Primary and secondary filters for enhanced sand control

Abstract

A screen assembly for use within a wellbore. The screen assembly may include a primary screen filter and a base pipe. The base pipe may be positioned within the primary screen filter such that an annular space is formed between the primary screen filter and the base pipe. The base pipe may include a plurality of secondary screen filters positioned along an axial length of the base pipe such that particulates from an inflowing fluid stream from the wellbore create a sand bridge in the annular space if the primary screen filter becomes damaged.

What is claimed is: 
     
         1 . A screen assembly for use within a wellbore, the screen assembly comprising:
 a primary screen filter; and   a base pipe positioned within the primary screen filter such that an annular space is formed between the primary screen filter and the base pipe, the base pipe comprising a plurality of secondary screen filters positioned along the base pipe such that particulates from an inflowing fluid stream from the wellbore create a sand bridge in the annular space if the primary screen filter becomes damaged.   
     
     
         2 . The screen assembly of  claim 1 , wherein the secondary screen filters are formed from the base pipe. 
     
     
         3 . The screen assembly of  claim 1 , wherein the secondary screen filters are disposed within holes formed in the base pipe. 
     
     
         4 . The screen assembly of  claim 1 , wherein the secondary screen filters each comprise an erosion resistant material. 
     
     
         5 . The screen assembly of  claim 4 , wherein the erosion resistant material comprises at least one of a ceramic material, tungsten carbide, or a porous powdered metal. 
     
     
         6 . The screen assembly of  claim 1 , wherein the primary screen filter comprises a metallic material. 
     
     
         7 . The screen assembly of  claim 1 , further comprising a plurality of ribs positioned within the annular space and extending between the primary screen filter and the base pipe. 
     
     
         8 . The screen assembly of  claim 1 , further comprising a shroud disposed around the primary screen filter. 
     
     
         9 . A production system disposable within a wellbore, the production system comprising:
 a tubing string disposable within the wellbore; and   a screen assembly coupled to the tubing string and comprising:
 a primary screen filter; and 
 a base pipe positioned within the primary screen filter such that an annular space is formed between the primary screen filter and the base pipe, the base pipe comprising a plurality of secondary screen filters positioned along the base pipe such that particulates from an inflowing fluid stream from the wellbore create a sand bridge in the annular space if the primary screen filter becomes damaged. 
   
     
     
         10 . The production system of  claim 9 , wherein the secondary screen filters are formed from the base pipe. 
     
     
         11 . The production system of  claim 9 , wherein the secondary screen filters are disposed within holes formed in the base pipe. 
     
     
         12 . The production system of  claim 9 , wherein the secondary screen filters each comprise an erosion resistant material. 
     
     
         13 . The production system of  claim 12 , wherein the erosion resistant material comprises at least one of a ceramic material, tungsten carbide, or a porous powdered metal. 
     
     
         14 . The production system of  claim 9 , wherein the primary screen filter comprises a metallic material. 
     
     
         15 . The production system of  claim 9 , further comprising a plurality of ribs positioned within the annular space and extending between the primary screen filter and the base pipe. 
     
     
         16 . The production system of  claim 9 , further comprising a shroud disposed around the primary screen filter. 
     
     
         17 . A method for producing formation fluids from a formation, the method comprising:
 positioning a tubular comprising a screen assembly within a wellbore extending through the formation; and   filtering an inflowing fluid stream from the wellbore via the screen assembly; and   creating a sand bridge in an annular space of the screen assembly formed between a primary screen filter of the screen assembly and secondary screen filters of a base pipe of the screen assembly when the primary screen filter becomes damaged.   
     
     
         18 . The method of  claim 17 , further comprising positioning a plurality of ribs within the annular space and extending between the primary screen filter and the base pipe. 
     
     
         19 . The method of  claim 17 , further comprising forming the secondary screen filters from an erosion resistant material. 
     
     
         20 . The method of  claim 19 , wherein the erosion resistant material comprises at least one of a ceramic material, tungsten carbide, or a porous powdered metal.