Current State of the Premium Screen Industry: Buyer Beware, Methodical Testing and Qualification Shows You Don't Always Get What You Paid For

Abstract

Summary Within the sand-control-technology sector today, there are many sand-exclusion screen options available for use in completion design. Sand-control screens have steadily improved with the introduction and enhancement of metal sand-retention-media-based sand-exclusion products in the early 1990s. However, recent catastrophic sand-exclusion failures have led some operators and independent laboratories to perform additional testing and quality control checks on sand-exclusion products to ensure full life cycle field value. This paper describes a process to select sand-exclusion products by uniquely qualifying an individual product design, which includes retention media, metallurgy, subcomponents, manufacturing process, and the final assembled product. The technical evaluation is based on a two-tier qualification process that "uniquely qualifies" products for purchase consideration. Step 1 of the process tests the sand-retention media for plugging potential and solids retention. Step 2 then tests full-joint screens manufactured using media qualified during Step 1 for burst and collapse to ensure the product meets downhole performance specifications. Recent testing has illustrated a range of significant conclusions that the industry should be aware of: Published screen burst and collapse ratings are not always equivalent to actual screen performance. Burst and collapse pressures are not equivalent to basepipe rating. Welds can vary by plant; therefore, screens may vary by manufacturing location. Excessive drainage layer gap leads to premature burst or collapse failure. Not adjusting screen design for changes in metallurgy may lead to premature failure. Delamination has been observed in some sintered retention media. Scaling a product design up or down without conducting a detailed engineering analysis may lead to premature failures.