Portable manufacturing and assembling facility for modular downhole sand control screens and flow-control devices

Abstract

The present subject matter illustrates a portable-arrangement for assembling a down-hole tool for usage in a well-bore. The arrangement comprises a plurality of intermodal-containers for multi-modal transportation of freight defined by a plurality of modules. The modules are adapted for perforating a received base-pipe, de-burring the perforated pipe, and facilitating assembly of a plurality of screen-units around the base-pipe to achieve a screen assembly for sand and flow control. A roller flow conveyor-module is configured for providing automated-conveyance in respect of the base pipe within and across the modules. Accordingly, the assembling cum manufacturing is achieved at a local location (i.e. onsite) in the country of oil and gas wells operations enabling delivery in shorter lead times, improved inventory management and high in country value.

We claim: 
     
         1 . A portable-arrangement for assembling a down-hole tool for usage in a well-bore, said arrangement comprising:
 a plurality of intermodal-containers for multi-modal transportation of freight defined by one or more of:
 a first module for circumferentially perforating a received base-pipe; 
 a second module for de-burring the perforated pipe; and 
 a third module for facilitating assembly of a plurality of screen units around the base-pipe across a pre-defined length of the base-pipe to achieve a screen assembly for at least one of sand and flow control; and 
   a roller flow conveyor module for providing automated conveyance in respect of:
 (a) the base pipe within each of the first, second and third modules and across the first, second and third modules; and 
 (b) each of the screen-units across the length of the base-pipe 
   
     
     
         2 . The portable-arrangement as claimed in  claim 1 , wherein said at-least one base-pipe comprises a blank-tubular body having a first end, a second end, and a bore there-between forming a flow path for production fluids. 
     
     
         3 . The portable-arrangement as claimed in  claim 1 , wherein said plurality of screen units are connectable end to end to further achieve a pre-defined screen length on-site, each of the unit adapted to surround the base-pipe for creating an indirect flow path for production fluids moving from a surrounding subsurface formation towards an outer diameter of the base pipes. 
     
     
         4 . The portable-arrangement as claimed in  claim 1 , wherein said plurality of screen-units are pre-configured as at least one of:
 a sand control apparatus;   an inflow control device; and   an injection control device   
     
     
         5 . The arrangement as claimed in  claim 1 , wherein at least one of the plurality of intermodal containers comprises a fourth module for subjecting the base-pipe to a quality-control process prior to undergoing perforation in the first module. 
     
     
         6 . The arrangement as claimed in  claim 1 , the first module comprises a drilling station comprising multiple spindle systems to drill the required perforation pattern on the basepipe. 
     
     
         7 . The arrangement as claimed in  claim 1 , wherein the second module subjects the perforated base pipe to undergo cleaning and deburring mechanism to remove the metallic burrs inside the basepipe. 
     
     
         8 . The arrangement as claimed in  claim 1 , wherein the deburring system is configured to traverse a complete length of perforations and comprises:
 a cleaning head moving inside the basepipe;   air-circulation to remove debris resulting from the drilling operation.   
     
     
         9 . The arrangement as claimed in  claim 1 , wherein the third module is an installation stage pertaining to the installation of a prefabricated screen-unit and comprises a resilient-mechanism to:
 guide the plurality of downhole screens units extracted from a screen-stock over a cleaned and drilled base-pipe and thereby enable a concentrical arrangement of the screen units over the cleaned and drilled base-pipe to provide cover for a pre-defined length of the basepipe.   
     
     
         10 . The arrangement as claimed in  claim 9 , wherein the third module further comprises:
 a first welding stage for subjecting the plurality of screens units arranged over the base-pipe during the installation stage to undergo welding with each other   a crimping stage for crimping outer edges of the screen units to the basepipe, and   a second welding stage for welding the crimped edges to the basepipe, thereby resulting in a finished screen assembly.   
     
     
         11 . The arrangement as claimed in  claim 1 , wherein the plurality of intermodal containers optionally comprise a facility for subjecting the screen-assembly provided by the third module to a manual or automated quality-control process to render a quality-checked screen assembly. 
     
     
         12 . The arrangement as claimed in  claim 1 , wherein the roller flow conveyor module is transported as a knock-down kit through the intermodal container as the freight and assembled post-transportation. 
     
     
         13 . The arrangement as claimed in  claim 1 , wherein the roller flow conveyor module in the assembled state comprises:
 a deck defined by a raised platform; and   a plurality of motion sources defined by one or more of:
 a first type of mechanism for linearly sliding the base-pipe in and out of any of the module; 
 a second type of mechanism for lifting and lowering the base-pipe; and 
 a third type of mechanism for pushing the base pipe to roll from one module to another module. 
   
     
     
         14 . A process for on-site assembly of a down-hole tool for usage in a well-bore, said process comprising:
 setting up a roller flow conveyor module based on a knock-down kit transportable as freight;   guiding a base pipe via the conveyor module to reach a first intermodal-container for circumferentially perforating the base-pipe; said base-pipe comprising a blank-tubular body having a first end, a second end, and a bore there-between forming a flow path for production fluids;   further guiding the perforated base-pipe via the conveyor module to reach a second intermodal-container for deburring the perforated pipe; and   further guiding the deburred base-pipe via the conveyor module to reach a third intermodal-container for facilitating assembly of a plurality of screen units around the base-pipe across a pre-defined length of the base-pipe to achieve a screen-assembly, wherein each of the screen unit is adapted to surround the base-pipe for creating an indirect flow path for production fluids moving from a surrounding subsurface formation towards an outer diameter of the base pipe.   
     
     
         15 . The process as claimed in  claim 14 , wherein the third intermodal container is adapted to enable performance of at least one of:
 guiding a plurality of downhole screens units extracted from a screen-stock over the deburred base-pipe to achieve a concentrical arrangement of the screen units over the deburred base-pipe for a pre-defined length;   welding the plurality of screens units arranged over the base-pipe welding with each other;   crimping of outer edges of the screen units to the basepipe, and   welding the crimped edges to the basepipe to thereby result in the screen-assembly.