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PE40002 Slides Midsem (1997)
PE40002 Slides Midsem (1997)
PE40002 Slides Midsem (1997)
HYDROCARBON PRODUCTION
ENGINEERING( PE40002 )
Course outline
Well Completion
Artificial Lift
Text Book/References
Evaluation Scheme
Assignment: 10%
Quiz: 10%
Midsem: 30%
EndSem: 50%
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Million bbl/d
US (17.1 million bbl/d)
China (14.22 million bbl/d)
India (4.6 million bbl/d)
Saudi Arabia (3.5 million
bbl/d)
Russia (3.2 million bbl/d)
US (16.4 mbbl/d)
Saudi Arabia (11 mbbl/d)
Russia (10.6 mbbl/d)
Canada (5.1 mbbl/d)
Iraq (4.1 mbbl/d)
Indian Scenario
Source: CEIC
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Sedimentary rocks
Secondary rocks – from weathering of older rocks
Porosity
Denoted usually by Φ
SATURATION
Saturation is defined as that fraction, or percent, of the pore volume occupied by a
particular fluid (oil, gas, or water).
Darcy’s Law
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A porous medium (shown schematically in the figure) has the following properties.
Length L = 600 m, Width W = 8 m, Height h = 0.5 m, Permeability k = 100 mD, Porosity
ϕ = 15%. An incompressible fluid having a viscosity of 2 cP is flowing through a porous
medium at the inlet and exit pressures of 7 × 106 Pa and 6 × 106 Pa, respectively. The
actual fluid velocity through the porous medium is ____________× 10-7 m/s.
(1 Darcy = 10-12 m2)
A porous medium is blended with three types of sediment fractions, fine pebble gravel
with porosity (∅𝑝𝑒𝑏𝑏𝑙𝑒 =38 %), sand ( ∅𝑆𝑎𝑛𝑑 =32% ) and fine sand (∅𝑓𝑖𝑛𝑒−𝑠𝑎𝑛𝑑
=30%). The three sediments are mixed in such proportions that the sand fill the pore
volume of fine pebbles completely and the fine sand fills the pore volume of sand
completely. The total porosity of such an irregular system is %
(Write answer with two decimal places)
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Drilling overview
Rotary system
Hoisting system
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Circulating system
Power system
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Casing
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• blowout preventers
• production packers, and
• production tubing.
5-in. production
liner
Features
Features
Features
Features
Challenges:
Production Liner
o Function same as production casing.
o Provide isolation across the production or injection zones.
Tie-back Liner
o connected to the top of the liner and extends to the surface,
o converts liner to full string of (detachable) casing.
Scab Liner
o A section of casing used to repair existing damaged casing.
o It may be cemented or sealed with packers.
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Casing Accessories
Cementing
What is cementing?
Cementing is the process of mixing a slurry of cement,
cement additives and water and pumping it down through
casing to critical points in the annulus around the casing or in
the open hole below the casing string.
Oil well cement is made up • Accelerators
of API specification 10A • Retarders
and depending upon • Weighting agents
properties they are divided • Dispersants
into 8 classes : A - H • Fluid loss additives
Class A, C, G and H are the • Loss circulation
basic well cements control agents
Chemical additives are • Etc.
added to the cements to
control properties of the
cements (such as density,
rheology, fluid loss) and to
cover a wide range of
down-hole conditions
Main class of additives are:
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Secondary Cementing
When a primary cementing job objectives have not been achieved or
when cement or casing has failed over time secondary cementing jobs
Method
are performed
Purpose of secondary cementing job:
Seal loss circulation zone
Repair improper zonal isolation
Prevent water or gas intrusion
Repair casing leaks
Abandonment of depleted zone
Selective shut off for water injection
Well abandonment
Squeeze cementing
Plug cementing
Need
Set the casing in place.
Prevent formation-fluid influx and potential blowout
Prevent flow in un-intended sections behind casings.
Prevent sustained annular pressure.
Prevent loss of casing integrity due to corrosion.
Provide zonal isolation
Support axial load of casing string
Support the borehole
Cement
Head
Water
Tank
Water Line
Bulk Cement
Discharge line
Cementing is a process of placing a cement slurry in a well by mixing powdered cement, additives
and water at the surface and pumping it by hydraulic displacement to desired location.
8) Plug Down
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Cement Casing
Initial condition
Drilling
Fluid
Casing
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Drilling
Fluid
Casing
Bottom plug
Spacer
Fluid
Drilling
Fluid
Casing
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Spacer
Fluid
Drilling
Fluid
Casing
Tail
Cement
Lead
Cement
Drilling
Fluid
Bottom plug
Spacer
Fluid
Casing
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Top plug
Tail
Cement
Lead
Cement
Drilling
Fluid
Casing
Bottom plug
Spacer
Fluid
Top plug
Tail
Cement
Drilling
Fluid
Casing
Spacer
Fluid
Bottom plug
Lead
Cement
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Plug Down
Drilling
Fluid
Spacer
Fluid
New
Fluid system
Lead
Cement
Casing
Job complete
Well Completion
“Stage of preparing a well ready for production”
Careful interpretation of formation evaluation data (Core, mud logging, wireline logs,
Method
DST etc.) allows decision making:
To set production casing and complete
Or to plug and abandon Well
Well completion involves a series of activities to make the well to flow under
controlled and safe manner:
Installation of production tubing
Setting production casing and packer
Perforation Installation of well head
equipments
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Well Completion
Well Completion
Options and Major
decisions
Method in the
reservoir completion
are:
Well Completion
Producers vs Injectors: Completions can
produce oil, gas and water. Completions
Method
can inject hydrocarbon gas, water, steam
and waste products such as carbon
dioxide, sulphur, hydrogen sulphide, etc.
Well Completion
Options and Major
decisions in the upper
completion are:
Perforations
Perforations
Perforating gun
The shapes charges are commonly arranges in helical
pattern to achieve higher perforation density with small
phase angle
The cable-head connects the string to the wireline and at
the same time provides a weak point to break the cable in
an event of stool stuck
The depth positing of the gun is achieved with help of
correlation device by correlating with gamma logs and
casing collar locators
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Perforations
Shaped charge
Perforations
Detonation process
The explosive detonation is actuated
from the surface by usually by an
electrical current (wireline conveyed)
or by mechanical, hydraulic or
electrical means in case of tubing
conveyed perforation
The target area depends on the
diameter of the cone exit and
distance from the target
Actuation mechanism initially
detonates the primer charge in turn
detonates the main charge results in
a detonation wave of 30,000 ft/sec
Liner flows towards the center of the
cone to form a jet of fluidized
material (~33%) followed by a slug
(~67%)
The velocity of the jet is ~20000
ft/sec, impact pressure 100Gpa
The casing material of target area plastically flow away and cement along with
formation crushed and compacted to form perforation tunnel
Perforations
Charge Performance
Charge Performance is gauged in terms of
: perforation tunnel length; diameter;
volume and burr height on inside casing
wall
Influencing Factors:
• Charge Size
• Diameter of jet
• Jet velocity
• Materials of the liner
• Gun clearance
• Casing strength
• Formation strength
• Formation temperature
Burr
Allowable exposure time
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Perforations
Gun Conveyance
Perforations
Overbalanced and Underbalanced Perforation
An overbalanced perforation
required the well to be killed
with a high density mud which
exerts a bottom hole pressure
greater than the formation
pressure which could result into
formation damage
When the well is placed on
production only a limited clean
up of the debris within the
perforation owing to insufficient
flow velocity from the tip of the
perforation
A solid free clear completion
fluid can be used to prevent
formation damage but it can
excessively leak into the
formation
An underbalanced pressure
regime can immediately clean up
the perforation high velocity
formation fluid influx into the
perforation
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Perforations
Crushed zone and perforation skin estimation
Tubing Design
The tubing must have the following qualities:
The Method
inside diameter of the tubing must provide a produced fluid velocity to
minimise the total pressure loss
The tensile strength of the string (both tubing and coupling) must be high enough
to allow suspension of the complete string without tensile failure
The completion string must be able to withstand the maximum conceivable internal
(or burst) pressure.
The tubing must be resistant to chemical corrosion which may arise because of
fluid contact in the wellbore, and might ultimately accelerate string failure by one
of the loads and stresses mentioned above
Tubing Design
Tubing Size
Nominal size: is the outside diameter of
Method
the pipe body. The most used sizes are: 2-
⅜”, 2-⅞”, 3-½” and 4-½”
Internal diameter (ID): is a result of the
OD and the wall thickness, and it is used to
calculate pressure losses and velocities
Nominal weight: is the average linear weight of the tubing including connections. It
is expressed in lb/ft. It determines the tubing wall thickness
Maximum outside diameter: It depends on the nominal diameter and the
connection type. It is critical as it determines the strings size that we can run in a
given casing.
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Tubing Design
Tubing Size
The wall thickness influences the tensile strength of the steel as well as its
Method
resistance to failure with high burst and collapse pressure
Tubing must be sized to support the expected rates of production of oil and
gas
Undersized tubing will limit the production rate due to the increased friction
resistance caused by excessive flow velocity.
Contrarily, oversized tubing may lead to an excessive liquid phase loss due to
slippage effect or an excessive downhole liquid loading during lifting
Sensitivity analysis of tubing size should be carried out using the nodal analysis
Integral joint tubing has external thread at An external coupling requires that a male thread
one end and internal thread at the other be cut on each end of the tubing joints and while
end. This oil pipe can be connected the coupling has two female connection
without the use of couplings. An external coupling has a larger effective wall
Integral joint tubing is very practical. With thickness in the coupling section (Dc > D) giving
the integral joint structure, the oil pipe it higher load capacity compared to an integral
connecting procedure is saved. coupling
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Tubing Design
Tensile strength
The maximum allowable tensile load that a joint of tubing is determined by the
Method
tensile strength of the steel, the wall thickness of the tubing (and hence the
“plain end area”) and the tensile strength of the threaded coupling
Tubing Design
Burst pressure/Internal Yield Pressure
Minimum
Method
differential pressure between
inside and outside of tubing that causes
the tubing to yield
The "highest“ burst condition is usually
encountered at the surface where the
external pressure is at its minimum.
From Barlow's formula
Tubing Design
Collapse pressure/ Yield point collapse
TheMethod
collapse condition occurs when the
external pressure exceeds the internal
pressure
Minimum pressure differential acting
from outside to inside of tubing to
causes a permanent deformation
This condition is normally greatest at
the bottom of the well when the
annulus is full of fluid and tubing is
evacuated. Lame’s formula
For D/t ratio < 15
Pc
Tubing Design
API Tubing Specifications
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Tubing Design
Problem: Calculate the collapse resistance for a section of 27 ⁄8 in, API J-55 nonupset tubing near
the surface of a 10,000-ft string suspended from the surface in a gas well.
Calculate:
(1) Maximum burst resistance
(2) Maximum collapse resistance
(3) Axial stress of the tubing string at surface
Pc
Production Packers
Create casing tubing annular seal
Also serves as down-hole
anchor/hanger for tubing string
A variety in packer designs is
numerous
Selection of right packer requires
knowledge on operational and
completion requirements
The packers must be
o Compatible with tubing size
o Compatible with string
movement
o Metallurgically compatible with
produced fluid
o Elastomer must be stable at
operating temperature and
pressure
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Production Packers
All packers have four basic
elements:
Production Packers
Packer classification
Based on Lifetime
Permanent packer
Retrievable packer
Production Packers
Permanent Packers:
Once they are they can’t be unset
Can only be removed on through milling operation
The running mechanism (tubing/wireline) can be removed after setting
Offers higher performance in both temperature and pressure ratings
compared to retrievable packer
The permanent packer also offers the largest inside diameter (ID) to make it
compatible with larger-diameter tubing strings and monobore completions
Retrievable Packers:
The design could be very simple (for LTLP) to very complex (HPHT)
For the same performance level retrievable packers cost more than
permanent packers because of their design
However they can be resettable or reusable which offset the cost
Difficult to fish because hard to mill
Production Packers
Hydraulically Set Packers:
Hydraulically set packers are particularly suited to
conditions where tubing manipulation might be
problematic due to well characteristics:
High deviation
Excessive Depth
The hydraulically set packer is actuated by a pressure
differential between tubing and casing at the packer
A means of temporarily plugging the tubing must be
incorporated in the tubing below the packer or in the
bottom of the packer itself
On reaching setting depth, a ball is dropped down the
tubing, to land on the expendable seat held by shear
pin
The tubing pressure is built up by a pump at surface
which forces the body downward and compresses the
sealing element
Also the shear pin breaks and fall along with the ball
to leak off
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Production Packers
Mechanically Set Packers:
Mechanical packers are set and released by
manipulation of the tubing string
Tubing Accessories:
Landing Nipple:
A landing nipple is a short, tubing
accessory/short sub with an internal profile
which can accommodate and secure a
mandrel run into its bore on wireline or
coiled tubing
Recess to mechanically lock the mandrel in
place using a set of expandable keys
It has a an internal diameter smaller than
the tubing
Functions:
o Seating area for flow control devices
o Installation of Downhole pressure and
temperature gauges
o Isolation or plugging of the tubing
string for well shut in, during workover
o Emergency closure of tubing
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Tubing Accessories:
Flow coupling:
A relatively short, heavy-
walled completion component
installed in areas where
turbulence is anticipated
The additional wall thickness
prevents early failures due
to erosion in the turbulent
flow area
Flow couplings are typically
installed above and below
completion components, such
as landing nipples, that may
affect the flow
Tubing Accessories:
Perforated joint or flow tubes :
The perforated joint allows for flow to enter
the string even if the base of the packer tail
pipe is plugged by say, pressure gauges.
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Tubing Accessories:
Sub surface Safety valves (SSSV):
These valves are the primary closure system
for the well
Well security is endangered in the absence
of an effective surface closure system
Upper Completion
Well-head and X-Mass Tree
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Upper Completion
Well-head
Functions of a wellhead:
Suspension of all individual casings and
tubular, concentrically in the well
Installation point for the X-mass tree
Hydraulic access to the annuli between
casing to allow cement placement and
between the production casing and
tubing for well circulation
Upper Completion
Casing Head
Surface
casing
Conductor
casing
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Upper Completion
Tubing Spool
Upper Completion
Tubing Spool