of apertures. 
     
     
         21 . The method of  claim 19 , wherein each of the plurality of longitudinal ribs include a series of scallops on one edge thereof, the scallops facing the helically disposed wire and therewith forming the plurality of second apertures. 
     
     
         22 . A wellbore comprising:
 a borehole extending into an earth formation; and   a tubular member extending into the borehole, the tubular member having a well screen system positioned along a length thereof, the well screen system comprising i) a tubular defined by a circumferential wall having an outer surface and a first plurality of apertures circumferentially disposed longitudinally along at least a portion thereof, the first plurality of apertures extending radially through the circumferential wall; ii) a series of circumferential channels positioned about the outer surface of the circumferential wall; iii) a plurality of longitudinal ribs positioned adjacent the series of circumferential channels and extending radially therefrom, the plurality of longitudinal ribs forming a series of longitudinal channels; and iv) a wire helically disposed around the tubular, substantially enclosing the series of circumferential channels and the series of longitudinal channels.   
     
     
         23 . The wellbore of  claim 22 , wherein the series of circumferential channels is structured and arranged to permit fluid communication with the series of longitudinal channels. 
     
     
         24 . The wellbore of  claim 23 , wherein the series of circumferential channels is defined by a plurality of circumferential ribs. 
     
     
         25 . The wellbore of  claim 24 , wherein the plurality of circumferential ribs is affixed to the outer surface of the circumferential wall and the plurality of longitudinal ribs is affixed to the plurality of circumferential ribs. 
     
     
         26 . The wellbore of  claim 23 , wherein the series of circumferential channels is defined by a plurality of grooves formed within the outer surface of the circumferential wall. 
     
     
         27 . The wellbore of  claim 26 , wherein the plurality of longitudinal ribs is affixed to the outer surface of the circumferential wall. 
     
     
         28 . The wellbore of  claim 23 , wherein the plurality of longitudinal ribs is affixed to the outer surface of the circumferential wall. 
     
     
         29 . The wellbore of  claim 28 , wherein the series of circumferential channels is defined by a second plurality of apertures, the second plurality of apertures formed along each of the plurality of longitudinal ribs. 
     
     
         30 . A method of forming a completion system within a wellbore, the method comprising installing a tubular member into the borehole, the tubular member having a well screen system positioned along a length thereof, the well screen system comprising i) a tubular defined by a circumferential wall having an outer surface and a first plurality of apertures circumferentially disposed longitudinally along at least a portion thereof, the first plurality of apertures extending radially through the circumferential wall; ii) a series of circumferential channels positioned about the outer surface of the circumferential wall; iii) a plurality of longitudinal ribs positioned adjacent the series of circumferential channels and extending radially therefrom, the plurality of longitudinal ribs forming a series of longitudinal channels;
 and iv) a wire helically disposed around the tubular, substantially enclosing the series of circumferential channels and the series of longitudinal channels.   
     
     
         31 . The method of  claim 30 , wherein the series of circumferential channels is structured and arranged to permit fluid communication with the series of longitudinal channels. 
     
     
         32 . The method of  claim 31 , wherein the series of circumferential channels is defined by a plurality of circumferential ribs. 
     
     
         33 . The method of  claim 31 , wherein the series of circumferential channels is defined by a plurality of grooves formed within the outer surface of the circumferential wall. 
     
     
         34 . The method of  claim 31 , wherein the plurality of longitudinal ribs is affixed to the outer surface of the circumferential wall. 
     
     
         35 . The method of  claim 31 , further comprising installing one or more packers to isolate one or more production zones within the wellbore. 
     
     
         36 . A method of producing hydrocarbons from a subterranean formation, the method comprising:
 providing a borehole extending into a hydrocarbon-bearing zone of the formation, installing a tubular member into the borehole, the tubular member having a well screen system positioned along a length thereof, the well screen system comprising i) a tubular defined by a circumferential wall having an outer surface and a first plurality of apertures circumferentially disposed longitudinally along at least a portion thereof, the first plurality of apertures extending radially through the circumferential wall; ii) a series of circumferential channels positioned about the outer surface of the circumferential wall; iii) a plurality of longitudinal ribs positioned adjacent the series of circumferential channels and extending radially therefrom, the plurality of longitudinal ribs forming a series of longitudinal channels; and iv) a wire helically disposed around the tubular, substantially enclosing the series of circumferential channels and the series of longitudinal channels and   producing a fluid comprising hydrocarbons.   
     
     
         37 . The method of  claim 36 , further comprising installing one or more packers to isolate one or more production zones within the wellbore.