Integrated Completion String and Method for Making and Using

Abstract

An integrated apparatus for use in hydrocarbon-producing wells is provided. A device for controlling inflow from a subterranean formation (ICD), a filtration medium for fine particle exclusion and a sealing element (packer) are disposed along a single cylindrical mandrel, preferably an oilfield tubular. The apparatus may be used in a completion method to enhance production rates and increase the total recovery from a subterranean hydrocarbon-producing formation.

1 . A well completion assembly, comprising:
 a cylindrical mandrel having a wall and a port therethrough;   a first screen assembly affixed outside the mandrel;   a packer mechanism affixed outside the mandrel; and   a first inflow control device affixed outside the mandrel and disposed to receive flow from the screen and deliver flow to the port in the wall of the mandrel.   
     
     
         2 . The well completion assembly of  claim 1  wherein the cylindrical mandrel is an oilfield tubular. 
     
     
         3 . The well completion assembly of  claim 1  wherein the first inflow control device includes a labyrinth. 
     
     
         4 . The well completion assembly of  claim 1  wherein the first screen comprises a layered wire mesh. 
     
     
         5 . The well completion assembly of  claim 1  wherein the first screen comprises a wire wrapped on the cylindrical mandrel. 
     
     
         6 . The well completion assembly of  claim 1  wherein the packer mechanism comprises a material formulated to swell in water or oil. 
     
     
         7 . The well completion assembly of  claim 1  wherein the packer mechanism comprises an inflatable packer. 
     
     
         8 . The well completion assembly of  claim 1  wherein the packer mechanism comprises a pliable material that is expanded by application of mechanical force. 
     
     
         9 . The well completion assembly of  claim 1  wherein the first inflow control device is disposed between the first screen and the packer mechanism. 
     
     
         10 . The well completion assembly of  claim 1  further comprising a second inflow control device affixed outside the mandrel and a second screen affixed outside the mandrel and disposed such that the packer mechanism is disposed between the first inflow control device and the second inflow control device and between the first screen and the second screen. 
     
     
         11 . A method for making a well completion assembly, comprising:
 providing a cylindrical mandrel having a wall;   forming a port through the wall of the mandrel at a selected location;   providing an inflow control device having an outflow end and affixing the device outside the mandrel and disposed to deliver flow from the outflow end to the port;   providing a screen and affixing the screen outside the mandrel and in flow communication with the inflow control device so as to deliver flow from the screen to the inflow control device; and   providing a packer mechanism and affixing the packer mechanism outside the mandrel.   
     
     
         12 . The method of  claim 11  wherein the method of affixing is welding. 
     
     
         13 . The method of  claim 11  wherein the inflow control device is affixed between the screen and the packer mechanism. 
     
     
         14 . The method of  claim 11  wherein the mandrel is a piece of oil field tubular. 
     
     
         15 . An inflow control device, comprising:
 a mandrel;   a first sleeve having an axis and a wall thickness and adapted to slide over the mandrel and a channel through the wall thickness of the first sleeve from a first location at an inflow end to an outflow end disposed along the axis of the sleeve; and   a second sleeve over the first sleeve, the second sleeve forming an outside wall of a flow channel through the first sleeve and being affixed to the mandrel.   
     
     
         16 . The inflow control device of  claim 15  wherein the mandrel is a piece of oil field tubular. 
     
     
         17 . A method for forming an inflow control device, comprising
 providing a mandrel;   providing a first sleeve having an axis and a wall thickness and adapted to slide over the mandrel;   cutting a channel through the wall thickness of the first sleeve from a first location at an inflow end to an outflow end disposed along the axis of the sleeve; and   sliding a second sleeve over the first sleeve, the second sleeve forming an outside wall to the channel through the first sleeve and being sized to slide over the first sleeve; and   affixing the second sleeve to the mandrel.   
     
     
         18 . The method of  claim 15  wherein the mandrel is a joint of oil field tubular. 
     
     
         19 . A method for forming an inflow control device, comprising:
 providing a flat piece of material sized for a first sleeve of an inflow control device when rolled into the first sleeve having an inflow end and an outflow end;   cutting a channel through the wall thickness of the flat piece from a first location to a second location such that the channel is disposed from an inflow end to an outflow end along the axis of the first sleeve formed from the flat piece;   rolling the flat piece to form the first sleeve; and   placing a second sleeve over the first sleeve, the second sleeve forming an outside wall to the channel through the first sleeve and being sized to slide over the first sleeve; and   affixing the second sleeve to the mandrel.   
     
     
         20 . The method of  claim 17  wherein the mandrel is a joint of oil field tubular.