Petroleum Production Concepts - Conventional Completions

1
Revised 2010 HWU MSc. PT - David Davies

Institute of Petroleum Engineering, Heriot-Watt University, Edinburgh, U.K.
Production Technology
David Davies
2
Institute of Petroleum Engineering, Heriot-Watt University, Edinburgh, U.K.
Completion Concepts
D. R. Davies
Chapter 1: Learning Objectives
1. Selection criteria for:
Bottom Hole Completion Technique
Flow Conduit between Reservoir & Surface
2. Describe:
Completion String Components & their Function
Multiple Zone Completions
3. Wireline Servicing of Completion Accessories
3
Design & Completion Objectives for
Production & Injection Wells
1. Provide optimum production/injection performance.
2. Minimise the total costs per unit volume of fluid
produced or injected
minimise the cost of initial completion, maintaining
production & any remedial measures
3. Ensure safety.
4. Maximise the integrity and reliability of the completion
over the envisaged completed well life
Well Integrity includes:
1. Well Construction Integrity:
Wellhead & X-mass tree
Casing & Cement Integrity (CBL, Zonal Isolation etc.)
Casing Corrosion Logs
2. Completion Integrity Assurance:
Wellhead & Christmas tree
Down Hole equipment (Safety Valve, Sliding Side Door, Dual
or Single Packer either Permanent or Retrievable, etc.)
Artificial lift (Gas Lift or Pump)
3. Flow Assurance
Scale, Asphaltene, Corrosion Management, Etc.
4. Well Life Cycle Management
4
Examples of
Well Integrity
Failures
Introduction
The fundamental design of a completion consists of four
principal decision areas:
1. Specification of bottom hole completion technique.
2. Selection of the production conduit.
3. Assessment of completion string facilities.
4. Evaluation of well productivity &/ or injectivity
Followed by:
1. Specification of all equipment and materials
2. Optimisation of completion inflow performance
3. Optimising total well design.
5
Completion
Strategy
Design
Open Hole or
Barefoot Completion
Simple/low cost completion
Drawback - all zones open to
(cross)flow, no control
Consolidated formations only:
a) E.g. deep wells with depletion
drive
b) Naturally fractured reservoirs
e.g. limestone
c) Long completion intervals or
limited access. E.g. horizontal
& multi lateral wells
6
Slotted Liner/Wire Wrapped/
Expanding Screen Completion
Drawback
1. All zones open to (cross)flow,
no control
2. Screen may become plugged
Controls sand production from
weaker formations:
1. Reservoirs with large &
homogenous sand grains
2. Long completion intervals or
limited access e.g. horizontal
& multi-lateral wells
Cemented & Perforated
Production Liner/ Casing
Liner has lowest cost
Commonest type of
completion
Inflow selectivity
achieved by careful
positioning of
perforations if
cement hydraulically
seals casing annulus
Multi-zone
completions possible
7
Production Conduit Options
Tubingless Casing Flow
Tubingless
Casing Flow
Casing & Tubing Flow or
Tubing Flow without
annulus isolation
Tubing Flow with
annulus isolation
Tubingless Completion Flow
Provides maximum production rate BUT
1. The well must be killed by squeezing
(injecting) the wellbore contents into the
formation along with any rust, scale, etc.
reducing the permeability
2. May require high fluid pressures & potential
for possible casing burst
3. Need to overcome the tendency of the
denser kill fluid to fall through the low
density hydrocarbons during the operation
8
Tubing and/or Casing Flow
Highest production rates achieved by
combined Tubing & Annular flow
Beneficial for high PI wells
Deep circulation capability allows annulus
& tubing contents to be circulated to surface
(U-tube) during well killing
Lower pressures than for squeeze kill
No need to inject into reservoir
Casing corrosion & erosion still possible
Tubing Flow without Annulus Isolation
Tubing Flow only gives some protection to
casing & phase slip reduced
Gas accumulates in annulus if FBHP<
Bubble Point
Gas eventually fills the annulus leading to
annulus heading when gas slug flow up the
tubing at regular intervals
Casing exposed to produced fluids
But corrosion inhibitor can be continuously
injected into annulus if required
9
Tubing Completion Flow
Most widely used completion type for
naturally flowing wells
Packer isolates annulus with
compressed or inflated rubber elements
Packer located close to top of reservoir
Minimises trapped annular gas
volume below the packer.
Well killing via circulation port in
tubing OR punch hole in tubing
Packer
Basic Well Completion
Schematic
Pressure & Flow Containment
Annulus Isolation
Downhole Closure of the
tubing below the wellhead
Circulation between Annulus
& Tubing
Tubing Isolation
10
Completion String must be able to:
1. Withstands anticipated pressures during production
and well operations e.g. stimulation
2. Produce or inject into the reservoir with minimal loss
of flowing pressure
3. Minimise reservoir fluid contact with the production
casing (annulus isolated from the production tubing)
4. Remotely shut-off flow downhole when required.
5. Selectively circulate between annulus & tubing.
6. Install a plug in the tubing e.g. for pressure testing.
The
General
Well
Completion
Scheme
11
Casing Spool
Well Head
Assembly
Suspend casing and tubing strings
Support surface closure/flow control device:
i) Blow-out preventer stack whilst drilling or
ii) Xmas tree for production or injection
Provide Hydraulic access to the annuli between :
(i) Casings for cement placement
(ii) Production casing & tubing for well circulation
Christmas tree
placed on top
of well head
assembly
12
A basic
Xmas Tree
Xmas tree controls the flow of produced or injected fluids
Attached to wellhead after installing the production tubing.
Two wing valves - for production & well killing (injection)
Snubbing, wireline or coiled tubing access via swab valve
Master valve controls all hydraulic & mechanical access to well
Often duplicated to increase well safety
Valves may be manual, electical or hydraulic operated.
The Production Tubing
Tubing is not just a piece of pipe!
It is special equipment manufactured to a high
standard to withstand high mechanical stresses,
fluid pressures & temperatures for long periods in
an often corrosive environment
Failure to select & correctly install a suitable tubing
results in expensive workovers or loss of the well
13
The Production Tubing must be specified to:
1. Minimise pressure losses (tubing internal diameter).
2. Have sufficient tensile strength to allow suspension of
the complete string without tensile failure.
3. Withstand the maximum conceivable internal pressure
4. Withstand the maximum conceivable collapse pressure
5. Resistant to chemical corrosion from the produced or
injected fluids, Corrosion reduces the tubings strength,
potentially leading to the above failures
The Production Tubing
1. Many grades of steel are available e.g. N80, C75 etc.:
N, C, etc. defines the composition & heat treatment
Figure is the minimum tensile strength (1,000s psi)
2. Tubing size defined by its outside diameter
3. Tubing wall thickness defined by its weight/foot
4. Both tubing & coupling type define the completion
strings tensile strength & hydraulic integrity
Full Tubing Specification
14
Two types of Threaded Couplings:
1. Internal pressure necessary to produce a pressure seal.
E.G. API round thread &buttress connections
Thread compound (or pipe dope), applied to the
threads, is compressed by external pressure acting on
the coupling & fills any void spaces in the coupling.
2. Premium metal-to-metal or elastomeric connections
E.G. Extreme Line, Hydril or VAM thread designs.
Seal is generated by torque bringing together seal
shoulders or a tapered surfaces within the thread itself
VAM developed for completing high pressure gas wells
where rigorous sealing & pressure integrity is essential
15
A box type
tubing
connection
Production Packers annular seal:
1. Improves flow stability &
production control
2. Protects the outer pressure
containment system (production
casing/wellhead)
3. Selectively isolate zones e.g. two
producing zones of different fluid
properties, GOR, pressure, etc.
Annular Pressure Seal (Packer)
16
(1) Retrievable Packers can be easily retrieved.
Packer integral part of the tubing string
Run to the setting depth
Setting mechanism actuated
(2) Permanent Packer cannot be easily retrieved.
Usually run & set separately e.g. on wireline
Run with or without a tailpipe
Tubing is run later, pressure seal achieved by
Part of the packer milled away, allowing the
rubber element to collapse & the packer retrieved
Packer Retrievability
Revised 2010 HWU MSc. PT - David Davies Permanent Packer system includes Anchor & Mill Out Extension
17
Packer setting involves compression & extrusion of a
rubber element:
Mechanically e.g. by rotation of tubing string.
Compression or Tension - based on weight of tubing
A mechanical device transfers the force to compress
the rubber element.
Packer Setting Mechanism
Sealing elements compressed against casing wall
Slips grip casing wall due to downthrust of lower cone
Unidirectional sealing & resistance to tubing movement
A Compression Set Packer
18
Packer setting involves compression & extrusion of a
rubber element:
Mechanically e.g. by rotation of tubing string.
Compression or Tension - based on weight of tubing
A mechanical device transfers the force to compress
the rubber element.
Hydraulic Ball plugs tubing below the packer.
Pressure sets the packer without being exerted on the
formation or annulus
Electrical - Packer & tailpipe lowered on electric line
to the setting depth. A small explosive charge is
detonated to actuate the packer setting mechanism
Packer Setting Mechanism
Dynamic Tubing Seal Assemblies allow Tubing Movement
19
Tubing Anchor prevents tubing
movement without sealing the
annulus
Static Packers use metal-to-metal
rather than elastomer to achieve a
pressure seal
Suitable for gas wells
Tubing has to be run under
tension to avoid tubing buckling
when well placed on production
Tubing Anchor & Static Tubing Seal Packer
Subsurface Safety Valve
Provides a remote, failsafe, shutdown system of sub-surface
isolation for catastrophic Xmas tree failure
Manages:
Xmas tree removal while preparing to pull tubing
Removal of valves or valve components for servicing
Accidental damage to Xmas tree
Wellhead leaks at the Xmas tree flange seals
1. Direct Controlled SSSV (or "storm chokes) close well
when preset pressure drops or flow rates exceeded OR
2. Surface Controlled SSSV (SCSSSV) closes well by loss
of hydraulic pressure to the downhole valve assembly.
20
Wireline Retrievable ScSSSV
Valve nipple is part of the tubing string
Valve assembly is run & retrieved by wireline
Valve has smaller flow diameter than the tubing
Valve Action
Valve held open due to hydraulic pressure
Pressure acts on a piston which moves a flow tube
against the ball after pressure equalisation
Valve closure occurs on loss of hydraulic pressure
A spring ensures reverse movement of the piston &
flow tube
Surface Controlled Sub-Surface Safety Valve Operation
21
Surface Controlled Sub-Surface Safety Valve
Ball valve held in
open position by
control line
pressure during
normal operation
Ball valve closes
to seal tubing
when pressure lost
e.g. in an
emergency
Flapper ScSSSV is an alternative to the ball valve
Valve fully closed
Valve fully open
closed
22
Surface Controlled Subsurface Safety Valve
Provides a remote, failsafe, shutdown system of sub-surface
isolation for catastrophic Xmas tree failure
Allows:
Xmas tree removal while preparing to pull tubing
Removal of valves or valve components for servicing
Accidental damage to Xmas tree
Wellhead leak at the Xmas tree flange seals
2. Surface Controlled SSSV (ScSSSV) opens well by
hydraulic pressure fed to the downhole valve
Hydraulic pressure via a 0.25 in. control line in annulus
Many types of Valve can be
installed in a Side Pocket Mandrel:
Gas Lift Valve
Dummy Valve
Chemical Injection Valve
Circulating Valve
Differential Dump/Kill Valve
Water Injection Control Valve
Side Pocket Mandrel
Valve Body
No
restriction
to tubing
access
23
Aligning the outer & inner ports by moving the sleeve allows
circulation from tubing to annulus. E.g. to kill the well
Wireline Operated Sliding Side Door
permitted
Landing Nipples
Applications:
1. Isolate the tubing string
2. Ported device for tubing & annulus communication
3. Emergency closure of tubing
4. Downhole regulation or throttling of the flow.
5. Install downhole Pressure or Temperature recording
gauges
24
Landing Nipples
5. Install downhole P or T recording gauges
Two types of application
Nipples installed at various points in the string for:
(a) Plugging the tubing for:
Pressure tests, Setting Hydraulic packer & Zonal isolation
Landing Nipples
5. Install downhole P or T recording gauges
Two types of application
Nipples installed at various points in the string for:
(a) Plugging the tubing for:
Pressure tests, Setting Hydraulic packer & Zonal isolation
(b) Installing flow control equipment:
Downhole chokes, SSSVs & pressure recorders
25
Landing
Nipple
Installing flow control
equipment:
Subsurface Flow control valve
Nipples can be of two types:
- No-go: nipple size decreases
down string
(Largest nipple placed on top)
- Selective Nipples
Multiple, same size nipples use
selective locking mechanism
Flow Coupling
A 2 - 4 ft length of heavy
walled tubing installed in areas
where excessive turbulence
expected
E.G. above & below cross-
overs, landing nipples, ScSSSV,
sliding sleeves, etc.
Provides extra protection
against internal erosion
26
Completion
Equipment
Perforated
Flow Tube
Allows fluid to
enter when the a
plug is installed at
the base of the tail
pipe. E.g. by
pressure gauges
Courtesy Schlumberger
Wire Line Entry
Guide (WEG)
Provides easy re-
entry of wireline
tools into tubing
General
Well
Completion
Scheme
27
(a) Comingled Flow:
Multiple zones flow at the same time into the tubing
e.g. two zones producing via a single tubing string
(b) Alternate Zone Well Completion:
Only one zone flows into the tubing at any time
Lower zone produced first
28
(Selective)
Single String
Dual Zone,
Two Packers
Two zone
completion using
one tubing string to
commingle both
zones or selectively
produce each zone
Alternate Zone Well Completion Strategy
Advantages
(1) Effective control of all aspects of reservoir depletion
and well control.
(2) Depletion strategy can be easily changed to adapt to
new situations. E.g. change a producer to an injector.
(3) One wells problems do not production from other
zones/wells.
(4) Each well is relatively simple mechanically
risk of failure due to complexity minimised.
29
Alternate Zone Well Completion Strategy
Disadvantages
(1) More wells required to achieve the same degree of
depletion control
- Greater cost for same drainage reservoir efficiency
(2) Zonal productivity differences will defer production &
extend field life unless well count increased
Increase unit production costs.
Co-mingled Zonal Flow
(a) Advantages:
(1) Minimises well numbers & capital investment.
(2) Reduced drilling time accelerates production build-up
(b) Disadvantages
(1) Mixing of produced fluids can give problems:
(a) Corrosion/erosion: acids, H
2
S, CO
2
, produced sand.
(c) Different composition of fluids & economic value
(d) Different zonal WOR and GOR will influence the
tubing vertical lift performance
30
Co-mingled Zonal Flow
(b) Disadvantages (continued)
(2) Poor performance of the less productive/lower pressure
reservoirs due to inflow from more productive zones
(3) Control of individual zonal production not possible.
(4) Fluid injection, e.g. for stimulation, cannot easily be
diverted into required layer.
(5) Total well production influenced by change in
characteristics of one zone. E.g. increased WOR
Multizone Completion Options
(a) Comingled Flow:
Multiple zones flow at the same time into the tubing
e.g. two zones producing via a single tubing string
(b) Alternate Zone Well Completion:
A single zone flows into the tubing at any time
Lower zone produced first
(c) Segregated, Multi-Zone Flow:
Multiple production conduits within the same wellbore
Each tubing produces one zone only
31
Separate tubing
string for each zone
Production from
each zone monitored
& controlled.
Suitable completion
for problem well
fluids
Dual String, Dual Zone
Segregated Multiple Zone Depletion
Advantages
(1) Zonal production rates independently controlled.
(2) Changes in the production characteristics of one zone
will not influence the others.
(3) Some remedial work possible for individual zones
(stimulation, re-perforating, etc.)
(4) Continuous zonal monitoring possible gives better
reservoir management.
32
Segregated Multiple Zone Depletion
Disadvantages
1. Additional CAPEX & rig time required to install the
extra tubing string.
2. Smaller tubing sizes reduces well total flow capacity.
3. Increased mechanical complexity increases the chance
of equipment failure.
Dual Zone
Completion
Options
33
Extra Equipment for Dual Completions
Dual Tubing Head Hangers
Dual Packers
Blast Joints installed in tubings placed opposite upper
zone perforations
Min Max MD-RKB TVD-RKB
ID" OD" f t f t
Tubing hanger 350

10 3/4" Casing 5.5", 17 ppf tubing 4.767 5.953

1/4" Encapsulated control line
Flow coupling 4.767 5.953
SSV: T-5EMS TRDHSV w/ 3.5" AF Profile 3.500 9.200 850
Flow coupling 4.767 6.072
5.5" Pup Joint 4.767 5.953
5.5", 17 ppf tubing 4.767 5.953
10 3/4" x 9 5/8" X-over
5", 18 ppf Tubing 4.151 5.364 1000 1000
5.5" Tubing 4.767 5.953 1500 1500
2700 2695

5-1/2" Flow Coupling 4.767 6.072
5-1/2"Pup Joint 4.767 5.953
5-1/2"Pup Joint 4.767 5.953
Polished Bore Receptacle 4.872 8.125 3944
5-1/2" Pup Joint 4.767 5.364 3950
KC1-22 Anchor 4.884 6.468 3957
9 5/8" SAB-3 Packer 4.750 8.150 3972
7" MOE(Mill-Out Extention) 6.185 7.027 3988
X-over, 7" New Vam Bx 5" Fox RS P 4.151 7.693 4000 3989
5" Pup Joint 4.151 5.364
5" Pup Joint 4.151 5.364
5" Flow Coupling 4.151 6.072
4.135" AOF Wireline Nipple 4.135 6.050 4102
5" Pup Joint 4.151 5.364
5" Tubing Joint 4.151 5.364
5" Pup Joint 4.151 5.364
5" Pup Joint 4.151 5.364
5" Pup Joint - perf orated 4.151 5.364
5" Pup Joint 4.151 5.364
5" Tubing Joint with centraliser 4.151 5.364
5" Pup Joint 4.151 5.364
Wireline Reentry Guide 4.151 5.451 5600 5577
7" Liner 6.059 7.512 5600 5577
6.059 7.512
6.059 7.512
6.059 7.512
6.059 7.512
6.059 7.512
6.059 7.512
6.059 7.512
Completion
Schematic
Equipment listed include:
Pup joints
X- Overs etc.
ODs, IDs & Depths
34
Well Completion Design
Well characteristics such as:
(a) pressure, (b) productivity or injectivity index, (c) fluid
properties & (d) rock properties and geological data.
Geographical factors such as:
(a) location, (b) water depth (if offshore), (c) weather
conditions & (d) accessibility.
Operational design constraints such as:
(a) environmental regulations & (b) safety aspects
The number of producing zones.
Wireline Servicing of Completion Accessories
Typical Wireline applications:
1. Installation of completion equipment prior to running
the production tubing e.g. a packer and a tailpipe.
2. Installation or retrieval of equipment within the tubing
string e.g. valves, pressure gauges, etc.
3. Operation of downhole equipment to either divert or
shut off fluid flow. e.g. open a SSD, install bridge plug
4. Removal of materials which have built up in the tubing
string e.g. wax or sand.
5. Adjustment of the completion interval (perforating)
35
Wireline can work on a live well
Wireline intervention & surface equipment must allow:
Lowering and retrieval of the tool string to the
(downhole) work location & its subsequent retrieval.
Monitoring of tool position & cable tension.
Equipment to position lubricator & tool string vertically
above well & lower through Xmas tree & into the tubing
The ability to insert tool string into live well & prevent
well fluid from escaping into the environment
A blowout preventor capable of sealing the annulus
around the wire & cutting, if necessary, the wireline
Surface Wireline
Equipment mounted
on a Xmas Tree
36
Surface Wireline Equipment
The wireline is wound onto a reel on a
self contained skid with independent
power supply for drum rotation &
measurement of cable length & tension
Surface Monitoring Equipment
The wireline operator must know the tool strings
depth in the well & the tension on the cable
Length of cable inserted in the well gives the
approximate depth of the tool string
This length is measured by holding the cable against an
odometer (a wheel with a device that counts the number
of rotations) as the tool string is lowered into the well
Also:
The cable tension is continuously monitored to ensure
that the breaking strength of the cable is not exceeded
37
Monitoring Cable Tension
The cable tension will:
Increase as the tool string is lowered into the well due
to the increasing weight of the wire &
Reduce during recovery of the tool string from the well
Reduce (rapidly) when it does not easily fall down the
well due to increasing friction or a downhole restriction
Reduce as the tool string is lowered through a restriction
in the tubing string; giving an indication of tool position
Increase (rapidly) if the tool string is "caught" by a
downhole restriction during recovery of the wireline
Example Completions
38
Single Zone
(no tubing movement)
VAM tubing with anchor
seal assembly latched into
permanent packer.
The VAM tubing for high
pressure gas production
(high quality seal)
Permanent packer &
tailpipe are run & set on
drillpipe or electric wireline
No moving seal assembly -
tubing stress adjusted
when tubing landed
Single Zone
(with Locator Seal Assembly)
Well produced through a
tubing string with moving
seal assembly located inside a
permanent packer
Two nipples included in the
tailpipe (for gauge placement)
Upper one: Isolates formation
when the tubing is retrieved
Lower nipple: for installation
of pressure gauges
39
Single Zone
(with ELTSR)
Completion can produce at high
rates (20,000 - 30,000 b/d)
Large bore tubing minimises
pressure drop in the tubing
Packer and tailpipe set on
electric cable or coiled tubing
Tubing string is latched into the
packer with an anchor seal
assembly at the base of an
Extra Long Tubing Seal
Receptacle (ELTSR)
Tubing movement is ~ 5 -15 ft
(depends on flow rates &
operating temperatures)
MonoboreSingle Zone
(with PBR)
High Flowrate Completion with
Polished Bore Receptacle (PBR)
Monobore: constant diameter
from surface to reservoir (for
easier access / intervention)
PBR: moving seal assembly at
base of tubing string allows for
tubing expansion/contraction
No nipple for isolation below PBR
Isolate with tailpipe (& nipple)
below PBR or by thru-tubing
bridge plug
Circulation kill using a shear valve
in SPM or SSD
40
Single Zone
(with gas lift)
Gas lift string with Side
Pocket Mandrels
Gas Lift valves installed
in SPMs allows
controlled gas entry into
tubing from annulus.
Retrievable packer
preferred if frequent
mechanical repair
expected
Selective Completion
(with gas lift)
Gas lift gas is injected down
the short string or
Selective or commingled
production via a single string
Gas injection via the tubing
avoids excessive gas pressures
being exerted on the
production casing (casing
integrity & offshore safety
issues)
41
Single Zone
(with ESP)
An ESP installation
with Y tool allows
access to the producing
zone below the tailpipe
e.g. for production
logging surveys etc.
A retrievable hydraulic
set packer reduces
difficulties pulling the
string when replacing
the pump
Dual Completion
(segregated production)
Separate production & management
of two reservoir zones
Retrievable upper dual packer
Long string connects to lower
permanent packer via a moving seal
Tubing equipment is duplicated in
both strings e.g. two ScSSSVs, etc.
Thick walled tubing (Blast Joints)
mitigates erosion of the long string
at the upper zone fluid entry point
42
A Tubingless
Dual completion
Triple completion
also possible
Tubing repair more
difficult than for a
conventional well
possible with extra
equipment
Chapter 1: Learning Objectives
1. Selection criteria for:
Bottom Hole Completion Technique
Flow Conduit between Reservoir & Surface
2. Describe:
Completion String Components & their Function
3. Wireline Servicing of Completion Accessories

Petroleum Production Concepts - Conventional Completions

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Petroleum Production Concepts - Conventional Completions

Uploaded by

Copyright:

Available Formats

1

Revised 2010 HWU MSc. PT - David Davies

You might also like