Filson gravel pack screen

  • Tight slot size control to improve sand retention rate
  • Lower entrance velocity to provide minimal pressure drop
  • Maximum open area to ensure high permeability
  • Support to periodic maintenance with long lifespan
  • Excellent corrosion resistance for underground operation
  • Difficult to clog due to wedge wire construction

Filson manufactures gravel pack screens with relatively high porosity and superior permeability, therefore it can lower entrance velocity of water and minimize pressure drop. All Filson advanced gravel pack screens are quality manufactured with 100% unique & exclusive.

  • Base pipe OD: 2.375-7.000 in.
  • Base pipe ID: 1.995-6.366 in.
  • Coupling OD: 2.875-7.657 in.
  • Perforation flow area: 0.375 in.
  • Slot size: down to 0.1 mm
  • Screen length: 1-6 m

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Your Premium Quality Gravel Pack Screen Manufacturer In China

Filson gravel pack screen is a metal filter assembly commonly used for downhole working conditions. It is designed to maintain open access within the aquifer while prevent unwanted formation sands to enter the screen.

When you prepare to select a gravel pack screen for your well application, the first thing you need to do is analyzing the sand size from the surrounding formation. Choosing the proper-sized gravel-pack sand is extremely significant to avoid gravel pack completion failures and high costs.

Filson gravel pack screen sizes and configurations will be selected according to wellbore, production fluid, and formation sand characteristics. Standard Filson gravel pack screen is fabricated with slot size down to 0.1mm, or other independent design upon your needs.

Since the unique wedge slot and gravel packed design, Filson gravel pack screen offers the maximum open area consistent with strength. It allows closer contact between screen and aquifer, meanwhile improving well development and production efficiency.

Filson has a certified facility and owns a complete production line to supply exceptional quality gravel pack screens. Contact us know!

Gravel Pack Screen: The Ultimate FAQ Guide

In this guide, you will find all information you’re looking for about gravel pack screen.

From definition, features, benefits, working principle, to customization option – you will find all information you’re looking right here.

Keep reading to learn more

What Is Gravel Pack Screen?

A Gravel pack screen is an assembled metallic filter mainly used to reinforce and retain the sand positioned during a gravel pack operation.

The Gravel Pack screens help provide a uniform distribution gravel size.

The screens are acceptable for drilling applications, during which the normal distribution of gravel distribution cannot be guaranteed.

Overview of a Gravel Pack Screen

Overview Of A Gravel Pack Screen

What Are The Uses Of Gravel Pack Screen?

Gravel Pack screen is an example of a sand control screen that is mostly used for gravel packaging. Its main function in Gravel packaging is to provide stability by reinforcing the gravel in the gravel pack.

Gravel Pack Screen

A Gravel Pack Screen

It can, however, be used in several other applications such as;

  • A separator for Gas and sand.
  • It can also be used as conventional sand screens
  • The screen can serve as a screen for the Pump strainer.
  • It is mainly designed for gravel and frack packaging.
  • It can also serve as an Industrial filter
  • The Gravel Pack Screen can be used for prolonged contact and extreme-reserve wells.
  • Additionally, it can be applied in Stand-alone completions
  • As a high rate screen in water wells
  • Lastly, the screen is commonly found in domestic water wells

A Gravel pack screen in use inside a domestic well

A Gravel Pack Screen in Use Inside A Well

What Are The Available Sizes Of Gravel Pack Screen?

There is an extensive range of Gravel Pack Screens sizes and configurations available. It is important to get the correct size of the Gravel Pack Screen.

The size of the gravel pack sand determines the gravel pack screen’s size.

You can get the size of the Gravel Pack Sand by calculating the median grain size and the grain size distribution of the formation sand.

Typically, the sizes of the gravel pack screens range from 1 to 20 inches.

What Are The Main Features Of Gravel Pack Screen?

Several features of the gravel pack screen may differ from one Gravel Pack Screen to another. The main features found in most Gravel Pack Screens include;

  • An increased open area
  • Customization option to meet various requirements.
  • Even slots that are placed precisely.
  • A relatively easy installation.
  • Great mechanical and tensile strength.
  • A long shelf life.
  • Reduced pressure drop.
  • Stability over a wide scope of pressure and temperature.

What Are The Different Types Of Gravel Pack Screen?

There are several types of Gravel Pack Screens. They include;

Slotted Liner

The slotted liner has a tubular cylinder with slots that are cut axially through it. The slots operate by forming inter particles that bridge across the slots.

Notably, the slotted screens have a flow average ranging between three to six percent of the complete pipe area. Its tensile strength can, however, be negatively affected if exposed to a higher flow.

Also, the slotted liner is not only the simplest and the most affordable screen, but it is also the oldest.

Slotted Liner

The Slotted Liner

Wire-Wrapped Screens

The wire-wrapped screens are composed of a jacket wrapped with wire around a perforated pipe. The various types of wire-wrapped screens include;

  • Rod-based screens
  • Pipe based slip-on
  • Pipe-bases direct build screen

Wire Wrapped Screen

Wire Wrapped Screen

Pre-packed Screens

Pre-packed screens are similar to the wire-wrapped screen. The difference is in the filtering media.

The pre-packed is composed of inner and outer screen jackets, a perforated base pipe, and a support rib. The pre-packed are more economical than normal gravel packs.

Remarkably, they provide stability while simultaneously filtering the sand.

Pre Packed Screen

A Pre packed screen

Metal Mesh Sand Screen

The metal mesh sand screen has a broad range of sizes, from as small as 40 microns to as large as 1000 microns.

It is available as both single-layered sintered laminate and multiple layered. It is also made from several materials, including; stainless steel, Monel among others.

Metal Mesh Screen

Metal Mesh Sand Screen

Wedge Wire Screens

The wedge wire screen is made up of v-shaped wires that are attached to a support rib.

These screens have an extremely low-pressure drop, uniform, elevated open area, and precise slot spacing. Clogging does not occur with wedge wire screens.

Wedge Wire Screen

Wedge Wire Screen

Expandable Sand Control Screens

An expandable sand control comprises the vital expandable connector, outer protection shroud, base pipe, and filter medium.

Notably, it is placed into a wellbore. Afterward, an expansion insert is placed to enlarge them to fit the production well.

Expandable SAnd Control Screen

Expandable Sand Control Screens

When Is A Gravel Pack Extension Required?

Gravel pack extensions coupled with service tools are used to create a flow path from the tube. Together with the service tools and gravel-pack packer, they help provide a flow path from the tubing and the screen between the packer.

It consists of an upper and lower extension. The upper extension contains the gravel pack fluids flow ports.

The lower extension houses a crossover tool for the gravel pack all through its scope of movement. It also has a seal bore.

There are two types of Gravel-pack extensions available:

  • The Sliding sleeve gravel pack extensions
  • The Perforated gravel pack extensions

How Is The Gravel Pack Structured?

An ordinary gravel pack is made up of the following parts;

  • Screen.
  • An annulus that is filled with gravel.
  • Casing.
  • A perforated base pipe.
  • Formation sand.
  • A massive plug.
  • Cement.
  • Perforation is packed with gravel.
  • Ribs.

What Is Screen Out In Gravel Pack?

Screen out is a condition that occurs during select gravel pack procedures. It occurs when solids in the treatment fluid form a bridge across the flow area, such as the perforation.

This occurrence causes a rapid increase in pump pressure due to a significant and sudden restriction to the flow of fluids.

Under the right conditions, a screen out indicates that the sand packing procedure is a success.

However, if it occurs early, it may be a sign that there are unwanted voids in the parking area and a sign of incomplete treatment.

What Are The Service Tools Required For Gravel Pack Screen?

There are a variety of service tools that are needed for Gravel Packing. They include;

The Hydraulic Setting Tool

Force is needed to place the packer for the gravel pack. The hydraulic setting tool, which is a hydraulic piston, helps generate this force.

The hydraulic setting tool is connected to the head of the crossover tool.

The setting sleeve of the packer has a sleeve pushed against it. In the crossover tool, there is a setting ball that is released to the ball seat. Consequently, it seals off the ID of the work string.

A piston inside the hydraulic setting tool pushes the sleeve downwards to squeeze the packing element and slips off the packer using pressure applied on the work string.

Gravel Pack Crossover Tool

This tool forms the multiple paths of circulation for the flow of fluids during the gravel packing. It is made up of a series of shaped seals that surround a gravel pack.

There are three ports; one in the middle, a return port near the top of the tool, and the last port down the tool.

It features a parallel tube design.

The design plus the packer and the gravel pack extension permits the fluid pumped below the work string, on top of the packer, to cross over to the casing annulus at the bottom of the packer.

Likewise, the returning fluids that flow up the wash pipe and at the bottom of the packer can “crossover” to the work string annulus on top of the packer.

There are three positions normally used with this tool.

  • Reverse circulating
  • Circulating
  • Squeeze

Wash Pipe

The wash pipe is situated below the crossover tool. It is placed inside the screen and blank pipe to secure the circulation point of return for the gravel pack carrier fluid below the screen.

This tool helps in putting the gravel pack below the screen.

It also assists with packing from down. This tool’s end should be situated close to the screen’s bottom.

Boosting the outer diameter of the wash pipe helps increase the resistance flow into the screen annulus.

Also, the maximized flow resistance pushes the gravel pack carrier fluid to flow in the screen and transport the packed sand to the well’s bottom.

Thus, fully completing the gravel packing of the screen.

Showing the various service tools in a gravel pack screen

An Image showing the various service tools in gravel pack screen

How Long Does The Gravel Pack Screen Last?

The gravel pack screen has a relatively longer lifespan in comparison to other sand screens. The lifespan of any sand screen in service differs with application changes.

Factors such as maintenance, regularity of use, and the conditions of operations affect the lifespan of the Gravel pack screen.

Gravel packs can last for as long as the wellbore exists.

Conclusively, the gravel pack screen can be replaced after every four years to ensure that the Gravel Pack continues to function optimally.

How Does The Gravel Pack Screen Work?

The Gravel Pack Screen is used to hold the gravel pack sand in place. The Gravel pack method works by pumping a sludge containing a carrier fluid, gravel sand that is appropriately sized to the size of the formation grains.

First, the sludge is pumped through the annulus into the formation. This occurs between a centralized screen and either an open hole or a perforated casing.

Typically, the gravel size is usually five to six times more than the formation sand’s size. The sludge containing the carrier fluid can leak into the formation creating a granular filter with a permeability of as high as 120 Darcy.

It can also flow through the centralized screen. The Gravel Pack Screen provides the entire structure with stability.

How a Gravel Pack Works

How Gravel Pack Works

What Are The Advantages Of Gravel Pack Screen Over Other Sand Control Methods?

Below are some of the benefits gravel pack screens have over the other conventional sand control methods;

  • They come in various diameters hence can be used in various applications.
  • Also, they require no drilling, consequently reducing the drilling costs.
  • It has a larger collapse strength.
  • Gravel pack screens ensure 100% gravel packing.
  • Moreover, they significantly eliminate sand pumping.
  • Lastly, they increase the well’s efficiency.

What Are The Gravel Placement Techniques?

There are several gravel placement techniques. They include;

The Simplest Method

It involves only a gravel pack. In this method, the screen is not installed. It is done by drilling a hole, usually twenty-five to thirty-five feet, then creating a wide hole at the bottom.

The next step is to fill the hole gravel. In this method, the gravel pack acts as a screen.

Using A Gravel Pack And A Screen

The first step when installing a Gravel pack screen is to ensure that you have a 1.25 inch Gravel Pack screen and three-inch drill pipe. Next, you use the drill to make a hole and loosen the pipes.

After removing the drill, place the Gravel Pack screen pipe of 1.25 inches down to the end of the hole.  Pour the gravel down in the middle of the two pipes.

Good Screen Only

It is the most common method. It uses a two-inch drill and a three feet screen. The most important thing to note in this method is exposing the good screen at the bottom of the wellbore.

How Do You Test Quality Of Gravel Pack Screen?

Two main tests can be carried out to ascertain the quality of a gravel pack screen. These tests include;

Slurry Test

The slurry test is carried out by prompting contrary wellbore conditions. You will need to suspend sand on a slurry and pass it through the screen.

Afterward, you record the weight of the particles that get through the screen and the pressure rate building up across the screen against the amount of sand touching the screen.

Sand Pack Test

The sand pack test prompts a passive sand control or a collapsed wellbore. It is carried out by placing the sand directly on the screen.

A wetting fluid is passed through the screen and the sand pack. You then record the weight of the amount of sand passing through against the changes in pressures across the screen.

How Porous Is The Gravel Pack Screen?

The permeability of the gravel pack may be very high or low, depending on screen perforation sizes. Typically, it ranges from as low as 45 to as high as 2703 Darcy’s.

What Factors Affect The Efficiency Of Gravel Pack Screen?

Several factors can affect a Gravel Pack Screen efficiency. These factors include;

  • The fluid flow rate of the Gravel Pack screen
  • Micron rating of the Gravel Pack screen
  • Permeability of the screen.
  • Reservoir particle size, distribution, and uniformity.
  • The conditions of Sand formation.
  • Design of the Gravel Pack screen.
  • Amount of flow and open areas.
  • Pressure gradient of the Gravel Pack screen.

Can You Customize A Gravel Pack Screen?

Yes, you can customize a gravel pack screen.

When customizing your gravel pack screen, several factors are taken into consideration.

The key factors include;

  • Adequate size for efficiency.
  • The type of gravel pack screen.
  • Gravel Pack Screen’s permeability.
  • Strength of material used to make the screen.
  • The flow rate
  • The size of your well.
  • Inflow capacity.

The most important step before designing your gravel screen pack is to conduct an in-depth sand analysis. This is to ensure that the screen is modified to suit the sand you want to control.

Does Sand Pass Through The Gravel Pack Screen?

No, the gravel pack screen is designed only to allow fluids to pass through. The main aim of the Gravel pack is to ensure that your wellbore is sand-free. Therefore, an efficient Gravel pack screen does not allow sand to pass through.

Which Materials Are Used To Make Gravel Pack Screen?

Sand control screens should be durable as well as economically feasible. Several materials can be used to construct a Gravel pack screen. However, the most recommended materials are;

  • Monel.
  • Stainless steel.
  • Inconel.
  • PVC.
  • High strength carbon steel.
  • ST37-2.
  • Titanium.

What Are The Benefits Of Using Gravel Pack Screen As A Method Of Sand Control?

The benefits of using a gravel pack screen as a sand control method include;

  • Minimization of productivity impairment through proper design
  • It can be used in heterogeneous sands.
  • Gravel packs have high permeability.
  • Gravel Pack Screens have a longer lifespan.
  • Easy cleaning of the screens.

How Is Gravel Pack Screen Assembled?

Below is the basic procedure of assembling a gravel pack screen;

  1. The first step when assembling a gravel pack screen is to ensure that you have a 1.25 inch Gravel Pack screen and a three-inch drill pipe.
  2. The next step is to use the drill to make a hole and loosen the pipes.
  3. After removing the drill, place the Gravel Pack screen pipe of 1.25 inches down to the end of the hole.
  4. Pour the gravel down in the middle of the two pipes.
  5. Then, work the pipe up and down as you pour the gravel. The pipe can show you the amount of gravel at the bottom by hitting the top.
  6. Add a bit more to cover the length of the screen, and that is it.

What Factors Should You Consider When Selecting Gravel Pack Screen?

Selecting a suitable gravel pack is key, as its efficiency depends on using the most suitable gravel pack. The factors that will guide you in your gravel pack screen selection include;

  • The micron rating of the Gravel Pack screen
  • Permeability of the Gravel pack screen
  • The Particle size distribution

Is Gravel Pack Screen Calculator Necessary?

A gravel pack screen calculator is important in calculating the well’s size, formation size, and flow rate. As such, it is crucial when looking to install a gravel pack screen.

The calculator will help you get the right gravel pack screen that will serve you efficiently.

However, you will need the help of a professional to use a gravel pack screen calculator effectively.

What Is The Lifespan Of Gravel Pack Screen?

The gravel pack screen can last for more than four years. Compared to other sand control methods, this is a lengthy life span.

Notably, the gravel pack itself can last for as long as the wellbore exists.

What Is The Difference Between Pre-packed Screen And Gravel Pack Screen?

Pre-packed screens are made up of interior and exterior slip-on wire jacket screens.

The screen has different diameters that are held together over a perforated base pipe.

The sizes of the diameters depend on factors such as the flow rate and the borehole size.

Pre-Packed Screen

Pre-Packed Screen

The pre-packed screen is an example of a stand-alone screen.

Its design makes it applicable in many other areas, such as oil and gas control. This screen is a modified pipe-based wire-wrapped screen.

Gravel pack screen, on the other hand, is used together with hydraulic fracturing. It is, however, engaged at low pressure. Notably, the gravel pack screen is assembled on site.

Array of Gravel Pack Systems

An array of Gravel Pack Systems

The grave pack screen mainly offers stability in the formation. It also assists in maintaining the productivity of the well.

What Are The Different Types Of Pipes Used With The Gravel Pack Screen?

Some of the most common pipes include:

PVC Pipes

The PVC pipes have been proven useful in the construction of wells.

They have corrosion resistance and are lightweight. Thus, making them ideal for most applications since they;

  • Can accommodate various media
  • Are easy to handle
  • Increase stability

Ribbed Pipes

The ribbed pipes are made of plastic. They are mostly used in small-scale operations.

Steel Ram Pipes

They consist of a meter-long, galvanized steel pipe slotted and covered in a stainless steel wire mesh.

Lengthwise Slotted Pipe

The lengthwise slotted pipe is made from PVC-U. Consequently, making them good for water applications.  They also have increased tensile strength.

How Do You Maintain Gravel Pack Screen?

Proper maintenance of a gravel pack screen ensures the longevity and continued effectiveness of your gravel pack screen. It is, therefore, necessary to do routine maintenance.

You can do the following to maintain your gravel pack screen:

  • Regular schedule inspection of the wellbore to spot any signs of erosion of the screen.
  • Increase the wellbore’s test frequencies if there are changes in the sand concentration or the flow velocity.
  • Install an intelligent well system to carry out multi-rate tests on select zones to spot completion pressure changes.
  • Conduct chemical sand treatment and sand screen cleaning.

How Can You Clean Gravel Pack Screen?

The Cleaning process of a gravel pack screen is done by dissolving scales, fines, and sand from plugged screens using treatment fluids.

The fluids are pumped by a high-energy jetting tool coiled tubing for thorough penetration.

Apart from gravel pack screens, I know you may be interested in intake screens, rotary drum screen, wedge wire screen, sieve bed screen, irrigation screen, hydro screen or extruder screen.

In case you have any question about gravel pack screen, contact FilSon now.

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