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Types of Well Completion: 1. Open Hole Completions
Types of Well Completion: 1. Open Hole Completions
Oil and gas well completions can be divided into two main categories: open hole well
completions, and the case-hole completions.
1. Tubingless Completion
The tubingless completion method is used in wells where the pay rock pressure is low
and high flow rates are required. In this case production must take place directly
through the final lining of the well, with no support from production strings or
isolation systems.
2. Packerless Completion
Packerless completion is a more financially advantageous system. Here, only the
production tubing is placed in the well, and it is possible to produce both through it
and through the annulus. The production tubing can be used for injecting inhibitors or
killing fluid. This method is somewhat limited in terms of flow conditions and the
protection of the tubing materials. Moreover, it is difficult to detect leaks in the tubing
or the casing, and to gather bottomhole pressure data.
Drilling, displacing
Displacing the drill-in fluid with brine by applying reverse circulation techniques is the most
efficient way for cleaning the hole. Once the open hole is effectively displaced, the well can be
completed by either running a stand-alone screen or with a gravel pack.
Horizontal wells
Because lateral lengths often are more than 2,000-3,000 ft, costs for casing, cementing, and
perforating can be significant in cased holes. Open holes simplify the completion and are
economically attractive because of cost and productivity.
From one perspective, the horizontal lateral can be viewed as a gigantic perforation with the
exception that tools can be run in it. This is appealing from a productivity perspective because
greater perforation penetration is usually related to greater flow capacity in spite of having only a
single perforation.
Guidelines
Open hole completions are reasonably simple. However, conducting each completion step
correctly and in the proper sequence significantly affects the completion and subsequent well
performance. By contrast, a cased hole can be completed with sloppy procedures. While the well
may be completion limited (damaged) when it is placed on production, at least, the completion
equipment can usually be run and operated without complications. Such is not the case in many
open hole completions.
One main requirement for sand-control is well bore and fluid cleanliness. Hence, drilling must
deliver a clean, stable, and undamaged well bore.
The first step in an open hole completion is to set production casing so that shales and other
strata contributing to borehole instability are behind pipe. The next step is to drill into the
reservoir with a drill-in fluid. The well must then be displaced with a brine in preparation for
running completion equipment. Generic steps are as follows:
Drill-in fluids
After the production casing is set, the drilling mud is displaced with drill-in fluids, which are
used to drill the open hole interval.
One must remember that the first opportunity to damage the formation is when the drill bit enters
the pay section. Unfortunately, this will not be the last. Selection of a drill-in fluid that will not
cause formation damage is important for obtaining high productivity wells.
Currently, there are two generic water-based drill-in fluids available: calcium carbonate and
saturated-salt systems. Water and oil-based drilling fluids have been used to drill the open hole
interval but are not usually viewed favorably when compared to the generic drill-in fluids.
Regardless of which drill-in fluid is used, it should meet the following requirements:
Wide density range
Compatible with the formation
Low fluid loss
Thin, friable filter cake
High return permeability.
One main role of a drill-in fluid is to develop a thin, non-damaging filter cake that can be easily
removed after placing a well on production. The breakout pressure, defined as the pressure
differential required to initiate backflow, should be less than 20 psi and reflect a return
permeability greater than 80%.
Displacing
The drill-in fluid may contain as much as 10%, or more, solids which is unacceptable for the
completion because these solids will likely plug the screen and/or contaminate the gravel pack.
Hence, the reason for the displacement is to completely remove all solids from the open hole that
potentially could plug a screen or gravel pack.
One approach for some stand-alone screen completions, which currently enjoys some use, has
been to condition the drilling fluid so that it will backflow through the screen.While some
particulate backflow through the screen probably does occur, complete flow through the screen is
unlikely with the consequences of flow impairment due to plugging.
Another approach is to run the screens into the drill-in fluid and to remove damage by
circulating, washing, and acidization. However, there are concerns such as:
These methods may be moderately acceptable for some stand-alone screen completions, but they
are unacceptable and incompatible with gravel packing because particulates will plug and
contaminate the completion.
Brine is the displacement fluid of choice. It should have a density of at least the same as the drill-
in fluid and be sufficient to achieve an overbalance of 300-500 psi.
Exceeding the original formation breakdown pressure (fracturing) is almost never recommended.
Also, under no circumstances should the system be underbalanced because this will either cause
hole collapse or well-control problems.
Isolating shales
As previously mentioned, in most open hole completions where problems have occurred,
unstable shales invariably have been the main source of dirty fluids, borehole instability, and low
productivity. The cause seems to be that some shales react adversely with the drilling fluid and
promote swelling and entry in to the circulation path.
Also, a filter cake does not form because there is no fluid loss across the shales. The consequence
is that the exposed shale continues to erode and creates plugging and fluid-cleanliness problems.
Casing-off troublesome shales seems to be the best solution
Fortunately, not all shales are sensitive and present problems, and when these situations exist,
intervals have been successfully completed even with exposed shale. However, should shale
problems occur after setting casing, an uncemented liner can be run across the shale section to
take it out of the circulation path.
Reference:
Agip (1996) Well completion and workover course, Agip, 2v. Economides M.J. et al. (edited by)
(1998) Petroleum well construction, Chichester-New York, John Wiley.
McLarty, J.M., Dobson, J.W., and Dick, M.A., "Overview of Offshore Horizontal
Drilling/Completion Projects in the Gulf of Mexico," SPE Paper No. 24842, 1992.
Pardo, C.W., and Patricks, A. N., "Completion Techniques Used in Horizontal Wells Drilled in
Shallow Sands in the Gulf of Mexico," SPE Paper No. 27350, 1992.