Wedge Wire Pipe Based Well Screen for Oil Well

Wedge Wire Well Screens
June 13, 2026

 

API 5CT Base Pipes and Precision Wedge-Wire Sand Screens

Wedge Wire Pipe Based Well Screen for Oil Wells

Pipe-based sand screens combine a perforated API casing or tubing base with a welded V-wire jacket for controlled sand retention in oil and gas completions.

Heavy-Wall Base Pipe Options
304L / 316L / Duplex Materials

Outer Diameter Range
2-3/8″ – 20″
60mm to 508mm Standard
Slot Precision
0.05 – 3.0mm
±0.015mm Ultra Tight Tolerance
Standard Compliance
API 5CT
J55, K55, N80, L80, P110
Open Area Ratio
Up to 68%
Maximizes Inflow Performance

Technical Overview

Construction, materials, and operating considerations

The Pipe-Based Wedge Wire Well Screen uses the base pipe as the structural member and the screen jacket as the filtration surface. The base pipe can be supplied in an API casing grade or in a stainless or duplex alloy, depending on the well design. Perforations provide the flow path between the screen jacket and the pipe bore, while the V-shaped wire controls the size of particles entering the completion. This arrangement is useful when a screen has to carry deployment loads as well as provide a defined filtration opening.

The wire jacket is resistance-welded at the contact points between the profile wire and the support rods. The welded construction keeps the slot pattern in place during handling and installation. For horizontal, deviated, and high-pressure wells, the load carried by the screen is primarily transferred through the base pipe and end connections, so the pipe grade and wall thickness need to be selected with the completion loads in mind.

Data Table 1.0

Primary System Specifications & Supply Capability

Specification Parameter Imperial Value Metric Value Manufacturing Standard / Option
Outer Diameter Range 2-3/8 in – 20 in 60.3 mm – 508 mm API 5CT / Custom Sizing
Base Pipe Wall Thickness 0.205 in – 0.635 in 5.21 mm – 16.13 mm SCH 40, SCH 80, STD, Heavy Wall
Slot Opening Precision 0.002 in – 0.118 in 0.05 mm – 3.0 mm (50-3000µm) High-Precision Micro Gap Control
Length Classifications R1 (16-25 ft), R2 (25-34 ft), R3 (34-48 ft) R1 (4.88-7.62m), R2 (7.62-10.36m), R3 (10.36-14.63m) API 5CT standard length ranges
Base Pipe Manufacturing Type Seamless (SMLS) / ERW / EFW Seamless / Welded Construction ASTM A312, ASTM A358, API 5CT
Material Options Stainless Steel (304, 304L, 316, 316L, 904L), Duplex 2205/2507, Alloy 825/625, API Carbon Steels Corrosion-Resistant Alloys (CRA)
End Connection Types API Threaded (STC, LTC, BTC), Premium Gas-Tight Threads, Beveled Weld Ends, Flanged Ends API Spec 5B / ISO 11960 Compliant
Surface Treatments Pickling & Passivation, Mechanical Polishing, Bright Annealing, Sand Blasting, Electro-polishing ASTM A380 Standard Passivation
Data Table 2.0

API Casing Pipe Base Dimensions & Nominal Weight Matrix

Nominal Size (in) Outside Diameter (mm) Linear Weight (lb/ft) Linear Weight (kg/m) Wall Thickness (mm) Available Steel Grades
4-1/2 114.30 11.60 / 13.50 17.26 / 20.09 6.35 / 7.37 304 / 304L / 316 / 316L / J55
5 127.00 15.00 / 18.00 / 21.40 22.32 / 26.79 / 31.85 7.52 / 9.29 / 11.10 304 / 304L / 316 / 316L / N80
5-1/2 139.70 17.00 / 20.00 / 23.00 25.30 / 29.76 / 34.23 7.72 / 9.17 / 10.54 304 / 304L / 316 / 316L / L80
7 177.80 23.00 / 26.00 / 29.00 34.23 / 38.69 / 43.16 8.05 / 9.19 / 10.36 304 / 304L / 316 / 316L / P110
9-5/8 244.48 43.50 / 47.00 64.74 / 69.94 11.05 / 11.99 304 / 304L / 316 / 316L / 2205
10-3/4 273.05 40.50 / 51.00 60.27 / 75.90 8.89 / 11.43 304 / 304L / 316 / 316L / 2507
13-3/8 339.73 54.50 / 68.00 81.80 / 101.19 9.65 / 12.19 304 / 304L / 316 / 316L / J55
16 406.40 65.00 / 75.00 96.73 / 111.61 9.53 / 11.13 304 / 304L / 316 / 316L
18-5/8 473.10 87.50 130.21 11.05 304 / 304L / 316 / 316L
20 508.00 94.00 / 106.50 139.89 / 158.49 11.13 / 12.70 304 / 304L / 316 / 316L

Construction of a Pipe-Based Sand Screen

The screen is built around two main parts: a perforated base pipe and a continuous-slot wedge-wire jacket. The pipe carries the main tensile and collapse loads, while the jacket provides the sand-retention surface. The two parts are joined at the ends and, depending on the design, supported at intermediate locations.

1. Perforated Base Pipe

API 5CT casing or tubing can be drilled with CNC equipment using staggered, longitudinal, or other specified hole patterns. Hole diameter and density are selected to provide the required flow area without removing more pipe wall than the design permits. The finished holes are normally deburred before the screen jacket is fitted.

2. Wedge-Wire Jacket

The jacket is made by winding V-shaped profile wire around longitudinal support rods and welding the contact points. Because the slot is narrower at the outside surface and opens toward the inside, particles that enter the opening are less likely to become wedged in the slot.

3. End Rings and Collars

End rings or collars secure the screen jacket to the base pipe. Their dimensions and weld details depend on the connection design and the loads expected during running in hole (RIH), including handling, torque, and axial forces.

Data Table 3.0

Base Pipe Perforation & Screen Open Area Performance Data

Nominal Size (in) OD (mm) Base Pipe Perforation Specifications Screen Open Area (in²/ft) by Slot Size
Hole Dia. (in) Hole Density (/ft) Hole Area (in²/ft) Screen Jacket OD (in) 0.008″ (0.20mm) 0.012″ (0.30mm) 0.015″ (0.38mm) 0.020″ (0.50mm)
2-3/8 60.0 3/8 96 10.60 2.86 12.68 17.96 21.56 26.95
2-7/8 73.0 3/8 108 11.93 3.38 14.99 21.23 25.48 31.85
3-1/2 88.9 1/2 108 21.21 4.06 18.00 25.50 30.61 38.26
4 101.6 1/2 120 23.56 4.55 20.18 28.58 34.30 42.88
4-1/2 114.3 1/2 144 28.27 5.08 15.63 22.53 27.35 34.82
5 127.0 1/2 156 30.63 5.62 17.29 24.92 30.26 38.52
5-1/2 139.7 1/2 168 32.99 6.08 18.71 26.96 32.74 41.67
6-5/8 168.3 1/2 180 35.34 7.12 21.91 31.57 38.34 48.80
7 177.8 5/8 136 42.16 7.58 23.32 33.61 40.82 51.95
7-5/8 194.0 5/8 148 45.88 8.20 25.23 36.36 44.16 56.20
8-5/8 219.0 5/8 168 51.08 9.24 28.43 40.98 49.76 63.33
9-5/8 244.5 5/8 188 58.28 10.18 31.32 45.15 54.82 69.77
10-3/4 273.0 5/8 209 64.79 11.36 34.95 50.38 61.18 77.86
13-3/8 339.7 5/8 260 80.60 14.04 37.80 54.93 66.87 85.17

*Note: The values shown are reference configurations. Hole diameter, spacing, pattern, and open area can be changed to suit the completion design.

Data Table 4.0

Chemical Composition Analysis (Weight %)

Grade / Alloy UNS Code C (Max) Mn (Max) Si (Max) P (Max) S (Max) Cr Ni Mo N
AISI 304 S30400 0.08 2.00 0.75 0.045 0.030 17.5–19.5 8.0–10.5 0.10
AISI 304L S30403 0.030 2.00 0.75 0.045 0.030 17.5–19.5 8.0–12.0 0.10
AISI 316 S31600 0.08 2.00 0.75 0.045 0.030 16.0–18.0 10.0–14.0 2.0–3.0 0.10
AISI 316L S31603 0.030 2.00 0.75 0.045 0.030 16.0–18.0 10.0–14.0 2.0–3.0 0.10
Duplex 2205 S31803 / S32205 0.030 2.00 1.00 0.030 0.020 22.0–23.0 4.5–6.5 3.0–3.5 0.14–0.20
Super Duplex 2507 S32750 0.030 1.20 0.80 0.035 0.020 24.0–26.0 6.0–8.0 3.0–5.0 0.24–0.32
Data Table 5.0

Mechanical Properties & Yield Strengths

Steel Grade Tensile Strength Rm (MPa) Yield Strength Rp0.2 (MPa) Elongation A5 (%) Hardness (HBW Max) Hardness (HRB Max) Density (g/cm³)
AISI 304 ≥ 515 ≥ 205 ≥ 40 201 92 7.93
AISI 304L ≥ 485 ≥ 170 ≥ 40 201 92 7.93
AISI 316 ≥ 515 ≥ 205 ≥ 40 217 95 7.98
AISI 316L ≥ 485 ≥ 170 ≥ 40 217 95 7.98
Duplex 2205 ≥ 655 ≥ 450 ≥ 25 290 31 HRC 7.80
API J55 (Base) ≥ 517 379–552 ≥ 19 7.85
API L80 (Base) ≥ 655 552–655 ≥ 19 241 23 HRC 7.85
API P110 (Base) ≥ 862 758–965 ≥ 15 7.85

Manufacturing and Welding

Automated Resistance Welding of the Screen Jacket

Manufacturing starts with inspection of the base pipe and screen wire and continues through drilling, jacket forming, welding, assembly, end preparation, and final inspection. The exact sequence depends on the pipe size, material, slot opening, and connection required.

1. Base Pipe Perforation

The base pipe is positioned on a CNC drilling machine and the specified hole pattern is produced around the pipe. Hole position and diameter are checked during production, and burrs are removed from the bore and outside surface so that they do not interfere with flow or screen assembly.

2. Screen Jacket Winding

The V-wire is formed around the support rods while the winding pitch is controlled by the welding machine. Slot opening is checked against the purchase specification, and the wire-to-rod contacts are welded as the jacket is formed.

3. Direct Slip-On Assembly

After welding, the jacket is fitted over the perforated base pipe. Where support rings are specified, they are installed at the required spacing to keep the jacket aligned with the pipe during handling and service.

4. Robotic End Shield Welding

End rings are welded to the base pipe and jacket using the welding procedure specified for the selected materials. The joint is intended to hold the jacket in position and limit flow bypass around the screen ends.

Data Table 6.0

Comparative Engineering Matrix: Wedge Wire vs. Slotted Liner

Evaluation Parameter Wedge Wire Pipe-Based Screen Conventional Slotted Liner Wire-Wrapped Non-Pipe Screen
Anti-Clogging Performance High (V-shape inner widening) Poor (Straight cuts trap sand) High (V-shape profile)
Collapse Strength Maximum (API Casing Core Strength) Moderate to High Low to Moderate (No internal pipe)
Open Area Index High (30% to 68%) Low (2% to 5%) Very High (40% to 70%)
Sand Retention Efficiency 99.5% Precision Control 75% – 85% Moderate Control 99.0% Precision Control
Deep Well Adaptability Good (Depths > 4,000m) Good (Shallow to Medium) Poor (Shallow applications only)
Service Life Expectancy 20 – 30+ Years Downhole 5 – 10 Years (Erosion prone) 8 – 12 Years

Quality Control, NDT & Testing Standards

Inspection Before Shipment

Each completed screen is checked before packing. Inspection may include dimensional checks, visual examination, weld inspection, material verification, thread inspection, and other tests listed in the purchase specification. API, ASTM, ISO, or project requirements are applied where they govern the product.

Hydrostatic Testing
100% of base pipes are hydrostatically tested up to 15,000 PSI according to API 5CT specifications to verify internal pressure integrity.
Slot Width Verification
Optical shadowgraph and digital feeler gauges check slot gap uniformity across the entire length of the screen jacket.
Ultrasonic Wall Thickness (UT)
Non-destructive ultrasonic thickness measurement ensures base pipe wall integrity meets tight ASTM tolerances after drilling.
Weld Shear Strength Testing
Destructive shear tests on sample ribbon welds ensure every wire intersection withstands high downhole drag forces.
Data Table 7.0

Standard Factory Quality Inspection Plan (QIP)

Inspection Item Testing Method Acceptance Criteria Sampling Frequency
Chemical Composition Spectrometric Analysis (PMI) ASTM A312 / API 5CT Grade Limits 1 heat per raw material lot
Tensile & Yield Strength Universal Tensile Tester API 5CT / ASTM Mechanical standard 2 samples per production batch
Slot Size Accuracy Optical Comparator / Feeler Gauge Nominal Slot ± 0.015mm 10 points per length of pipe
Base Pipe Perforation Pattern Laser Coordinate Measurement Engineering Drawing Tolerances 100% Visual and Dimensional
Weld Fusion Integrity Push-Off Shear Strength Test ≥ Base metal yield threshold 1 test per shift start
End Thread Gauging API Working Thread Gauges API Spec 5B Standard Thread Specs 100% of threaded ends
Data Table 8.0

Manufacturing Dimensional Tolerances

Dimension Category Standard Specification Tolerance Precision Class Tolerance
Outer Diameter (OD) – Base Pipe ± 0.75% of OD ± 0.50% of OD
Wall Thickness (WT) – Base Pipe – 12.5% / + 15.0% – 10.0% / + 10.0%
Slot Opening Width ± 0.020 mm ± 0.010 mm
Pipe Straightness Deviation 1.5 mm / meter 1.0 mm / meter
Total Length Variance ± 50 mm per 12 meter joint ± 15 mm per 12 meter joint

Downhole Field Applications & Deployment Environments

Typical Downhole Applications

Heavy Oil & Thermal Recovery (SAGD)

SAGD and other thermal-recovery wells expose completion components to repeated heating and cooling. For these services, stainless or duplex screen materials may be considered where the temperature, fluid chemistry, and mechanical loads justify their use. The selected alloy and base pipe still need to be checked against the actual completion conditions.

Deep High-Pressure Hydrocarbon Wells

Deep wells can impose substantial collapse and tensile loads on the screen assembly. A heavier-wall L80, P110, or other specified base pipe can be selected when the calculated loads require it. Collapse resistance should be established from the actual pipe dimensions, grade, connection and well conditions rather than from a single nominal pressure figure.

Extended Reach Horizontal Wells

Horizontal completions can place the screen under drag, bending, and side loads during running. A rigid base pipe helps carry these loads, while centralizers and the running procedure are used to control contact with the wellbore.

Data Table 9.0

Corrosion Resistance & Downhole Fluid Suitability

Material Grade H2S Service (Sour Oil) CO2 Corrosion Resistance Chloride Pitting Resistance (PREN) Max Operational Temp
AISI 304 / 304L Not Recommended Moderate PREN ≈ 18–20 up to 250°C
AISI 316 / 316L Acceptable (Low H2S) Good PREN ≈ 23–25 up to 300°C
Duplex 2205 NACE MR0175 Qualified Good PREN ≈ 34–36 up to 280°C
Super Duplex 2507 NACE MR0175 Qualified High PREN ≥ 42 up to 300°C
Incoloy Alloy 825 Severe Sour Environments Maximum Protection PREN ≥ 45 up to 450°C

*PREN (Pitting Resistance Equivalent Number) = %Cr + 3.3x(%Mo + 0.5x%W) + 16x%N.

End Connections and Thread Selection

The end connection is normally machined on the base pipe or supplied with the connection specified for the completion string. API Spec 5B connections or premium connections can be used, provided the thread, coupling, seal and joint strength are suitable for the planned loads.

API STC (Short Threaded and Coupled)

An 8-round connection is commonly used where the casing design calls for this thread form and the expected joint loads are within its rated capacity.

API LTC (Long Threaded and Coupled)

Longer or premium connections may be selected when higher joint strength or improved sealing performance is required. The connection should be rated as a complete pipe-and-coupling assembly.

API BTC (Buttress Threaded and Coupled)

Buttress or other high-strength connection profiles are used when the completion design calls for greater axial load capacity. The choice should follow the casing program and connection manufacturer’s rating.

Data Table 10.0

API Casing Thread Dimension & Mechanical Rating Table

Casing Size (in) Thread Type Threads per Inch (TPI) Thread Taper (in/ft) Coupling OD (in) Joint Strength – J55 (kN)
4-1/2 STC / LTC 8 0.750 5.000 680 kN
5-1/2 LTC / BTC 8 / 5 0.750 6.050 1,010 kN
7 LTC / BTC 8 / 5 0.750 7.656 1,470 kN
9-5/8 LTC / BTC 8 / 5 0.750 10.625 2,540 kN
13-3/8 STC / BTC 8 / 5 0.750 14.375 3,210 kN

Slot Geometry and Flow Through the Screen

Why the V-Wire Slot Profile Is Used

Screen geometry affects pressure drop and the way formation fluids enter the completion. A conventional slotted liner has straight slot walls, so particles can lodge across the opening as the slot becomes restricted. Local velocity can then rise around the remaining open area, increasing the chance of uneven flow and wear.

In contrast, the Vee-shaped profile wire features a precise narrow aperture at the outer surface that widens internally toward the base pipe. Any sand particle small enough to pass through the outer slot edge flows freely through the internal widening channel without getting stuck. This design minimizes pressure drops across the screen section, preserves uniform inflow velocity, and reduces erosion.

Data Table 11.0

Standard Vee-Wire Profile Dimensions & Specifications

Wire Profile Designation Wire Width (mm) Wire Height (mm) Relief Angle (Degrees) Recommended Application
Profile 63 Wire 1.50 mm 2.50 mm 13° Fine slot media filtration (<0.15mm)
Profile 90 Wire 2.28 mm 3.50 mm 10° Standard Oil & Gas Sand Control
Profile 120 Wire 3.00 mm 4.50 mm 12° Heavy-duty gravel pack support
Profile 150 Wire 3.80 mm 5.00 mm 15° Severe erosion & deep high-flow wells

Use with Gravel-Pack Completions

In formations with fine or poorly sorted sand, a pipe-based screen can be installed as the retaining element in an open-hole or cased-hole gravel-pack completion. The screen slot and gravel size are selected as a matched system rather than as separate items.

During gravel placement, the selected gravel is pumped into the annulus around the screen. The slot opening is chosen so the screen retains the gravel while allowing produced fluid to pass through. The base pipe carries the mechanical load during placement and subsequent production.

Data Table 12.0

Gravel Pack Media & Screen Slot Selection Reference

Gravel Pack Sand Size (U.S. Mesh) Gravel Grain Diameter (Inches) Gravel Grain Diameter (mm) Recommended Screen Slot (Inches) Recommended Screen Slot (mm)
12/20 Mesh 0.0331″ – 0.0661″ 0.841 mm – 1.680 mm 0.020″ 0.50 mm
16/30 Mesh 0.0234″ – 0.0469″ 0.595 mm – 1.190 mm 0.015″ 0.38 mm
20/40 Mesh 0.0165″ – 0.0331″ 0.420 mm – 0.841 mm 0.010″ – 0.012″ 0.25 mm – 0.30 mm
40/60 Mesh 0.0098″ – 0.0165″ 0.250 mm – 0.420 mm 0.006″ – 0.008″ 0.15 mm – 0.20 mm
50/70 Mesh 0.0083″ – 0.0117″ 0.210 mm – 0.297 mm 0.005″ 0.125 mm

Packaging and Field Handling

Packaging for Transport

The screen jacket and end connections need protection during transport because dents, bent wires, and damaged threads can affect installation. Packaging is normally selected according to pipe length, weight, destination, and handling method.

1. Thread Protection Caps

Thread protectors are fitted to exposed pin and box ends where applicable. They help keep dirt and handling damage away from the connection surfaces.

2. Multi-Layer Protective Bubble Wrapping

The screen jacket can be wrapped and restrained with suitable protective material to reduce impact from adjacent pipes and lifting equipment during transport.

3. Export Wooden Crate & Frame Bundles

Depending on shipment size and destination, screens may be packed in treated wooden cases or bundled on steel frames. Spacers are used where necessary to keep adjacent screen surfaces from rubbing against each other.

Data Table 13.0

Standard Logistics & Container Capacity Matrix

Container Type Max Pipe Length Capacity Max Payload Weight Est. 4-1/2″ Pipe Quantity Est. 7″ Pipe Quantity
20ft Standard (20’GP) 5.80 meters (19 ft) 21,500 kg 180 – 210 Joints 80 – 100 Joints
40ft Standard (40’GP) 11.80 meters (38.7 ft) 26,500 kg 120 – 140 Joints 60 – 75 Joints
40ft High Cube (40’HC) 11.80 meters (38.7 ft) 26,500 kg 130 – 150 Joints 70 – 85 Joints

BLOCK 25: Technical Installation Guidelines Block

Running the Screen into the Well

Handling and RIH Considerations

The screen should be handled in the same way as other precision completion equipment, with particular attention to the wire jacket and threaded ends. The completion program and the connection manufacturer’s running procedure take precedence over general handling advice.

1. Rig Floor Handling

Use suitable lifting slings and protectors, and keep elevator dies or slips from contacting the wire jacket directly. The screen surface should not be used as a lifting or gripping point.

2. Thread Compound Application

Apply the specified thread compound to the connection surfaces in accordance with the casing running procedure. Keep excess compound away from the screen slots and verify makeup according to the connection specification.

3. Controlled Running Speed

Run the assembly at a controlled speed to limit surge effects. In deviated wells, centralization and the planned RIH procedure can reduce contact between the screen and the low side of the hole.

Data Table 14.0

Downhole Operational Troubleshooting Matrix

Observed Downhole Symptom Potential Root Cause Immediate Remedial Action Preventative Specification Adjustment
Unexpected Pressure Drop Across Screen Drilling Mud Filter Cake Plugging Perform Acid Wash or Matrix Stimulation Optimize Drilling Fluid Solids Size / Increase Slot Width
Sand Production in Surface Separator Slot Erosion or Incorrect Gravel Sizing Reduce Well Inflow Velocity / Choke Down Re-evaluate Grain Size Distribution (PSD) / Upgrade Alloy
High Drag Forces During RIH Wellbore Dogleg / Ledge Obstruction Rotate String Gently & Circulate Fluids Install Positive Heavy-Duty Spring Centralizers

Data Table 15.0

Engineering Order Request Checklist

Required Order Parameter Example Parameter Entry Engineering Importance
Base Pipe OD & Weight 7.00 in (177.8mm), 26.00 lb/ft Determines clearance inside casing and burst/collapse rating
Base Pipe Steel Grade API 5CT L80 or AISI 316L Ensures compatibility with H2S, CO2, and structural depth loads
Screen Jacket Slot Opening 0.012 in (0.30 mm / 300 microns) Matches formation Sieve Analysis (PSD) to stop sand inflow
Screen Jacket Material Alloy AISI 316L Stainless Steel or Duplex 2205 Prevents localized pitting, slot erosion, and chemical attack
End Connection Thread Specification API 5CT LTC Thread Pin x Box Guarantees mechanical joint strength and seal integrity on rig
Pipe Joint Length Range API Range 2 (7.62m – 10.36m) Matches rig derrick height and handling equipment setup

Custom Screen Design and Quotation

Custom drilling patterns, slot openings, jacket materials, base-pipe grades, lengths, and end connections can be specified from the completion data. Provide the well depth, casing size, expected fluid, sand characteristics, temperature, pressure, and connection requirements when requesting a quotation.

Comments are closed.