Production Technology

Conventional Completions

Conceptual
Well
Completion
Scheme

HWU IPE MSc PE Production Technology 2015/2016

1
 Design & Completion Objectives for
Production & Injection Wells
1. Ensure safety.
2. Provide optimum production/injection performance.
3. Minimise the total costs per unit volume of fluid
produced or injected
– Minimise the cost of initial completion, maintaining
production & any remedial measures
4. Maximise the integrity and reliability of the completion
over the envisaged well & completion lifetime

Completion
Design

HWU IPE MSc PE Production Technology 2015/2016

2
Bottomhole
Completion

HWU IPE MSc PE Production Technology 2015/2016

3 Common Bottomhole Completion

Techniques
Slotted Liner/Wire Cemented &
Open Hole or
Wrapped/ Expanding Perforated Production
Barefoot Completion
Screen Completion Liner/Casing

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 Open Hole or
Barefoot Completion
• Simple/low cost completion
• Drawback - all zones open to Gas
(cross)flow, no control breakthrough

• Consolidated formations only:

a) E.g. deep wells with depletion
drive
b) Naturally fractured reservoirs
e.g. limestone
c) Long completion intervals or Water
limited access. E.g. horizontal breakthrough
& multi lateral wells

Open Hole Completion

Advantages Disadvantages
• No perforation, production • Liable to “sand out” as
casing & cementing whole production zone is
expenses. open to flow.
• Minimal rig time. • No selectivity for
• Full diameter hole in the production, stimulation
pay zone, which improves and workover.
productivity. • Limited ability to isolate
• No critical log zones.
interpretation is required to
specify exact location for
flow of fluid from
formation.

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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

Slotted Liner/Screen Completion

Advantages
• No perforating or
cementing expense for
production casing.
• Assists in preventing sand
production.
• No critical log
interpretation is required.
Disadvantages
• No selectivity for
production, stimulation or
workover.
• Cost of slotted liner.
• Difficult to isolate zones
for production control
purposes.
• Slightly longer completion
time than open hole
completion.

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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 completion
now possible

Perforation Schematic

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 Cemented & Perforated Completion

Advantages Disadvantages
• Introduces flexibility • Requires critical log
allowing isolation of zones interpretation to specify
and selection of zones for actual perforation zone.
production/injection, e.g., • Cost of casing, cementing,
where to perforate or and perforating.
isolate. • Rig time cost for longer

Completion
string

HWU IPE MSc PE Production Technology 2015/2016

7
 Production Conduit Options

Tubingless Casing & Tubing Flow or Tubing Flow with

Casing Flow
Tubingless
Tubing Flow without annulus isolation
Casing Flow
annulus isolation
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Production Conduit Options

Key selection criteria:

• Exposure to production fluids
• Exposure to excessive pressure
• Flow stability and assurance
• Cost and reliability
• Ability to circulate the well without damaging theMSc
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PE Production Technology 2015/2016

8
 Tubing Completion Flow
Packer

• Most widely used completion type for

naturally flowing wells
• Packer isolates annulus from fluids
flowing in the tubing
• Packer located close to top perforations
– Minimises trapped annular gas
volume below the packer.
• Well killing via circulation port in
tubing OR by creating a hole in the
tubing

Basic Completion String Functions

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
4. Remotely shut-off flow downhole
when required.
5. Allow annulus to tubing circulation
when required.
6. Enable plug installation in tubing
e.g. for pressure testing. HWU IPE MSc PE Production Technology 2015/2016

9
 The
General
Well
Completion
Scheme

HWU IPE MSc PE Production Technology 2015/2016

Casing Spool
Wellhead
Assembly

• Suspend casing and tubing strings

• Support surface closure/flow control device:
i) Blow-out preventer stack whilst drilling or
ii) Christmas tree for production or injection
• Provide Hydraulic access to the annuli between :
(i) Casings for cement placement
(ii) Production casing & tubing for well circulation

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Christmas tree
placed on top
of well head
assembly

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)
• Swabbing, 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, electrical or hydraulic operated.

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 The
General
Well
Completion
Scheme

HWU IPE MSc PE Production Technology 2015/2016

The Production Tubing

• 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

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 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
string’s tensile strength & hydraulic integrity
Full Tubing Specification

HWU IPE MSc PE Production Technology 2015/2016

Two types of Threaded Couplings:

1. Internal pressure necessary to produce a pressure seal.
• Examples:- API round thread, buttress connections, etc.
• Thread compound (pipe dope) coating the threads will
fill any void spaces in the coupling when compressed
by pressure acting on the coupling
2. Premium metal-to-metal or elastomeric connections
• Examples: Extreme Line, Hydril, VAM, etc.
• 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

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 VAM:- An Integral
Internally
An Internally
Upset
Flush
Coupling
Coupling

Annular Pressure Seal (Packer)

Annular seal:
1. Improves flow stability &
production control
2. Protects the production casing &
wellhead from produced fluids
3. Selectively isolates reservoir zones
– two or more producing zones
with different fluid properties,
GOR, pressures, etc.

HWU IPE MSc PE Production Technology 2015/2016

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 Packer Types: - Retrievability
(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.
– Run & set separately e.g. on tubing, wireline, etc.
– Run with or without a tailpipe
– Tubing is run later. Pressure seal achieved by
elastomer sealing on packer’s polished surface
– Packer retrieved by milling, allowing the rubber
element to collapse & the packer retrieved

Packer Setting Mechanism

• 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.

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 A Compression Set Packer

• Sealing elements compressed against casing wall

• Slips grip casing wall due to downthrust of lower cone
• Unidirectional sealing & resistance to tubing movement

Packer Setting Mechanism

• 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

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Completion Annular Seal

• This completion
allows Tubing
Movement
• Protects the
production casing
be seal achieved by
the polished packer
bore and
elastomeric seals at
the bottom of the
tubing

Completion Downhole
Closure

ScSSSV: Surface
controlled SubSurface
Safety
Valve

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 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.

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

HWU IPE MSc PE Production Technology 2015/2016

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 Flapper ScSSSV is an alternative to the Ball Valve

closed

Valve fully open Valve fully closed

Side Pocket Mandrel

– 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 Valve Body

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 Completion
Functions
- Opening the Sliding
Side Door (SSD) allows
circulation between
tubing & annulus
E.G. for well killing

Wireline Operated Sliding Side Door

Aligning the outer & inner ports by moving the sleeve allows
circulation from tubing to annulus.
HWU IPE MScE.g. for well
PE Production killing
Technology 2015/2016

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 The
General
Well
Completion
Scheme

HWU IPE MSc PE Production Technology 2015/2016

Landing Nipples
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 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

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Flow Control Equipment Landing
installed in Nipples: Nipple
E.G. Subsurface Flow control
valve

• Nipples can be of two types:

- No-go nipples: nipple size
decreases down string with
the largest nipple on top
- Selective Nipples
Multiple, same size nipples use
selective locking mechanism
HWU IPE MSc PE Production Technology 2015/2016

Completion
Equipment

Perforated Wire Line Entry

Flow Tube Guide (WEG)

• Allows fluid to • Provides easy re-

enter when a plug entry of wireline
is installed at the tools into tubing
base of the tail
pipe. E.g. by
pressure gauges

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 Flow Coupling

• Provides extra protection

against internal erosion
• A 2-4 ft length of heavy
walled tubing installed where
excessive turbulence expected
• E.G. above & below cross-
overs, landing nipples, ScSSSV,
sliding sleeves, etc.

HWU IPE MSc PE Production Technology 2015/2016

General
Well
Completion
Scheme

HWU IPE MSc PE Production Technology 2015/2016

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 Classes of Well Problems
3. Completion
string

2. Wellbore casing

1. Reservoir &
bottomhole
completion

+ complex (interactive) problems! A->B->C

HWU IPE MSc PE Production Technology 2015/2016

Well completion (string) associated problems

Temporary or
permanent

Reasons for Completions Equipment Malfunctions or

Failure:
(1) effects of pressure
(2) effects of thermal stress
(3) applied and induced mechanical loadings can cause the
tubing to part or unset packers. They can also be induced by
temperature & pressure changes.
(4) internal corrosion failure due to O2, CO2, H2S and acids.
External casing corrosion can result from corrosive
formation waters.
(5) erosion due to high rate flow and/or sand production.

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The nature and consequence of completion
failure
Example failure events

HWU IPE MSc PE Production Technology 2015/2016

Well completion problems: vertical lift

performance problems

Depends on the
completion Mechanical or
complexity chemical plugging

Remedial measures:
• Wireline fishing
• Tubing retrieval
• Chemical treatment
• Scraping
vs • Hot wash

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 Wireline Operations
Typical wireline applications are the:
• Installation of completion equipment
prior to running the production tubing
e.g. a packer and a tailpipe assembly.
• Installation or retrieval of equipment
within the tubing string e.g. valves,
pressure gauges, etc.
• Operation of downhole equipment to
either divert or shut off fluid flow. e.g.
open a sliding side door or install a
bridge plug
• Removal of materials, which have
built up in the tubing string, such as
wax or sand.
• Adjustment of the completion interval
e.g. perforating.

HWU IPE MSc PE Production Technology 2015/2016

Multiple Zone Completions

• Comingling the Flow from various zones in
which fluid from more than one reservoir
simultaneously flows into a single tubing string
e.g. two zones producing up a single tubing
string.
• Segregated, Multi Zone Depletion multiple
production conduits are installed within the
same wellbore. Each tubing controls the
production of one reservoir.
• Alternate Zone Well Completion Strategy each
well is completed on more than one reservoir.
However, only one reservoir is produced up one
tubing string at any particular time. The
advantages and disadvantages of each of the
above techniques is discussed below.

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 Example: Dual Zone Completions
Key selection criteria:
• Cost, N of wells, flow rate
• Flow assurance
• Well integrity
• Compatibility/interference
between layers
• Selective control SSD

• Complexity and installation

risks; work-overs
• Well conversion
• Well and reservoir
monitoring

Completion
Design –
What Next?

Some
Examples:
HWU IPE MSc PE Production Technology 2015/2016

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 Haggis Field, Well 3 Figure 1
Completion Schematic
Dev Min Max MD-RKB TVD-RKB
degs ID" OD" ft ft
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

Completion
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

Schematic 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

• Schematic covers everything: 2700 2695

• Pup joints 5-1/2" Flow Coupling

5-1/2"Pup Joint
5-1/2"Pup Joint
Polished Bore Receptacle
4.767
4.767
4.767
6.072
5.953
5.953
3944

• X- Overs etc.
4.872 8.125
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 B x 5" Fox RS P 4.151 7.693 4000 3989
5" Pup Joint 4.151 5.364

• Details, OD’s, ID’s & Depths

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" Flow Coupling 4.151 6.078
5" Pup Joint 4.151 5.364

of ALL installed equipment

5" Tubing Joint 4.151 5.364
5" Pup Joint 4.151 5.364
5" Flow Coupling 4.151 6.077
4.125" AOF Wireline Nipple 4.125 5.950 4765
5" Flow Coupling 4.151 5.364
5" Pup Joint 4.151 5.364
5" Tubing Joint 4.151 5.364
5" Pup Joint - perforated 4.151 5.364
5" Flow Coupling 4.151 6.124
4.000" AOF Wireline Nipple 4.000 5.950 5500
5" Flow Coupling 4.151 6.077
5" Pup Joint 4.151 5.364
5" Tubing Joint w ith centraliser 4.151 5.364
5" Pup Joint 4.151 5.364
5" Tubing 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

HWU IPE MSc PE Production Technology 2015/2016

6.059 7.512
6.059 7.512
6.059 7.512

A single-zone,
highly producing
well completion
example

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Completion Tutorial: Spot the Errors

Completion Tutorial: A Solution

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