See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/376228939

Introduction To The Basics Of Well Completions

Chapter · December 2023

DOI: 10.5281/zenodo.10276860

CITATIONS READS

0 3,067

1 author:

Dzevad Hadzihafizovic
University of Sarajevo
985 PUBLICATIONS 23 CITATIONS

SEE PROFILE

All content following this page was uploaded by Dzevad Hadzihafizovic on 05 December 2023.

The user has requested enhancement of the downloaded file.

Introduction To The Basics Of Well Completions

DSc Dževad Hadžihafizović (DEng)

Sarajevo 2024
COMPLETION COMPONENT SELECTION
 CONTENTS
SECTION 9 age

9 COMPLETION COMPONENT SELECTION 1

9.1 SUMMARY 1
9.2 INTRODUCTION 1
9.3 COMPLETION FUNCTIONALITY 1
9.4 CONVENTIONAL COMPLETION COMPONENTS 5
9.4.1 Mule Shoe/Wireline Entry Guide 5
9.4.1.1 Mule Shoe Guide 5
9.4.1.2 Wireline Entry Guide 6
9.4.2 Landing Nipples/Flow Controls 6
9.4.2.1 Landing Nipple Flow Control Systems 6
9.4.2.2 Nippleless Lock Systems 9
9.4.3 Protection Joint 12
9.4.4 Perforated Joint 12
9.4.5 Production Packers 13
9.4.5.1 Retrievable Packers 14
9.4.5.2 Permanent Packers 16
9.4.5.3 Permanent Retrievable Packers 16
9.4.6 Packer Setting Methods 18
9.4.6.1 Mechanical Setting 18
9.4.6.2 Electric Wireline Setting 18
9.4.6.3 Hydraulic Setting 19
9.4.6.4 Setting Adapter Kit 19
9.4.7 Retrievable Packer Accessories 20
9.4.7.1 Travel Joint 20
9.4.7.2 Adjustable Union 20
9.4.7.3 Snap Latch 20
9.4.7.4 Safety Joint 20
9.4.7.5 Pump-Out Ball And Seat 20
9.4.8 Permanent Packer Accessories 22
9.4.8.1 Locator Tubing Seal Assembly 22
9.4.8.2 Seal Bore Extension 22
9.4.8.3 Tubing Anchor Seal Nipple 22
9.4.8.4 Polished Bore Receptacle 22
9.4.8.5 Tubing Seal Receptacles 25
9.4.9 Sliding Side Doors 26
9.4.10 Side Pocket Mandrels 28
9.4.10.1 Gas Lift Valves 28
9.4.10.2 Dummy Valves 28
9.4.10.3 Chemical Injection Valves 28
9.4.10.4 Circulating Valves 30
9.4.10.5 Differential Dump Kill Valves 30
9.4.10.6 Equalising Dummy Valves 30
9.4.11 Sub-Surface Safety Valve Systems 30
9.4.11.1 Applications Of Sub-Surface Safety Valves 31
9.4.11.2 Types Of Sub-Surface Safety Valve Systems 33
9.4.11.3 Sub-Surface Controlled Sub-Surface Safety Valves 34
9.4.11.4 Surface Controlled Sub-Surface Safety Valves 41
9.4.11.5 SSSV Depth Setting 46
9.4.12 Annular Safety Valve Systems 48
9.4.12.1 Baker ‘AVLDM’ 48
 9.4.12.2 Camco 'TRAC' 48
9.4.12.3 PES ‘AV CAPS’ 50
9.4.13 Flow Couplings 51
9.4.14 Blast Joints 51
9.5 DOWNHOLE PERMANENT GAUGE SYSTEMS 51
9.6 INTELLIGENT WELL COMPLETIONS 52
9.6.1 Value of Intelligent Wells 52
9.6.2 Estimating The Value of Continuous Downhole Surveillance 52
9.6.2.1 Optimised Drawdown 53
9.6.2.2 Optimised Completion Efficiency 53
9.6.2.3 Early Detection Of Compartmentalisation 53
9.6.2.4 Reduced Lost Production Time And Operational Risk 53
9.6.3 Estimating The Value Of Downhole Flow Control 54
9.6.3.1 Selective Production Of Stacked Pay Zones 54
9.6.3.2 Commingled Production 54
9.6.3.3 Optimised Injection Performance 54
9.6.3.4 Surface Controlled Downhole Gas Lifting 54
9.6.3.5 Auto-Downhole Injection 58
9.6.4 I-Well Terminology And Abbreviatations 60
9.7 APPLICATIONS OF CURRENT I-WELL TECHNOLOGIES 61
9.7.1 Surveillance Systems 61
9.7.1.1 Electronic Permanent Gauge Surveillance 62
9.7.1.2 Electronic Downhole Flowrate Surveillance 65
9.7.1.3 Fibre Optic Based Surveillance 66
9.7.2 Flow Control Systems 68
9.7.2.1 Hydraulic Flow Controls 68
9.7.2.2 Electro/Hydraulic Flow Controls 69
9.7.2.3 Electric Flow Controls 69
9.7.3 Current Flow Control Technologies 69
9.8 I-WELL COMPLETION COMPONENTS 70
9.8.1 Packers 70
9.8.2 Inflow Control Valve 71
9.8.3 Lubricator Valve 74
9.8.4 Gas Lift Valve 75
9.9 I-WELL TECHNOLOGY RELIABILITY 75
9.10 REFERENCES 76
9 COMPLETION COMPONENT SELECTION

9.1 Summary
For the selection of completion components it is essential that the completion engineer first
confirms the detailed completion design provides all the functions required to satisfy the SoR.

This section addresses the architecture of the completion and the method of selecting completion
components to provide the required completion functions. It also describes the most commonly used
components, their applications, strengths and weaknesses when used in various environments.
Included in this are some of the more modern remote activated completion tools used in what is
termed ‘Smart or Intelligent’ completions systems for which applications are becoming more
widespread especially in multizone producers and injectors.

9.2 Introduction
The architecture of completions is a term that describes the overall layout of the well completion.
The final completion design developed at the end of the detailed design stage will include all of the
functional requirements of the design, This is provided by the individual components or tools, or
combination of individual tools.
An aim for this chapter is to provide information to enable completion equipment to be selected on
an objective basis. It is not the intention to provide rigid rules for equipment selection. The final
selection of equipment can only be based on particular well conditions and local knowledge. A
feature of a particular piece of equipment may be a necessity in some well designs and a handicap in
other applications. The performance of vendors can also vary geographically, and what is regarded
as a poor performing company in one location may provide the best service in another. However, by
using the pooled experience presented in this manual, adopting the system proposed for evaluating
equipment and using your knowledge of the wells, the best equipment should be selected.
A major part of this section of the manual describes the various types of equipment and discusses
the function, operation and regulations associated with the equipment. A key element in the
selection of completion equipment is selection of the appropriate metallurgy and types of elastomer.
Guidance on these topics is given in section 6.
Other key documents for completion design are:
 George King’s ‘An Introduction To The Basics Of Well Completions, Workovers &
Stimulation’ 2nd Edition

9.3 Completion Functionality

Each component in a completion design will have one or more functions within that particular
completion. The following example chart shows the functions for the most common types of tools
used in completions. As will be seen, some tools can have more than one function in a completion
string, for instance a side pocket mandrel (SPM) can be used for either circulating, gas lifting,
chemical injection or annulus overpressure protection. Similarly, a tubing hanger supports the
tubing weight but also seals off the top of the annulus.
The use of this chart or similar charts will help an engineer to select the components to satisfy the
features required from the completion design, however where options exist, it is up to the skill and
expertise of the engineer to select the optimum choice. This is often not an easy choice.

Page 1
 General Completion Design Features

Partially Consolidated
Unconsolidated Rock
Downhole Dump/Kill

Optimise Production

Downhole Chemical
Tubing Suspension
Annulus Protection

Tubing Movement

Surface Chenical
Pressure Testing
Annulus Gas Lift

BHP Monitoring
Well Circulation
Tubing/Annulus

Gas Protection
Surface Safety

Packer Setting
High Pressure
Tubing Safety

Well Plugging

Sand Control

Sand Control
Pump Lift
Injection
Isolation

Injection
Well Kill

Gas Lift
Related Equipment
Xmas Tree
Tubing Hanger Spool/
Side Outlet Valves
Tubing Hanger/Hanger Spool
Tubing Hanger Nipple Profile

Tubing
Sub-Surface Safety
Valve System
Annulus Safety Valve System

SSD
SPM

Tubing Nipple

Packer Tailpipe Nipple

Packer

Packer/Tubing Seal

PBR
ELTSR
Gauge Hanger Nipple

Permanent Downhole Gauge

Liner Hanger Packer

Chemical Injection Nipple

ESP

Hydraulic Pump

Rod Pump

Jet Pump

Gravel Pack
Pre-Packed Screen

Wire Wrapped Screen

Slotted Liner

Figure 9.1 – Example Completion Component Function Chart

Page 2
Figure 9.2 – Example Land Well Completion (Ravespurn N, Platform ST1, Well D-5)

Page 3
Figure 9.3 – Example Subsea Well Completion (Magnus Platform, Well A03)

Page 4
9.4 Conventional Completion Components
In this section are included the most commonly used conventional completion components are
described giving their applications/functions, positions in the completion string and strengths and
weaknesses. In order to aid the description of the these items example completion schematics are
shown in Figure 9.2 and Figure 9.3 showing some of these items and their relative positioning in the
completion string.

9.4.1 Mule Shoe/Wireline Entry Guide

A mule shoe or wireline re-entry guide is the bottom termination of the completion string whether
that is a packer tailpipe or upper completion packer seal unit. This tool enables entry of the string
through the wellbore and also the passage of intervention tools out of, and back into, the tubing
string.

9.4.1.1 Mule Shoe Guide

The function of a mule shoe guide is to guide the string into the well through restrictions such as
liner tops or packer bores. It achieves this due to the tapered angle on the side of the shoe and
sometimes requires rotation to engage the taper with the edge of the restriction. Where no rotation is
possible such as when there are multiple control lines or cables, or if working from a floating vessel,
the guide may impact with the edge of the restriction causing damage, an automatic mule shoe with
a scroll to rotate the bottom of the guide should be used.
The design should ensure as large chamfers as possible are machined on the internal and external
shoulders to enable well intervention tools ease of entry back into the tubing string. Compared to the
wireline entry guide the mule shoe is not as friendly to tools re-entering the tubing.

Figure 9.4 – Typical Mule Shoe Guide

Page 5
9.4.1.2 Wireline Entry Guide
A wireline entry guide (WEG) is used if there are no restrictions in the well to pass through such as
when the packer is run in the completion string and there are no liner tops. Although it acts as a
guide and a centraliser when the tubing is being run, its main function is to enable free passage of
well intervention tools back into the tubing.
The advantage of this item over a mule shoe guide is the size of the chamfers which can be
provided. Costly interventions have resulted from a poorly designed WEG which failed to allow
toolstring re-entry into the tubing string. Sufficient care and attention must be given to this simple
but essential tool if subsequent well interventions are to be optimised.

Figure 9.5 – Typical Wireline Entry Guide

9.4.2 Landing Nipples/Flow Controls

9.4.2.1 Landing Nipple Flow Control Systems
Landing nipples, (refer to Figure 9.6 and Figure 9.8), are short profiled tubulars installed in
strategic positions in the tubing string into which various wireline retrievable flow controls can be
set and locked carried on a lock mandrel (refer to Figure 9.7). These can seal within the nipple
bore, if required dependent upon the tool's function. The most common tools run are plugs, chokes,
and pressure and temperature gauges. The main features of a landing nipple are:
 Locking groove or profile
 Polished seal bore
 No-Go shoulder (only on non-selective nipples)
Landing nipples are supplied in ranges to suit most tubing sizes and weights with, either, API or
premium connections and are available in two basic types: 1) Selective or 2) No-Go or Non-
Selective.

Page 6
Non-Selective
The non-selective nipple receives a locking device that uses a No-Go principle for the purposes of
location. This requires that the OD of the locking device is slightly larger than the No-Go diameter
of the nipple shoulder. The No-Go diameter is usually a small shoulder located below the packing
bore (bottom No-Go) but in some designs, the top of the packing bore itself is used as the No-Go.
Only one No-Go landing nipple of a particular size can be used in a completion string. In most
completion types, other than a monobore, it is common practice to use a bottom No-Go nipple as
the last nipple in the packer tailpipe to prevent dropped tools falling into the sump.
As the No-Go provides a positive location, they are widely used in high angle wells where wireline
tool manipulation is difficult and weight indicator sensitivity reduced.

Selective
In the selective system, the locking devices are designed with the same key profile as the nipples
and the means of nipple selection is determined by operation of the running tool and the setting
procedure. The selective design is full bore and allows the installation of several nipples of the same
size.
Uses of landing nipples are to:
 Plug tubing from above, below or from both directions for pressure testing
 Leak detection
 Install safety valves, chokes and other flow control devices
 Install bottomhole pressure and temperature gauges

Figure 9.6 - Halliburton/Otis Wireline Landing Nipples

Page 7
Figure 9.7 - Halliburton/Otis Type ‘X’ or ‘XN’ Lock Mandrel

Figure 9.8 - Other Typical Wireline Landing Nipples

Page 8
9.4.2.2 Nippleless Lock Systems
In particular well environments where the conditions may be extremely
corrosive to landing nipple materials, and/or it is company policy not to
use nipples, wireline installed and retrieved nippleless systems can be
used. See Figure 9.9 for a typical nippleless plug system and Figure
9.10 for a typical installation procedure. The retrieving procedure is
shown in Figure 9.11. These systems are also referred to as ‘wireline
retrievable bridge plugs’.
When nippleless systems are employed, there is a risk of tubing damage
due to repeated setting of the tool and it may be good practice to install
thick walled tubulars or flow couplings at strategic points in the tubing
string to counteract any wear or tear due to the slips of such systems.
Due to their more complex design and installation procedure, there is a
higher risk of malfunction of these systems than conventional nipple
systems.

Figure 9.9 – Halliburton Monolock Nippleless Lock System

Page 9
 DPU Pulls The Releasing Mandrel Upwards

Releasing Shear pins break

‘C’ ring latches into retaining

groove

Elements and slips

relaxed by separation of
the upper and lower
inner mandrel after
shearing releasing pins

Equalising Valve Opened

Equalising Position Retrieving Position

Figure 9.10 - Monolock Running/Setting

Page 10
 DPU Pulls The Releasing Mandrel Upwards

Releasing Shear pins break

‘C’ ring latches into retaining

groove

Elements and slips

relaxed by separation of
the upper and lower
inner mandrel after
shearing releasing pins

Equalising Valve Opened

Equalising Position Retrieving Position

Figure 9.11 - Monolock Equalising and Retrieving

Page 11
9.4.3 Protection Joint
A joint of tubing is often installed in wells where BHP surveys are, or maybe likely, to be carried
out by well intervention methods. This entails the setting of the gauges in the lowest nipple in the
string and their subsequent retrieval usually by mechanical wireline methods. The protection joint
covers and protects the gauges from well flow turbulence. It has no special features but normally has
the same thread connection as the tubing above for ease of supply and use of the same tubing make-
up equipment as the next tubing run.
A full length joint is recommended but if the tailpipe length needs to be restricted, a pup joint a little
longer than the gauge assembly length will suffice.

9.4.4 Perforated Joint

In wells where flowing velocities are high, a restriction in the tubing, such as a
gauge hanger, can cause false pressure and temperature readings. Also, vibrations to
the toolstring can cause extensive damage to delicate instruments. To provide an
alternative flow path, a perforated joint is installed above the gauge hanger nipple
that allows unrestricted flow around the gauge toolstring eliminating these hazards.
The perforated joint is normally a full tubing joint that is drilled with sufficient
holes to provide a flow area greater than that in the tubing above (refer to Figure
9.12). Sometimes only the lower section of the joint is required to be drilled as
long as the flow area of the holes is much greater (typically four times) than the
flow area through the bore of the joint.

Figure 9.12 - Perforated Joint

Page 12
9.4.5 Production Packers
A production packer is a mechanical device designed to create a seal between the production casing
or liner and the production tubing. To enable this all packers have slip anchoring and elastomeric
seal mechanisms. The slips grip the inside of the casing wall and the seal element(s) provide the
hydraulic seal.
The main application for production packers are to isolate the production tubing to casing or liner
annulus from the well fluids. The reasons for this are to:
 Provide an annulus barrier at the bottom of the tubing as close to the producing zone as
is practical keeping well pressures off the casing.
 Isolate the casing from well fluids which could cause corrosion.
 Isolate the casing from high pressures during well operations, i.e. fracing, acid
stimulation, cement repairs, etc.
 Isolate artificial lift fluids from producing formation(s).
 Provide a thermal isolation barrier to producing fluids to retain fluid temperatures.
 Enable low density packer fluids to be used in the annulus which have a hydrostatic
pressure below formation pressure, useful in HPHT wells.
 Improve vertical flow conditions by preventing erratic flow and heading cycles.
 Separate producing zones in a single well bore in single selective or multiple string
completions.
 Anchor artificial lift hydraulic pumps systems to minimise tubing movement and stress
cycles.
 Isolate liner tops from the production tubing to casing annulus to provide integrity.

There are three generic types or classifications of production packers available with features which
have differing applications. These are:
 Retrievable
 Permanent
 Permanent Retrievable

In general, packers are classified depending on their mode of recoverability from the well i.e.
retrievable or permanent. A retrievable is recovered by pulling the tubing string whereas a
permanent must be milled. However, a hybrid was also developed, termed a ‘permanent/retrievable
packer’ which incorporates the features of the permanent packer but can be retrieved on a
workstring without milling.
Packers may be further classified according to the number of bores required for production i.e.
Single One concentric bore through the packer for use with a single tubing string.
Dual Two parallel bores through the packer for use with two tubing strings.
Triple Three parallel bores through the packer for use with three tubing strings.

A typical packer description, therefore, might be: 95/8 ins. Dual 31/2 ins. x 31/2 ins., hydraulic-set
Retrievable Packer.
These are described in the following sub-sections with their applications and features.

Page 13
9.4.5.1 Retrievable Packers
Retrievable packers are generally run into the wellbore on the production tubing string and are set
by; tubing rotation, applied tension, applied compression or by hydraulic pressure applied from
surface. As the title implies, retrievable packers can be recovered from the well after setting by
pulling the tubing.
Retrievable packers are most commonly used for segregated multi-zone production and can be,
either, single, dual or triple bore. Some quadruple bores have been used in the past but are relatively
uncommon. Prior to selecting multi-zone and multi-string completions, a risk assessment should be
conducted to evaluate the difficulty of installation.
Today the most common type of retrievable packer is the hydraulic set packer. Typical hydraulic set
retrievable packers are shown in Figure 9.13. When used in multiple zone completions, some
hydraulic packers can be selectively set by opening the hydraulic setting port by wireline to pressure
applied to the tubing.
Tension or compression set packers are rarely used today as tubing movement due to thermal or
pressure forces may accidentally release the packers.
Each manufacturer produces their own particular packers and designs may vary significantly
between them. An engineer selecting a retrievable packer system should consult previous well
histories and/or obtain performance data from the suppliers before making a balanced decision. He
should also compare the features of each of the packers to determine the advantages in installation
or retrieval procedures.
The main applications of this type of packer are to:
 Simplify workover or re-completion operations as the packer is retrieved on the tubing.
 Isolate discriminate zones within a single well bore.
 Enable segregated production of discriminate zones by selection of dual or triple bore
versions.

The advantages of this type of packer are:

 Single trip installation.
 Segregated production (up to three tubing strings).
 Re-useable (after redressing).

The disadvantages of these types of packers are:

 More complex design than other types.
 Generally have lower pressure rating.
 Generally have lower temperature rating.
 Smaller bore than same sized permanent packer types.
 Hard to retrieve after long term production causing fishing operations.
 Unable to isolate formation from foreign fluids when pulling tubing.
 Require a tubing movement device under most normal well conditions to prevent the
packer from self releasing due to tubing contraction.

Page 14
These packers are ideal under certain circumstances especially where there routine workovers are
necessary such as with electrical submersible pump (ESP) completions or where multiple zone
segregated production is desired using dual or triple packers. Single string multiple zone production
is also possible using shut-off devices between packers isolating each zone.
An inherent problem with such multiple packer completions is the inability to set and test the
packers individually with the zones already perforated. Setting the packers individually from the
bottom upwards is possible using wireline selective ports but this is wireline intensive and it is still
not certain that each packer has been set.

Figure 9.13 – Typical Retrievable Packers (Single And Dual Bore)

Page 15
9.4.5.2 Permanent Packers
Permanent packers are installed in the wellbore usually independently from the production tubing
string. A permanent packer system, once installed, may be considered as to have become an integral
part of the casing. Permanent packers can only be removed from the well by milling operations.
Typical permanent type packers are shown in Figure 9.14.
Due to their simplicity in design, these packers offer larger comparable bore size with higher
pressure differential and temperature ratings than retrievable or permanent/retrievable packers.
Although permanent packers are usually single bore packers, special dual bore packers are available
for particular applications.
The tubing accessories available for permanent packer applications are much more varied than with
retrievable packer systems, providing fullbore tubing seal devices for high angle wells and large
tubing movement, refer to Sections 9.4.7 and 9.4.8.
Setting methods are varied and are described in Section, although the use of single trip installation
systems run on the production tubing are in high demand today in order to reduce installation times
and, hence, costs. Typically in today’s industry single trip packers are run and set on the completion
string prior to pressure the string due to the reliability of modern packer systems and tubing
connections. This has a significant impact on rig time and, hence cost savings
The main applications of this type of packer are to:
 Simplify workover or re-completion operations as the packer is retrieved on the tubing.
 Isolate discriminate zones within a single well bore.
 Enable segregated production of discriminate zones by selection of dual or triple bore
versions.

9.4.5.3 Permanent Retrievable Packers

These packers have the same characteristics as permanent packers but can be released and recovered
from the well without milling. They generally have a smaller bore than a permanent packer does to
accommodate the addition of the releasing mechanism.
The applications for permanent/retrievable packers are:
 Temporary completions
 Temporary well plugging
 Gravel packing
 Long term well testing.

Packers, both retrievable and permanent versions, are installed in the production casing by one of
the methods described in Section 9.4.6.

Page 16
Wireline Set Packer Hydraulic Type Packer
Figure 9.14 – Example Permanent Packers

Page 17
9.4.6 Packer Setting Methods
There are two methods of installing permanent packers in a wellbore:
 Mechanical
 Hydraulic
 Electric Wireline

The first two methods are also those used for setting retrievable packers. All these methods are
described below.

9.4.6.1 Mechanical Setting

On an appropriate setting adaptor, permanent packers can be run on a workstring and set by
manipulation of the tubing, i.e. by rotation and/or in combination with applying compression or
tension on the workstring.

Note: Packers having rotation set (or release mechanisms) should not be used in
highly deviated wells since the application of tubing torque may not be able to
be transmitted downhole.

The use of such types of packers is less today as the run to install the packer takes an additional trip
costing rig time.
Retrievable packers can also be set in the same manner but on the completion tubing. Once the
packer is set, the hanger is landed and nippled down.

9.4.6.2 Electric Wireline Setting

This is generally confined to permanent packer systems. The packer is attached to a setting adapter,
which in turn is connected to a setting gun on the end of the wireline and run in the wellbore. On
reaching the desired depth an electrical signal transmitted to the gun activates an explosive charge
and, through a hydraulic chamber, provides the mechanical force to set the packer. Refer to Figure
9.15.

Figure 9.15 - Electric Line Setting Principle

Page 18
9.4.6.3 Hydraulic Setting
Permanent packers can be run on a workstring using a hydraulic setting tool and a setting adapter
kit. When the desired setting depth is reached the tubing is plugged below the packer with a check
valve, standing valve or a wireline plug and hydraulic pressure applied to the tubing to set the
packer which then self releases at the correct pressure similar to wireline setting.
Retrievable packers can also be set hydraulically and is the most popular method as no tubing
manipulation is necessary which can damage sensitive equipment such as control lines or electric
cables. This also enables the hanger to be landed, set and tested before the packer, if desired.
The preferred option for using hydraulic setting today is to use a hydraulic permanent packer run on
the completion string complete with the tubing movement device such as a PBR, etc. The
application of tubing or casing pressure options can be used to set the packer. This is particularly
useful in high deviations or to save rig time. Generally, a predetermined upward pull on the tubing
string will release the seal unit from the packer system or it may be left attached until changing well
pressure shears the pin or disc.

9.4.6.4 Setting Adapter Kit

The setting adapter kit connects between wireline set permanent type packers and the setting tool
(either hydraulic or electric wireline) and enables running in the hole and then transmition of the
force generated by the pressure setting tool to the packer during the setting motion.
Figure 9.16 shows an adapter kit assembly for a conventional top setting permanent packer. The
bottom of the release sleeve has a colleted left-hand thread which is threaded into the packer anchor
latch thread in the packer body. The colleted connection is kept in the latched position by the
mandrel guide and holds the packer while the force from the setting tool is applied to the packer
setting sleeve.
When setting is complete with the correct compression applied to the packer, the release stud breaks
enabling the mandrel guide to move downwards releasing the collet thread from the packer.

Figure 9.16 - Packer Adapter Kit Releasing Mechanism

Page 19
9.4.7 Retrievable Packer Accessories
There are a number of unique tools that have been designed specifically for retrievable packer
systems, especially multiple string completions. A few of main accessories are described below. Not
all tools are illustrated herein but these can be obtained from any manufacturers sales catalogues.

9.4.7.1 Travel Joint

A travel joint is used to compensate for tubing movement, due to temperature and/or pressure
changes during treating or production, with retrievable packer systems. Figure 9.17 shows a travel
joint commonly used. In dual or multiple string completions, travel joints may be installed in each
string, hence adding to the complication of such completions.

Note: Alternative names for travel joints are Telescoping or Thermal Expansion Joints.

9.4.7.2 Adjustable Union

An adjustable union is designed to enable make up and spacing out of multiple string retrievable
packer systems. It is installed below the tubing hanger to enable rotation of the final tubing
connection into the hanger and adjusts for variation in length to match the other string.
The joint consists of three parts, an upper connection that is screwed into tubing hanger, a lower
connection attached to the tubing and a lock nut to adjust the length and lock the parts together.

9.4.7.3 Snap Latch

Snap latches are used to enable the short string(s) in multiple string completions to engage into or
be retrieved from packers without pulling the packer via the long string side.

9.4.7.4 Safety Joint

Safety joints are used to enable the retrieval of tubing strings when a packer becomes stuck. It
usually relies on a shear pin release and rotation to release from the connection.

9.4.7.5 Pump-Out Ball And Seat

The pump-out ball and seat is used to set hydraulic set packers when it undesirable or not possible
to install a wireline plug such as in high deviations or to save trip time.
The seat is installed below the packer and when the packer is to be set, the ball is dropped and
pumped down to reach the seat, pressure can then be applied to set the packer and ultimately shear
out the ball and seat of the housing. Both the ball and seat must fall into the sump.

Page 20
Figure 9.17 - Travel Joint

Page 21
9.4.8 Permanent Packer Accessories
An important aspect of a completion with a permanent packer is the tubing/packer seal. As the
packer in effect becomes part of the casing after it is set, the tubing must connect to the packer in a
fashion so that it can be released. This connection whether it is a straight stab in, latched or
otherwise, must have a seal to isolate the annulus from well fluids and pressures.
This seal assembly usually consists of a number of seal elements as contingency for wear and tear of
the seals. The seal elements are classified as; premium or non-premium. The premium group is used
in severe or sour well conditions, i.e. H2S, CO2, etc. and are normally ‘V’ type packing stacks
containing various materials selected to be resistant to the particular environment. The non-
premium seals are for sweet service and are be either ‘V’ type packing stacks or moulded rubber
elements.

9.4.8.1 Locator Tubing Seal Assembly

Locator tubing seal assemblies, (refer to Figure 9.18a and Figure 9.18b), are fitted with a series of
external seals providing an effective seal between the tubing and packer bore. They also usually
have a No-Go type locator above the seals for tagging and, hence, locating the packer and enabling
spacing out of the tubing to place the seal assembly correctly within the packer bore.
Locator seal assemblies are normally positioned so that they can accommodate both upward and
downward tubing movement induced by changes in temperature and pressure conditions, (although
they may be set lower to limited downward movement if the stress caused to the tubing does not
exceed safe limits), (refer to Section 7).

9.4.8.2 Seal Bore Extension

A seal bore extension is used to provide additional sealing bore length when the use of a long seal
assembly is necessary for large tubing movement. The seal bore extension is a simple length of tube
installed below the packer and has a honed bore the same ID as the packer.
The use of the seal bore extension is to prevent the seals from passing out through the packer seal
bore causing damage due to pressure cycling of the seals.

9.4.8.3 Tubing Anchor Seal Nipple

Tubing anchor seal assemblies, also termed anchor latch or ratchet latch, (refer to Figure 9.18c and
Figure 9.18d), are normally used where it is necessary to anchor the tubing to a permanent packer. It
is also able to be unlatched by rotation whenever required. Anchor latches are normally used where
well conditions require the tubing to be landed in tension or to attach a PBR or ELTSR.
To anchor tubing to a packer where there are any SCSSV control lines, chemical injection lines or
permanent gauge carrier cables, etc, a straight pull release variant can be used as it may be
impractical to rotate the tubing string. The other option is to cut the tubing above the packer.

9.4.8.4 Polished Bore Receptacle

A PBR is simply a seal receptacle attached to the top of a permanent packer or liner hanger packer
in which the seal assembly lands instead of the packer bore. As the PBR bore can be made larger
than the packer, this provides a larger flow area through the seal assembly (refer to Figure 9.19).
The PBR female receptacle can be attached to the top of the packer by a retrievable anchor latch or
screwed to the packer. When screwed to the packer it cannot be retrieved, therefore if it becomes
damaged, it is removed along with the packer by milling.

Page 22
Figure 9.18 - Permanent Packer Seal Accessories

Page 23
The PBR system is wireline friendly and has some well servicing advantages over the ELTSR, (refer
to Section 9.4.8.5).

Figure 9.19 – Typical PBR And Seal Assembly Unit

Page 24
9.4.8.5 Tubing Seal Receptacles
A TSR system is an inverted version of a PBR whereby a polished OD male member is attached to
the top of the packer and the female (or overshot) is attached tubing. The seals are contained in the
female member so that they are recovered when pulling the tubing, (refer to Figure 9.20).

Figure 9.20 – Tubing Seal Receptacle

Page 25
9.4.9 Sliding Side Doors
Sliding Side Doors (SSDs) or Sliding Sleeves are installed in the production tubing during well
completion to provide a means of communication between inside and outside of the tubing when
opened by wireline or coiled tubing tools, (refer to Figure 9.21).
SSDs are used for the following applications:
 Bringing a well into production after drilling or workover by enabling circulation of the
completion fluid out of the tubing and replacing it with a lighter underbalanced fluid.
 Killing a well prior to pulling the tubing in a workover.
 Providing selective zone production in a multiple zone well completion.
 Installing concentric gas lift valves.

SSDs are available in versions that open by shifting an inner sleeve either upwards or downwards. A
number of SSDs can be installed in a completion string and selectively opened or closed by the use
of the appropriate wireline shifting tool. The shifting tool can be run or CT in highly deviated wells.
Many completion engineers prefer not to use SSDs as they are prone to leak especially if opened
and closed regularly, however in multiple zone completions there is little option that to use SSDs
for selective zonal production. A recent development has been the non-elasotmeric SSD which
reduces the risk of leaking. Leaks can be temporarily prevented by the installation of a straddle
however this reduces the flow area and intervention access below the sleeve.

CAUTION: Although SSDs have an equalising feature they may be accidentally moved
from the closed to open position so tubing and annulus pressures should be
equalised before opening to prevent wireline tools being blown up or down the
tubing.

Downward shifting to open an SSD is preferred to help prevent the tools being blown up the hole,
however, modern SSDs such as the Baker ‘CMD’ can be used which utilises a separate opening tool
to positively locate the sleeve in the equalising position.
A wireline landing nipple profile is normally provided in the top sub and a polished bore in the
bottom sub. This allows installation of a straddle if the assembly develops a leak or, in previous
times, gas lift valves in concentric gas lift designs. Concentric gas lift designs have been superseded
by the modern side pocket mandrel system as any valve can be changed out without pulling valves
higher up as in concentric designs.

Page 26
Figure 9.21 - Typical Sliding Side Door (Shift Down To Open)

Page 27
9.4.10 Side Pocket Mandrels
Side Pocket Mandrels (SPMs) were originally designed for gas lift completions to provide a means
of injecting gas from the casing-tubing annulus to the tubing via a gas lift valve. However in recent
times, they have also been commonly used in place of SSDs as circulating devices due to the ability
to be able to rectify seal failure by pulling the dummy gas lift valve (or kill valve) with wireline and
replacing the seals.
SPMs are installed in the completion string to act as receptacles for the following range of valves:
 Gas lift valves
 Dummy valves
 Chemical injection valves
 Circulation valves
 Differential dump kill valves
 Equalising valves.

It is essential to understand the operation of the device installed in an SPM before conducting any
well intervention as it may affect tool operation and well control. Refer to for a typical SPM.
Devices are installed in the sidepocket of the mandrel with a Kickover tool which is manipulated by
wireline to activate the kickover arm which first aligns and then sets the device in the pocket.
The various valves which can be installed in SPMs are described below.

9.4.10.1 Gas Lift Valves

There are many different designs for gas lift valves for various applications. They range from being
simple orifice valves to pressure operated bellows type valves. However, they all contain check
valves to prevent tubing to annulus flow. These check valves may leak after a period of use and they
should never be relied on as barriers in a well control situation. These should be replaced with
dummy valves and the tubing pressure tested to confirm integrity.

9.4.10.2 Dummy Valves

These are tubing/annulus isolation valves. They are installed in place of the valves in order that the
completion tubing string can be pressure tested from both sides during installation or when well
service operations are required.

9.4.10.3 Chemical Injection Valves

The injection valve is designed to control the flow of chemicals injected into the production fluid at
the depth of the valve. A spring provides the force necessary to maintain the valve in the fail-safe
closed position. Reverse flow check valves, which prevent backflow and circulation from the tubing
to the casing, are included as an integral part of the valve assembly.
Injection chemicals enter the valve from the annulus in an open injection system. which requires the
annulus to be full of the desired chemical. An alternative method is to install an injection line
running from surface to the SPM reducing the inventory of chemical and injection pressure from the
production casing.
When the hydraulic pressure of the injected chemicals overcomes the pre-set tension in the valve
spring plus the pressure in the tubing, the valve opens. Chemicals then flow through the crossover
seat in the valve and into the tubing.

Page 28
 Orienting Sleeve

Tool Discriminator

Latch Lug

Upper Packing Bore

Pocket
A A

Lower Packing Bore

Section A - A
Figure 9.22- Typical Side Pocket Mandrel

Page 29
9.4.10.4 Circulating Valves
It is recommended that a circulating valve be installed in the SPM whenever any circulating
operation is to be carried out, however this advice is not universally followed and some operators do
allow circulation at a controlled rate of no more than 2bpm. Damage to the pocket by flow cutting
would invariably lead to a workover to replace the mandrel.
The circulating valve is designed to enable circulation of fluid from the annulus through the SPM
into the tubing. A check valve prevents accidental flow from the tubing into the annulus. The valve
allows fluid to be dispersed from both ends allowing circulation of fluid at a minimal pressure drop.
There are some designs of valves which do permit circulation from the tubing to casing but the risks
of this need to be considered.

9.4.10.5 Differential Dump Kill Valves

Differential dump/kill valves are designed to provide a means of communication between the casing
annulus and the tubing when an appropriate differential pressure occurs. Below a pre-set differential
pressure, the valve acts as a dummy valve since it uses a moveable piston to block off the
circulating ports in the valve and the side pocket mandrel.
The differential pressure necessary to open the valve will depend on the type and number of shear
screws installed. The valve will only open when the casing annulus pressure is increased by the
differential (of the shear screw rating) above the tubing pressure. An increase in tubing pressure
above the casing annulus pressure will not open the valve. After opening, the piston is locked in the
up position and fluids can flow freely in either direction. The hydrostatic pressure from the column
of annulus fluid will kill the well and remedial operations can be planned.

9.4.10.6 Equalising Dummy Valves

The equalisation dummy valve is designed to equalise pressure between tubing and casing and/or to
circulate fluid before pulling the valve from the SPM.
The valve has two sets of packing, which straddle and pack off the casing ports in the SPM. The
tubing and annulus are isolated from each other until the equalising device is operated by a pulling
tool. Pressures equalise through a port before the valve and latch are retrieved.

9.4.11 Sub-Surface Safety Valve Systems

Sub-surface or downhole safety systems include all the equipment necessary to enable downhole
closure to prevent injury to personnel and damage to surface facilities and environment due to the
production of reservoir fluids. The ‘sub-surface safety system’ includes the downhole safety valve,
any device(s) required for installation of the valve, the control conduit or cable, and surface
controls.
The following section describes the applications for various types of sub-surface safety systems
available, types of valves available and methods of installation and operation.

Page 30
9.4.11.1 Applications Of Sub-Surface Safety Valves
The requirement for the use of SSSVs is dependent upon local operating company philosophy and
governmental legislation, refer to BP’s DHSV Guidelines document produced in 2002.
The major function of a Sub-Surface Safety Valve System is to close a well in downhole in the
event of an emergency occurring at surface. Although it is an emergency device it may be used
when any, or combination, of the following incidents may occur causing potential danger to
personnel, the environment, facilities and installation:
 Equipment failure
 Improper operation of equipment
 Collision to the wellhead
 Fire
 Leaks
 Sabotage

Although the prime function of an SSSV is for use in an emergency, it is also used for operational
purposes, such as; leak testing or providing additional barrier protection when work is being carried
out on the Xmas tree, wellhead or downstream equipment.
In general, the choice of the safety valve for an application must be considered on the well
conditions, location, company philosophy or local regulations, depth requirements, life of the well,
etc. The variety of systems available is wide and the choice may be difficult. It is often also based
on past operational history and experience and this would apply to safety systems on both tubing
and annular bores.
Figure 9.23 overleaf shows the range of valve systems available and their applications.
The selection of wireline retrievable valve versus tubing retrievable valve is dependent on a variety
of reasons. Table 9.1 shows some of the main reasons for this selection.

Page 31
 SSSV

APPLICATION: Tubing SSSV Annulus SSSV

Wireline Tubing Wireline Tubing

METHOD: Retrievable Retrievable Retrievable Retrievable

MEANS OF Sub-Surface Surface Sub-Surface

CONTROL: Controlled Controlled Controlled

Excessive Flow Pressure Drop

Hydraulic Electronic Electronic

Page 32
Annulus Control Line(s) Control Line(s)

Cable Wireless

Hydraulic Non Hydraulic

FEATURES: Balanced Balanced

Non Equalising Equalising

Figure 9.23 -Applications and Features of Sub-Surface Safety Valves

Poppet Ball Flapper Poppet Sleeve
 WRSV Applications
General application: where intervention by
wireline is available
High pressure gas wells
Extreme hostile environments where well
fluids or temperatures tend to shorten the life
of component materials
High velocity wells with abrasive production
Table 9.1 - Wireline and Tubing Retrievable Sub-Surface Safety Valve Criteria
TRSV Applications
General application: where larger flow area is
desired for the tubing size
High volume oil and gas wells
Subsea completions
Multiple zone completions where several flow
control devices are set beneath the TRSV
Greater depth setting capabilities

9.4.11.2 Types Of Sub-Surface Safety Valve Systems

The modern sub-surface safety valve was developed from early, much lower technological versions,
produced in the 1930's. The initial demand from operators was for a downhole valve that would
permit flow during normal flowing conditions but would isolate formation pressure from the
wellhead to prevent damage or destruction in the event of an emergency occurring. This valve
would be for installation downhole in the production tubing string.
The first valve that was developed was the Sub-Surface Controlled Safety Valve (SSCSV), which
had a poppet type of closure mechanism (a mushroom shaped valve that sealed against a
correspondingly shaped valve seat). Compared with today's valves, this simple type of valve had
several disadvantages such as; restricted flow area, tortuous flow path, and low differential pressure
rating and calibration difficulties. Despite these limitations, the valve was used successfully for
many years before other versions were eventually developed such as the ball and flapper valve,
which had less tortuous flow paths, and larger through bores.
From this simple beginning, the Surface Controlled Sub-Surface Safety Valve (SCSSV) was
developed later in the 1950's. This design moved the point of control from downhole to surface
(direct to remote control). This type of valve was a fail-safe valve, (i.e. it would close on loss of
control pressure), and provided a much higher degree of safety with manual surface control of
opening and closing, hence, higher responsiveness to a wide variety of abnormal surface conditions
(fire, line rupture, etc.) and larger flow area. Initial demand for this valve was slow due to its higher
cost and the problems associated in successfully installing the hydraulic control line; hence, its
usage was low until the 1960s.
The modern SCSSV in use today is still normally controlled by hydraulic pressure supplied from a
surface control system and is ideally suited to manual or automatic operation which pioneered the
sophisticated emergency shut-down systems required today. The versatility of the valve allows it to
be used in specialised applications as well as in conventional systems. Electronic or
hydraulic/electronic controlled versions are currently under development and will be available in the
near future.
A problem associated with SCSSVs as compared to SSCSVs was their operating depth, which was
limited by the hydrostatic head of pressure of the hydraulic fluid in conjunction with the fluid
friction in the control line. Continuing development of these valves now enables setting at depths
over 2,000ft.
SCSSVs are available in two variants; the Tubing Retrievable Safety Valve or the Wireline
Retrievable Safety Valve. SCSSVs are available with, either, ball or flapper type closure
mechanisms to enable through tubing interventions.

Page 33
A more recent development has been sub-surface annular safety systems which were developed for
a particular demand to protect offshore platforms against large gas escapes from annuli when they
are used for gas lifting on artificial lift wells or when an annulus is used for production. These are
also surface controlled systems which require some type of annular pack-off between the tubing and
the casing, such as a packer, used in conjunction with a safety valve for shut-in. These systems
usually employ a poppet valve arrangement that enables a pump through capability should the valve
become inoperable in the closed position (refer to section 9.4.12).
A report produced by a number of operators called the SINTEF report for which operators provide
their data on safety valve performance, indicates that the TRSV with a flapper type closure is the
most reliable valve in use today.

9.4.11.3 Sub-Surface Controlled Sub-Surface Safety Valves

Sub-surface controlled safety valves use the flowing characteristics of a well for operation of the
valve. Under normal flowing conditions, the valve will remain open, however, any increase of flow
out with these ‘normal’ flowing conditions, (e.g. destruction of the wellhead or a rupture of a
surface production flowline producing a change in flowrate), will cause the safety valve to close.
Such valves are sometimes also termed ‘storm chokes’. However, their weakness lies in situations
when an emergency occurs on surface, (e.g. surface fire near oil and gas separation equipment), but
does not directly affect the flowing characteristics of the well, hence, closure of the safety valve will
not occur. In conjunction the continually changing parameters of the well means that they must be
re-calibrated at frequent intervals otherwise they may not function as required.
Since such safety valves lack human control, their use today is less common although they still have
some specialist applications as listed below:
 Set very deep for temporary safety during drilling of nearby wells when collisions are
possible
 As insert valves in a failed TRSCSSV where the control line has failed and it is
uneconomic to conduct a workover.

These valves are attached to a lock mandrel and installed in the completion by locking into regular
wireline nipples specifically positioned at the desired operating depth. They may also be installed on
the more modern wireline retrievable bridge plugs without using a nipple.
There are three types of sub-surface controlled safety valves in use, two types for producing wells
and a third for injection wells. The types used in producing wells are, either, the Pressure-
Differential operated valve or the Ambient Pressure operated valve. Both of these, as previously
pointed out, also termed ‘storm chokes’ are described below in the following sub-sections.
Sub-surface controlled type safety valves are run attached to a lock mandrel to locate and lock the
assembly in a matching landing nipple profile with an equalising assembly to allow equalisation of
pressure across the valve should it close. They may also now be installed on wireline retrievable
bridge plugs or nippleless plugs.
A typical assembly is shown in Figure 9.24.

Page 34
Pressure-Differential Safety Valves
The pressure differential type of direct-controlled safety valve is a ‘normally open’ valve that
utilises a pressure-differential to provide the means of valve closure. Normally a spring holds a
valve off-seat until the well flow reaches a pre-determined set production rate. This rate can be
calculated to a pressure differential generated across an orifice or flow bean. When this differential
pressure is reached or exceeded, a piston moves upwards against a pre-set spring force closing the
valve.
There are three closure mechanisms available with these valves. These are:
 Poppet
 Ball
 Flapper

The valve is held open by a spring force that may be increased by adding spacers or changing the
spring size. The relationship between flow rate and differential may be adjusted by changing the
bean size. If the well pressure declines and the set threshold differential cannot be reached, the valve
will not close regardless of the emergency situation at surface.
A detent arrangement prevents throttling of the valve which causes damage to the operating
mechanism. The detent spring requires an extra small additional force against which closure begins
but is suddenly relieved after a short distance of travel by the detent balls which fall out into a relief
groove. The removal of the detent spring force causes a snap action of the closure mechanism.
The valve when closed will remain in this position until pressure is applied at surface to equalise
across the closure mechanism whereby the spring will return it back to the open position.
These valves are rarely in use today but a derivative, the Injection Valve, which is normally closed,
is widely used in injection wells. This injection valve opens when fluid or gas is injected and travels
to the fully open position when the predetermined minimum injection rate is reached, (refer to
Injection Valves below).

Ambient Sub-Surface Safety Valves

The Ambient Sub-Surface Safety Valve (ASV) is a direct-controlled fail-safe closed safety valve
which has a dome or chamber that is pre-charged with a calibrated pressure prior to running.
Ambient controlled valves operate on the principle that the valve will remain open when well
flowing pressure is above a pre-determined level. The valve will close when the flowing pressure of
the well, at the depth of installation, drops below the pre-determined set dome pressure, i.e. if there
is a large scale leak at surface. The dome pressure setting is adjusted to correct for the actual
temperature at the operating depth.
As the valve is closed by a pressure above that of the well flowing pressure, the valve will initially
be closed as it is run in the hole to be installed but will open when it reaches the depth at which the
pressure will equal the dome set pressure.
Well pressure decline can cause premature closure of the valve if it is not changed accordingly.
This type of valve is not limited by a flow bean which gives it a large internal diameter and, hence, a
large flow area making it suitable for high volume installations possibly producing abrasive fluids.
It is also not so susceptible to throttling.

Page 35
 Top Sub

Piston

Spring

Chamber

Nitrogen Charging Port

Body Weldment

Seat

Ball

Figure 9.24 - Typical Ambient Pressure Operated Safety Ball Valve

Page 36
Note: Both pressure differential and ambient controlled sub-surface safety valves close on pre-
determined conditions and do not close until these conditions exist. Changing well
conditions will require re-calibration of the valves, otherwise they may not operate
correctly. Valve operation is also effected if flow beans become cut.

Surface controlled safety valves should be considered where such conditions are likely to
cause these problems.

Note: Both pressure differential and ambient controlled sub-surface safety valves close on pre-
determined conditions and do not close until these conditions exist. Changing well
conditions will require re-calibration of the valves otherwise they may not operate
correctly. Valve operation is also effected if flow beans become cut.

Surface controlled safety valves should be considered where such conditions are likely to
cause these problems.

Injection Valve
Injection valves are ‘normally closed’ valves installed in injection wells. They operate like check
valves allowing the passage of injected fluids but will close when injection is ceased.
The choice of closure mechanisms can be; either, ball, flapper or poppet. The valves open when the
differential pressure caused by the injection pumps equalises the pressure below the valve. As the
injection rate is increased to the pre-calculated rate, a differential pressure across a choke bean
overcomes the force of the power spring and moves the mechanism to the fully open mode. If the
injection rate is insufficient or fluctuates, the mechanism will not be properly held in the open
position (termed throttling) and may be damaged as a result.
The flapper-type valve is the most popular as its operation is less complicated than the ball valve
and is less prone to damage if throttling occurs.
Examples of a Halliburton/Otis injection ball valve, typical flapper and PES poppet types are shown
on the following pages.

Page 37
 Top Sub

Orifice (or bean)

Flow Tube

Spring

Housing

Body Weldment

Seat

Ball

Figure 9.25 - Halliburton/Otis Ball Injection Valve

Page 38
 Top Sub

Orifice (or bean)

Flow Tube

Spring

Spring Housing

Flapper Housing
Seat
Flapper Pin
Flapper Spring
Flapper

Figure 9.26 - Typical Flapper Injection Valve

Page 39
 Adaptor Sub

Poppet Seat
Sleeve

Poppet

Wiper Rings

Seat Spring

End Sub

Figure 9.27 - PES ‘W1’ Poppet Injection Valve

Page 40
9.4.11.4 Surface Controlled Sub-Surface Safety Valves
The surface controlled sub-surface safety valve (SCSSV) is a downhole safety device that can shut
in a well at any time or in an emergency to provide a barrier between the reservoir and the surface.
As the name suggests, the valve can be controlled from the surface by hydraulic pressure
transmitted from a control panel through stainless steel tubing to the safety valve, (refer to Figure
9.30). They may also be used in production or injections wells.
The remote operation of this type of valve from the surface can also be integrated with pilots,
emergency shut down (ESD) systems, and surface safety control manifolds. This flexibility of the
surface controlled safety valve design is its greatest advantage.
In the simplest system an SCSSV is held open by hydraulic pressure supplied by a manifold at the
surface, the pressure being maintained by hydraulic pumps controlled by a pressure pilot installed at
some strategic point at the wellhead. Damage to the wellhead or flowlines causes a pressure monitor
pilot to exhaust pneumatic pressure from a low pressure line which in turn causes a relay to block
control pressure to a three-way hydraulic controller resulting in hydraulic pressure loss in the
SCSSV control line. When this pressure is lost, the normally closed safety valve automatically
closes, shutting off flow from the tubing.
There are two main categories of SCSSVs:
 Wireline Retrievable SCSSV.
 Tubing Retrievable SCSSV.

SCSSVs utilise only the ball or flapper type closure mechanisms.

Both categories are supplied with or without internal equalising features. This allows the pressure to
equalise across the valve so it can be re-opened. Valves without this feature need to be equalised by
pressure applied at surface. The former is more prone to failure due to having more operating parts
whereas for the latter equalisation pressure is often difficult to provide and possibly time
consuming.
SCSSVs are now designed with two different types of valve actuation, either the conventional
concentric piston or a rod piston, (refer to Figure 9.28).

Valve Actuation
As discussed in a previous section, both ball and flapper valve mechanisms require the downward
movement of an internal component to open the valve. This is achieved by applying hydraulic
pressure from surface, down the control line to the valve and allowing this hydraulic pressure to
force a piston (or pistons) downwards against the opposing force of an internal power spring. This
spring will provide the restoring force to close the valve when hydraulic pressure is bled off or lost.
The concentric piston was the original design having a piston area between the OD of the flow tube
and the ID of the housing into which hydraulic fluid is pumped to move the piston downwards
acting on the flow tube and opening the valve.
The problems associated with this design was the tight manufacturing tolerances required for
concentricity of the piston to the other parts of the valve in order that the valve could be assembled
and operated without metal-to-metal interference. This problem often resulted in galling of the
piston especially when high chrome materials were being used.
To overcome this problem and also obtain very accurate piston areas to enable exact hydraulic
forces to be applied, especially for deep applications, the rod piston design was developed.

Page 41
The rod piston design for valves was introduced to achieve deeper setting depths. They utilise small
bores machined in the valve body into which rod pistons fit. The rod pistons are attached to the top
of the flow tube by a yolk which counteracts the uneven action of the force of the pistons acting on
the flow tube.
As the piston and cylinder bore are relatively small, machining tolerances are easier to maintain than
the concentric piston design.
To accommodate the rod pistons, the body OD and the bore of the valve often requires to be
eccentric in order to reduce the OD to fit within completion limits.

Hydraulic Fluid
Inlets

Rod Pistons

Concentric Piston

Power Spring

CONCENTRIC PISTON ROD PISTON

Figure 9.28 - Valve Actuation Methods

Wireline Retrievable SCSSVs

Wireline retrievable sub-surface safety valves are located and locked, using standard wireline
methods, in a dedicated safety valve landing nipple (SVLN). The SVLN is connected to a hydraulic
control line pressure source at the surface normally by a 1/4 ins. OD stainless steel tubing.
When the safety valve is set in the nipple, the packing section seals against the bore of the nipple
below the port. The packing section of the lock mandrel forms a seal above the port in the nipple.
Control pressure, introduced through the control line, enters the valve through the port in the
housing and allows pressure to be applied to open the valve. Figure 9.30 shows a typical surface-
controlled, wireline retrievable safety valve.

Page 42
 Control Line (From Surface)

Lock Mandrel

Hydraulic Landing Nipple

Wireline Installed Surface Controlled

Sub-Surface Safety Valve

Figure 9.29 – Typical Surface Controlled Wireline Retrievable Safety Valve System

Page 43
Because a wireline retrievable SCSSV seats in a landing nipple installed in the production string, it
offers a much smaller bore than a tubing retrievable SCSSV for the same size of tubing. Frequently,
WRSVs have to be pulled prior to wireline operations being carried out below the valve depth.
Compared to a tubing retrievable SCSSV, the wireline retrievable SCSSV is easy to replace in the
case of failure. Introducing a planned maintenance schedule in which valves are regularly pulled and
serviced can prevent most failures. However, during wireline entry operations there is also a safety
risk and care must be maintained at all times.
The components that are required for the installation of a wireline retrievable SCSSV system are:
 Hydraulic control line.
 Control line protectors.
 Hydraulic control manifold.
 Wireline retrievable safety valve.
 Safety valve landing nipple.
 Locking mandrel.
 Wireline installation and retrieval tools for the locking mandrel

Figure 9.30 shows a wireline retrievable ball valve with the ball operating mechanism.

Page 44
Figure 9.30 – Typical Wireline Retrievable Ball Valve Type SCSSV

Page 45
Tubing Retrievable SCSSV
Tubing retrievable safety valves operate by the same principle as wireline SCSSVs except that all
the components are incorporated in one assembly which is installed in the completion string, (refer
to Figure 9.31). Some models have rod pistons instead of the more normal conventional concentric
piston designs.
Valves options have ball or flapper closures although the flapper is the most widely selected version
due to its simplicity in design and reduced frictional forces which makes it more reliable.
Should the tubing retrievable valve suffer a failure, can be locked open and a wireline retrievable
valve installed within the existing valve and operated through the original control line, although
with a reduced internal flow area. If the failure is due to a control line leak, then this procedure is
inapplicable and a workover would be required. Each manufacturer has their own design of lock-
open devices and requires specialised tooling with appropriate advantages and disadvantages.
Common valve selection throughout a field, or fields, helps reduce cost of such equipment.
The components required for TRSV are:
 Hydraulic control line
 Control line protectors
 Hydraulic control manifold
 Tubing retrievable safety valve.

and additionally for the insert capability:

 Wireline safety valve
 Locking mandrel
 Wireline installation and retrieval tools for the locking mandrel
 Lock-out tool for the tubing retrievable valve.

9.4.11.5 SSSV Depth Setting

The setting depth for any particular SSSV depends upon whether it is in platform, subsea or land
completions. The criteria for valve depth setting is that it must be deep enough that it is not at risk
from any potential source of damage.
The industry and BP’s common practices for valve depth setting is fully described in BP’s DHSV
Guidelines Document by P Adair. This is to be placed on the following web page.
http://upstream.bpweb.bp.com/EPT/home.asp?id=3290

Page 46
Figure 9.31 - Typical Tubing Retrievable Flapper Type SCSSV

Page 47
9.4.12 Annular Safety Valve Systems
The sub-surface safety valves discussed so far, i.e. tubing retrievable and wireline retrievable, only
provide well control on the tubing side. In some completion designs, the annulus is used to convey
fluid from reservoirs to surface or to deliver fluids downhole for artificial lift purposes. On such
completion types where personnel may be at risk from hydrocarbon escapes from the annulus,
annulus safety systems can be installed.
Annulus safety valve systems are usually associated with completions where artificial lift or
secondary recovery methods are employed e.g. gas venting in electric submersible pump (ESP),
hydraulic pump, and gas lift installations. Their application is to remove the potential hazard of a
large gas escape in the event there is an incident where the tubing hanger seal is breached.
There are a number of designs of such systems on the market with a wide variety in mode of
operation, however the basic concepts are all the same. With any annulus system, there must be a
sealing device between the tubing and the casing through which the flow of gas can be closed off.
This is generally a packer but may also be a casing polished bore nipple in some designs into which
a packing mandrel will seal. In the sealing device there is a valve mechanism operated by hydraulic
pressure similarly to an SCSSV. The valve mechanism opens the communication path from the
annulus below to the annulus above the valve which is fail-safe closed.
The closure mechanism may be a sliding sleeve, poppet or flapper type device.

9.4.12.1 Baker ‘AVLDM’

The Baker 'AVLDM' system, features two individual parts to the system; a ‘FLX’ packer to provide
the seal against the casing isolating the annulus above from below and a surface controlled fail-safe
closed valve which enables flow through an annular area within the assembly. The valve section
contains a hydraulic operated poppet valve system.
Closure of the valve is by removal of hydraulic control pressure to a rod type piston which allows
spring force to move two poppet valves onto valve seats. In case of valve failure such as a control
line rupture, etc, it is essential that the valve mechanism can be opened to enable well killing prior
to workover and is provided in the 'VLDM' by the poppet valves being spring loaded and able to be
pumped off-seat.
Figure 9.32 shows the ‘AVLDM’ annulus safety valve system.

9.4.12.2 Camco 'TRAC'

Camco 'TRAC' series valves feature large, straight-through bores for tubing flow, rod-piston
actuation and a sleeve seal closure mechanism which consists of a concentric hard/soft seal and a
spring loaded flow tube. The use of rod pistons, rather than a concentric piston, reduces the
hydraulic chamber area and permits operation of these valves at greater depths than concentric-
piston-actuated valves. Controlled independently of the tubing control valve through a separate
hydraulic control line, 'TRAC' series valves provide a large annular flow area for the injection or
production and also isolate tubing flow from annular flow at the valve.
Although designed specifically for use with Camco 'HAWS-AC' packers, 'TRAC' series valves can
be adapted for use with most large-bore, hydraulically set packers.
The 'TRAC' valve series includes 'TRAC-1' and 'TRAC-2' valves, which differ slightly in
configuration and method of installation.

Page 48
 Production Casing

Hydraulic Rod Piston

Multi-Purpose
Expansion Joint
Annulus Ports
Tubing
Poppet Valves
Tubing Retrievable Safety
Valve Control Line

Tubing Retrievable Safety

Valve
Power Spring Annulus Safety
Valve Control Line
Flow Coupling

Spacer

Annulus Safety Valve

Pack-Off Tubing Anchor

Annular Safety Valve Annular Safety Valve System Installation

Figure 9.32 - Baker ‘AVLDM’ Annulus Safety Valve System

Page 49
9.4.12.3 PES ‘AV CAPS’
The PES AV CAPS concentric annulus pack-off system is similar to the systems already described
in that the hydraulic operated valve utilises rod pistons with check valves to contain pressure below
the system. The system consists of the valve section run in conjunction with a hydraulic set packer
section. If top hole workovers are not required the system can be installed in a single trip. If top hole
workovers are a pre-requisite, then a PES HS hanger system is utilised and this then becomes a two
trip installation. The hanger slips are full circumferential with multi-flank cones.
This system does not require a tubing expansion device and there are no dynamic seals above the
annular barrier.
Retrieval of the system is by straight tubing pull which reduces the risk of damage to control lines or
clamps.

Figure 9.33 – PES AV CAPS Concentric Annulus Pack-Off System

Page 50
9.4.13 Flow Couplings
Flow couplings, which are thick walled tubulars, are installed above and below any completion
component which may cause flow turbulence such as wireline nipples, SSDs, SCSSV landing
nipples etc., to cater for internal erosion. Even although the material selected is often tougher,
erosion is still experienced but the added thickness of the flow coupling provides sufficient material
to prevent weakening over the projected life of the well. In lower velocity wells, such as low GOR
oil wells, flow couplings need only be placed above restrictions.

9.4.14 Blast Joints

Blast joints are installed opposite perforations (non-gravel packed) where external cutting or
abrasive action occurs caused by produced well fluids or sand. They are also heavy-walled tubulars
similar to flow couplings but are available usually in 10, 15, and 20ft lengths. Higher grades of
materials are selected for this application to resist the erosion, even ceramic-coated steels.
Blast joints should ideally be long enough to extend at least 4ft on either side of a perforated
interval as a safety margin.

9.5 Downhole Permanent Gauge Systems

Downhole permanent gauge (DHPG) systems are commonly used in modern completion designs to
provide continuous downhole pressures and temperatures to enable enhanced reservoir
management. The gauge systems available are electronic with either hard cabling or optical fibre
enclosed in a steel conduit of the same size as SCSSV control lines. The lines are available in an
option of materials for the well conditions also similar to SCSSV control lines.
These gauges are typically installed as close to the reservoir as is feasible in single string
completions. In multiple zone single string completions, gauges can be installed at each zone
although the complexity of cable penetration through packers and running of multiple cables along
side SCSSV control lines is increased.
The cables are usually fixed to the production tubing with all metal type protector clamps which are
mounted over the tubing connections where the cables are most at risk from damage. The protectors
usually have a number of slots to accommodate, either:
 A single cable or control line (with or without encapsulation)
 Two singles
 A dual encapsulated
 A dual encapsulated with a single
 A dual encapsulated with two singles

Encapsulation is a very hard plastic moulded around the conduit used to add further mechanical and
erosional protection to the conduit and is usually of a square section to enable better clamping.
For more detailed information refer to section 9.7.1.1.

Page 51
9.6 Intelligent Well Completions
Intelligent Wells (I-Wells also sometimes termed Smart Wells) Technologies comprise a selection
of permanent devices installed in the wellbore that acquire surveillance information such as
pressure, temperature profiles, flow rates and remotely control flow from individual producing
formations to optimise production rates. The term permanent is used to discriminate these devices
installed with the completion from those which can be used during well interventions.
Other permanent devices are currently under development which will increase the amount of
information obtainable from wells such as downhole fluid ratios, fluid densities and seismic data.
Optimum reservoir management is under-pinned by the information from effective reservoir
surveillance and the ability to take action on that information. Intelligent Well technologies offer the
ability to obtain the information, to improve the reliability of surveillance and perform the necessary
actions through flow-control valves installed in the completion.
I-Wells technology is targeted at higher rate wells where conventional methods of acquiring
surveillance data or changing flow from producing zones is high cost, high risk or operationally
difficult to perform. BP’s deepwater portfolio is a prime candidate for this technology and in
addition, there are many situations where permanent and reliable surveillance technology
significantly improves reservoir management effectiveness. These applications include:
 Subsea wells where intervention is cost prohibitive and carries significant risk.
 Remote land locations where intervention infrastructure is minimal.
 Any high rate producer where intervention with conventional means requires shut-in and
added risk.

To fully realise the e-field vision, and the fundamentally new reservoir management approach that it
proposes, requires the acquisition of continuous, high quality information from permanently
installed downhole sensors in the e-field and the ability to remotely control the inflow from
segments of the reservoir through valves installed in the completion.

9.6.1 Value of Intelligent Wells

The value of Intelligent Wells technology falls into two distinct areas; the value of continuous
downhole surveillance information and the value of down-hole flow control (although it could be
argued that surveillance is part and parcel of downhole flow control). However, in this document
they are addressed separately.

9.6.2 Estimating The Value of Continuous Downhole Surveillance

The value of continuous downhole surveillance is through obtaining:
 Optimised draw down
 Optimised completion efficiency and production start-up
 Early detection of compartmentalization or formation damage
 Reduced shut-in time and fewer well interventions

Page 52
9.6.2.1 Optimised Drawdown
 It has been conservatively estimated that around 5% increase in production rate can be
achieved by operating wells at optimum draw down limits.
 Avoiding over aggressive drawdown that damages the initial completion efficiency can
also optimise reserves recovery.

9.6.2.2 Optimised Completion Efficiency

 Increased production can be achieved through early detection of stimulation candidates.
Production and injection increases of 20%-50% can be realized by having the immediate
information provided by permanent installed sensors.
 Increased production and injection by improvements to completion practices.
Production increases of 10%-20% can be realized by utilizing early surveillance data to
optimise completion practices on future wells.

9.6.2.3 Early Detection Of Compartmentalisation

 Reduces drilling costs and increases reserves by optimising well placement and
understanding reservoir size. Preventing one well from being misplaced can save
between $5-$50 million.

9.6.2.4 Reduced Lost Production Time And Operational Risk

 Increases in production can be realized with permanent sensors by being able to acquire
surveillance information while producing, eg. Production welltests can be obtained for
high rate wells without the requirement to choke back rate.
 A significant amount of shut-in time can result when operational problems occur during
interventions to acquire information through convention means.
 Optimised well clean-up practices when bringing a new well on stream will result in the
well achieving higher rates sooner.
 Routine surveillance will provide a regular well health-check which can give early
identification of increased skin due to scaling or mechanical completion problems.
 Reduced operating expenditure for routine well surveillance.
 Reduced HSE exposure for wells located in politically unstable or hostile areas.

In the UKCS approximately forty new wells are added per year under current plans and an
evaluation of the value of permanent surveillance indicates a prize of $2 million per well on average
may be achievable.
As an example, In the NorthStar field, Alaska, estimates have been made that show permanent
surveillance will add $5 million in direct value and add 2,000,000bbls in increased reserves over the
life of field.

Page 53
9.6.3 Estimating The Value Of Downhole Flow Control
A small sample of downhole flow control is listed below but this is not comprehensive and there are
more applications which have not yet been accomplished and more being realised:
 Selective production of stacked pay zones (especially in deviated wells)
 Commingled production
 Optimisation of injection performance
 Surface controlled downhole gas lifting
 Auto-Downhole injection or dump flood

Examples of how other operators have found value in flow-control is illustrated in the link below:
http://houston.bpweb.bp.com/iwells/shared.files/articles/Welldynamics-value-of-iwells.pdf

9.6.3.1 Selective Production Of Stacked Pay Zones

Increased production can be realized in completions where there are stacked reservoirs in highly
deviated wells. Production from each individual zone can be selected to meet with changing well
parameters to obtain optimum flow conditions in wellbores where normal well intervention means
cannot be used due to the high angles or economics due to the well location, i.e. wells with
inclinations greater than 70o from vertical or remote subsea wells where intervention costs are
exceedingly high. Kings Peak completions are good examples of the application of this technology.
Refer to Figure 9.34

9.6.3.2 Commingled Production

Increased production can be realized in completions where there are stacked reservoirs. In a
commingled completion water production from one zone can impact and even prevent additional
production from the other zone. In high intervention cost environments flow-control technology can
enable a field development that would otherwise not be economical.
Typical examples of this type of completion are shown in Figure 9.35, Figure 9.36 and Figure 9.37.

9.6.3.3 Optimised Injection Performance

Increased reserves can be realized when a stacked reservoirs with heterogeneous rock properties are
present. The flow control device can proportionally distribute the injection water potentially
resulting in 20% increased recovery through improved sweep efficiency.
The type of completion is similar to the production well shown in Figure 9.35.

9.6.3.4 Surface Controlled Downhole Gas Lifting

Gas from other non-producing zones can be used for lifting oil from the producing zone. This
enhances the economics of a development by: reducing capital cost of surface gas lift equipment,
increases production rate and increases recoverable reserves.
Figure 9.38 shows a typical water encroachment problem in a horizontal well with the original
completion design shown in the insert. The solution to the problem is shown in Figure 9.39 where
the hole is drilled nearer the bottom of the thin oil leg and the gas leg is perforated for injection
through a surface controlled SPM gas lift valve lifting both the oil and produced water.

Page 54
Figure 9.34 – Typical Kingspeak Selective Smartwell Completion

Page 55
 Figure 9.35 – Typical Commingled Well With Individual Zonal Flow Control

Figure 9.36 – Commingled Gravel Packed Well With Individual Zonal Flow Control

Page 56
Figure 9.37 – Wytch Farm ESP Completion With Flow Control Of Two Laterals

Figure 9.38 – Water Coning Problem In A Conventionally Completed Well

Page 57
 Figure 9.39 – Solution To Water Coning Problem Using I-Well Technology

9.6.3.5 Auto-Downhole Injection

In layered reservoirs pressure maintenance of a producing oil formation can be achieved by
downhole injection of gas or water from another zone. The amount of injection can be controlled
and monitored from surface. This reduces the amount of injection wells required for producing and
the handling facilities at surface and reduce capital cost. It also reduces risk, as the injection fluid
does not require handling at surface.
The example shown in Figure 9.40 shows the normal methods of producing gas from one well for
re-injection into a gas injector and the I-Well solution. Although this scenario shows gas from a
lower producing zone there is also design solutions for higher zones.

Page 58
Figure 9.40 – Example Of Conventional Producer/Injection Wells With I-Well Solution

Page 59
9.6.4 I-Well Terminology And Abbreviatations
There are many the terms and abbreviations specific to I-Well completion technology and it is
necessary to first define these before describing the application of the various elements and tools
involved.
As well as having some generic terminology I-Well technology, the suppliers of surveillance and
control systems have developed their own terminology or trade names for their products. As an aid
to understanding, some of the mostly widely used terms and their definitions are listed below:
Direct Hydraulics Are control systems which are operated directly from a surface control
system with a dedicated hydraulic line for the opening function and
one for the closing function. Multiple controls may have networked
systems where the closing line is common to optimise the number of
lines required without affecting the function of any of the devices.
Digital Hydraulics This system enables up to three devices to be controlled using three
control lines. Each device shares common opening and closing lines
and a third line is a signal line for hydraulic pressure sequencing of a
downhole decoder. These systems reduce the number of lines hence
penetrations through packers.
Mini-Hydraulics This is adaption of direct hydraulics systems which uses one line to
power close and open each device. Selection of particular devices is by
using hydraulic amplitude and venting returns into the tubing.
Accu-Pulse This term refers to a completion with an incremental downhole choke
which is operated by hydraulic pulses applied to a mechanical
downhole control fluid meter in direct or digital hydraulics systems.
Each pulse moves the incremental choke a predetermined distance.
Electro/Hydraulic This term refers to a system which uses shared opening and closing
hydraulics with the selection via electronically operated downhole
valves via a cable and panel from surface. The use of electronics
instead of hydraulic signalling as in the digital hydraulic systems
enables a greater amount of tools to be controlled, hence control of up
to twelve zones.
Electric Is the term for fully electrically operated control and surveillance
systems. This is the ultimate in technology as all control and
surveillance is through one cable and, therefore, there is only one
penetration through packers.
Fibre Optics Is the newest technology introduced for in-well surveillance systems.
It is currently used for monitoring pressure, temperature, distributed
temperature, fluid velocity, fluid phase flow-rate, and seismic activity.
In-Force Bakers title for their electro/hydraulic control system which is
provided with either electric, or fibre optic permanent gauge systems.
InCharge Bakers title for their fully electrically operated system.
SCRAMS This is the Well Dynamics abbreviation their for Surface-Controlled
Reservoir Analysis and Management System which is an integrated
multi-drop communication, control and data acquisition system using
electro/hydraulics.

Page 60
Flow Control Valve (FCV) Usually refers to valves which open or close off production from
individual zones. Simple types are, either, fully opened and closed
with more complex types being variable to control the amount of flow
from or into a zone.
Gas Lift Valve Is a valve normally installed in a side pocket mandrel which is
adjustable electrically from surface to control the amount of injection
gas into the flowstream.
Lubricator Valve (LV) Is a valve which can close off the tubing, useful as a suspension plug
or to close in a lower zone in the event that the flow control valve
leaks. May also be used to lubricate long toolstrings into well such as
perforating guns.
EDGE Baker technology using acoustic signals through completion fluid to
select tool operating mode before applying hydraulic pressure for
actuation of the device. Useful for selectively setting multiple packer
systems, etc.
DTS Is an abbreviation for Distributed Temperature Sensing. This form of
downhole surveillance uses a fibre optic cable installed on the outside
of the completion and liner to measure a temperature profile along the
entire well.
PDG Is an abbreviation of Permanent Downhole Gauge
SCU Is an abbreviation for Surface Control Unit.

9.7 Applications Of Current I-Well Technologies

The applications of I-Well technology can range from a simple surface pressure and temperature
read-out of a single permanently installed gauge system through remotely monitoring pressure,
temperature, flow rate and oil/water ratio and activation of downhole flow control devices in multi-
layered reservoirs.
The systems can be broken into two categories, those used for surveillance, and those for flow
control.

9.7.1 Surveillance Systems

To obtain surveillance data the use of both electronic and fibre optic systems are widespread. The
use of electronic systems have been mainly for obtaining pressure and temperature data from
devices installed at a discriminate point (or points) in the completion and are very successful with
thousands installed. Venturi flow rate meter and water cut systems are also available which
effectively use an adapted electronic gauge system in conjunction with a venturi flow tube although
to date they have experienced relatively short run lives.
The use of fibre optic systems for temperature monitoring has also become more widespread and
has an advantage over electronic systems in that they can be used for continuous temperature
measurement along the whole length of the well. This is very useful for obtaining flowing
temperatures at any depth in the well input into reservoir modelling programs, determining inflow
distribution, hydrate formation, gas lift performance and where there is water or gas encroachment.
This accurate data is then used for production management and to improve reservoir recovery.
A description of these systems and their history can be found at the following website:
http://houston.bpweb.bp.com/iwells/shared.files/articles/Well-Connected.Iwells-Now-Future.PDF

Page 61
9.7.1.1 Electronic Permanent Gauge Surveillance
Applications are:
 Single point pressure monitoring
 Single point temperature monitoring
 Permanent pressure/temperature gauges are the least complex form of Intelligent Well
yet can be amongst the most valuable. Thousands of permanent pressure gauges have
been installed since the 1980’s. Until recently these gauges have exclusively been based
around downhole electronic devices.

Figure 9.41 shows a Kings Peak well completed with a permanent gauge as an example.
The gauge carriers can be designed to accommodate numerous gauges and can be configured for,
either, internal recording, external recording or both. This enables many permutations for multiple
applications and can allow for redundancy in the completion design. The early generations of
electronic downhole gauges developed a reputation for poor reliability due to the high rate of initial
failures. To address this issue, many vendors improved their QA procedures and adopted state of the
art reliability assurance techniques such as those used in the aerospace industry. This has resulted in
a significant improvement in downhole gauge reliability industry-wide.

Double Chemical Injection lines

Mudline
1/2” OD x .065” wall
38x36” Conductor
~250’ BML SCSSV control lines, 1/4” OD
Upper Chemical Injection Sub(s)
20” 129 ppf casing
Camco SCSSV ~2400’ BML
10 ppg PHPA Mud
11 ppg Synthetic Mud

~ 2000’ BML
10.3 CaCl2 Brine

4-1/2” 13CR 13.5 ppf Fox

Production Tubing

13-3/8” N-80, 72 ppf Casing

<500’ above KP-sands
I-Wire to Gauge Mandrel
1/4” OD

SLB Segnet Gauge Mandrel

Hydraulic Packer
Gravel Pack Packer
Formation Isolation Device

Perf Interval 5” OD 13CR Pipe Base

Perforated 21 SPF Screen and Blank

Sump Packer

9-5/8” P-110, 53.5 ppf SLX Casing

MFB 5-23-00
KPSINGLE.PPT
SKETCHBK.PPT

Figure 9.41 – Typical Kings Peak Completion With Permanent Downhole Gauge

Page 62
Figure 9.42 – Eccentric Gauge Carrier Showing Gauge Installed

Figure 9.43 - Cable Protection Over A Tubing Connection

Page 63
Sometime ago a JIP called ICON was formed by combination of some major Petroleum Operating
Companies and Permanent Monitoring Service Companies to track performance of gauge systems.
The following chart is taken from the ICON database and demonstrates the relationship between
electronic gauge reliability and reservoir temperature. A significant increase in failure rate can be
identified at temperatures above 120oC.
The ICON database is accessible to BP staff via the ICON website and provides a useful reference
source prior to selecting a gauge provider.

Figure 9.44 – Performance of Industry Leading Electronic Gauges

A review of the most common causes of failures in permanent downhole electronic pressure gauges
indicated the following key failure areas:
 Connections and splices
 Cable
 Gauge electronics

Gauge surveillance systems have evolved to address these failure areas, and many gauge vendors
have made significant improvements in these areas.
Further information on electronic pressure gauges can be found in the following documents:
http://houston.bpweb.bp.com/iwells/shared.files/articles/Downhole_Monitoring.pdf
Some factual testimonials to gauge reliability and value have been collated from various PE/RE/CE
staff within the company and can be reviewed at the following site:

http://houston.bpweb.bp.com/iwells/shared.files/articles/Gauge Justification.doc

Page 64
BP also produces a report on gauge survivability which was last updated in January 2003. This
report uses ICON as a basis for the report and is available on BP’s Integrated Subsurface
Information Systems (ISIS) web site at:
http://ebrochure.bpweb.bp.com/index.asp?id=7369643D312669643D30

Any asset that needs to know how the data base for this report reflects their specific well conditions
can request specific interrogations of the database to tune the general report findings for their
particular circumstances.

9.7.1.2 Electronic Downhole Flowrate Surveillance

Applications are:
 Provide production flowrates from individual zones
 Provide production flowrates from commingled zones
 Oil/water ratio measurement

The method of downhole flowrate measurement is based on the venturi effect. The system consists
of pressure gauges, as described in the previous section, and a venturi flow tube. With a gauge
upstream at the throat and another downstream, the pressure differential can be calculated to give a
flowrate of fluids. Systems based on this principle provide accurate measurement of liquid flow but
are not as accurate in gas measurement applications.
In May 1997, BP and Schlumberger entered into a joint collaboration to develop a compact
downhole multi phase flowmeter. Experimental work was conducted in Schlumberger’s research
facility in Cambridge and combined numerical modelling and flow loop testing to characterise the
performance and design specification for different flowmeters. This screening and experimental
work was completed in March 1999 and established the principles of the FWD (Flow Watcher
Densiometer) design.
The first prototype of this device was installed in Harding well PN1 on 26th August 2000 and
production started up on the 9th September 2000. The flowmeter was a technical success and is
continuing to operate to date.

Wireline Lock
Venturi

2 PressureWatch Densitometer
Quartz gauges
Figure 9.45 – Schlumberger FWD Flowmeter

Page 65
9.7.1.3 Fibre Optic Based Surveillance
Fibre optic based downhole surveillance is a relatively new technology in the oilfield compared to
downhole electronic-based monitoring devices.
The widest uptake of this technology to date has been for two distinct applications:
 Single point Pressure and Temperature monitoring
 Distributed Temperature Sensing

However, some other applications have also been introduced such as:
 Fluid Velocity and multi-phase flow measurement
 Seismic Monitoring

Once the fibre optic sensor technology has advanced to the point where it is proven to be
sufficiently reliable, it will deliver tremendous benefits to the industry due to the fact that multiple
sensors can be mounted on a single fibre.

Single Point Pressure And Temperature Monitoring

The modern optical P/T sensor is based on the Fibre Bragg Grating technology. These systems
operate by utilising an optical fibre cable to transmit light down to the Bragg Grating and an optical
signal interrogator unit at surface to receive reflections from the Bragg gratings and identify the
corresponding downhole pressures and temperatures. The Bragg gratings are etched into the core of
the fibre and that provides the complete downhole intelligent system. No electronic hardware is
required downhole. Since electronic component reliability has historically suffered at high
temperatures, the fibre optic system could offer a high reliability alternative, particularly for high
temperature applications.
Some early fibre optic gauge systems were developed and installed in the North Sea Gyda and
Marnock fields (circa 1997), but these suffered from low accuracy and degradation of the fibre
clarity over time. These design problems have been addressed and the Bragg Grating based sensors
have demonstrated a respectable track record since 1999.
Refer to Figure 9.42 and Figure 9.43 showing a typical gauge installation with cable protection.
An explanation of how Bragg gratings work can be seen at the link below:

http://houston.bpweb.bp.com/iwells/optical.projects/bragg.grating/page1.htm

Distributed Temperature Sensing (DTS)

The DTS system uses the fibre optic cable as the sensor and provides a continuous temperature
profile, typically at one metre intervals along the whole length of the fibre. This provides the
Reservoir Surveillance engineer with the means to monitor small temperature changes along the
reservoir producing interval which could provide data to identify changes in fluid phases or changes
in completion efficiency. Additionally, DTS data above the packer can provide an indication of
significant fluid changes behind casing, higher in the well, which could provide a useful insight into
the behaviour of offset wells.
One example of the value of DTS data was demonstrated on the Wytch Farm field in the South of
England, which showed significant cooling at the toe of a well indicating water from a nearby
injection well was unexpectedly in communication with the producer.

Page 66
The fibre in DTS systems is usually installed through two 1/4” OD control lines which are run
parallel alongside the tubing during completion of the well. The control lines are terminated
downhole at a sub which has a loop (termed a Turn-Around-Sub) connecting the two lines
downhole thus creating a continuous circuit. The fibre optic is then installed by pumping around this
circuit. Refer to for an example TDS installation from the BP Mahogany field in Trinidad.
The pump-down-fibre system, however, is not feasible for subsea well applications, and several
Service Companies are developing equipment to install DTS fibre across the reservoir interval in
subsea wells based on a hard-wired fibre optic cable. The first subsea DTS systems are expected to
be commercialised by mid 2004.

Figure 9.46 – Example DTS Completion From The Mahogany Field - Trinidad

Fibre-Optic Downhole Multiphase Flow Meters

The Fibre Bragg Grating technology has also been incorporated into a downhole flowmeter. The
fiber-based system measures pressure/temperature, bulk velocity, and speed of sound of the flowing
fluid and from those measurements, the surface data processing system can generate the multi-phase
flow data. The flowmeter is a full-bore tool, and requires no downhole electronics or power. Several
Field trials of this technology were performed in wells during 2001/2002.

Page 67
Fibre-Optic Seismic Sensors
A fibre-optic seismic sensor array has been developed and several field trials were performed
successfully in 2002. It is expected that this technology will become commercial in 2005. The
optical seismic sensors offer an alternative to conventional geophones since they require no
downhole electronics or power.
Further information on optical sensors can be found in the following document:

http://houston.bpweb.bp.com/iwells/shared.files/articles/SPE71529.pdf

The Service Companies providing fibre optic technology have made considerable progress in
developing high reliability systems for subsea applications and this technology presents an attractive
option for future deepwater HPHT wells.

9.7.2 Flow Control Systems

Permanent flow control valves (FCVs), likened to remote controlled SSDs, can be installed to
control flow from various zones or shut-in the tubing, a type of valve termed a ‘lubricator valve’. A
combination of these can be installed to provide permutations of flow from or into various zones.
There are currently three methods of actuation for these downhole valves:
 Hydraulic
 Electro/hydraulic
 Electric

9.7.2.1 Hydraulic Flow Controls

The first systems developed were direct hydraulic systems based on existing subsea technology and
have served well to date. However, such systems were inherently limited due to the amount of
control lines and cables, hence, packer penetrations which were required for single or dual zone
control systems.
Digital hydraulics were introduced which reduced the number of lines require due to sharing of
hydraulic supply and return lines. Tool operating selection was based on hydraulic sequencing
through a separate signal line using a downhole mechanical decoder sub. However, the margins
required on the hydraulic signalling to operate the various valve actuations meant that these systems
were still limited to control of a maximum of three zones.
Mini-hydraulic systems have since been developed which use one control line for each device. This
line uses pressure amplitude to select opening or closure and vents returns into the tubing. This still
imposes limitations on the number of tools which can be installed due to the quantity of control
lines and cable penetrations of packers.
Pulsed tools have been added to the range of tooling for I-Wells which use hydraulic pulses to
operate incremental downhole chokes through a downhole controlled metering systems.
All in all, fully hydraulic systems will always be limited in there ability to provide multiple zone
control. The solution to multiple zone control is through electro/hydraulics or all electric systems.

Page 68
9.7.2.2 Electro/Hydraulic Flow Controls
Similar to subsea technology, permanent downhole flow controls moved into electro/hydraulic
technology whereby all the signalling is accomplished with the electronics and the hydraulics
simply being the actuation power source. This provided more versatility but temperature rating is
still a limitation as applies to almost all downhole electronics.
Using line sharing for hydraulic supply and venting returns to the tubing, the number of lines
necessary are greatly reduced compared to full hydraulic systems.

9.7.2.3 Electric Flow Controls

Full electric systems are under development and are being introduced onto the market.

9.7.3 Current Flow Control Technologies

This section describes the flow control technology of intelligent well completion designs. The
essence of intelligent well designs is the ability to remotely control flow from, or into, various
zones. This means one of the main functions of the completions is to segregate these identified
zones. Examples of typical intelligent well completions were shown in section 52 and included an
example of individual zonal control in Figures Figure 9.34 and Figure 9.35.
The implications of flow control on the completion design are:
 Packers must be set between each producing zone for segregation.
 The packers must have sufficient penetrations for the passage of control lines, electronic
cables or optical fibre lines to reach valves and gauges.
 Shrouds are required for the passage of control lines, cables and optical fibre lines in
completions with sand control screens.

Examples of flow control applications is addressed in the following documents:

http://houston.bpweb.bp.com/iwells/shared.files/articles/Iwells.Application.Examples.pdf
(courtesy of SLB)

http://houston.bpweb.bp.com/iwells/shared.files/articles/SPE71677_Oseberg.pdf
(courtesy of SLB)

Further explanations of how flow-control valves work is addressed in the following documents:
http://houston.bpweb.bp.com/iwells/shared.files/articles/controlling.pdf
(courtesy of SLB)

http://houston.bpweb.bp.com/iwells/shared.files/articles/welldynamics.pdf
(courtesy of Well Dynamics)

http://houston.bpweb.bp.com/iwells/shared.files/articles/BOT-IWS.pdf
(courtesy of Baker Oil Tools)

Page 69
9.8 I-Well Completion Components
This section describes the basic components which are particular to intelligent well completions.
This section does not try to describe all the tools available in any great detail as the advancement in
technology will soon make the section outdated.

9.8.1 Packers
The packers used for isolation of the producing zones must be able to achieve all of the functions
required of a normal production packer but also enable pass-through of control lines, cables or
optical fibre lines. A typical packer is shown in Figure 9.47. These packers are hydraulically set
type tubing retrievable and are single trip installed.

Figure 9.47 – Typical Packer Showing A Control Line Penetration

Page 70
The problems associated with such packers are integrity testing and the increased risk of leaks
occurring across the packer due to the amount of penetrations required. Integrity testing of the
packers is difficult as the wellbore will normally be in connection with the producing formations,
therefore, the normal method of integrity testing by pressure testing above the packers is not
appropriate as test pressure will bleed-off into the formation above (except for the top packer).
However, if permanent pressure gauges are included in the completion, the setting of the packers
can be confirmed by surface read-out of the pressure below each packer leaking off to formation
pressure. This does not determine if there are any small leaks, however, as the pressure read-out will
remain stable at that particular formation pressure.
Multiple packers are usually set in sequence from the bottom packer upwards by varying the shear
pin setting pressures in each packer but if there are many packers the margin between packer setting
pressures will be small and independent setting not impracticable. In multiple packer completions
shear discs are now used by some packer manufacturers as the margin of error in shear discs are
much less than shear pins.
Baker introduced an EDGE product range which included packers which are set by first selecting
the individual packer setting mechanism by sending an acoustic signal down the well through the
completion fluid and then applying hydraulic pressure to the tubing. The performance of these
packers have been mixed due to problems with the acoustic signalling.
Packer penetrations or feed-throughs always pose a problem as they are time consuming to make up
on the rig floor and are always a potential leak source. A solution is to select a packer system where
it is possible to pressure test the penetrations in the workshop while testing the sub-assemblies,
however, in actuality this is not as simple as it first might seem. Cable or control line connectors
which have test ports are available but they are also time consuming to make up and pressure test
while running the completion and usually only test one of the ferrules from the correct direction.

9.8.2 Inflow Control Valve

An inflow control valve (ICV) can be likened to a sliding side door with hydraulic remote control
for opening or closing. Their applications are:
 Enable independent zonal production
 Enable independent zonal injection.

Like SSDs they have the same weaknesses of any downhole tool which has internal seals that move
past slots or large holes and are prone to damage and, hence, leakage.
The key aspects of a flow control valve are as follows:
a) Actuation methods:
 direct hydraulic
 digital hydraulic
 electro-hydraulic
 full electric

and
b) Position Control:
 On/Off
 Multiple position
 Infinite Variable

Page 71
Figure 9.48 – Typical Hydraulic Flow Control Valve (Schlumberger TRFC-H)

Page 72
Figure 9.49 – Typical Electric Flow Control Valve (Sclumberger TRFC-E)

Page 73
9.8.3 Lubricator Valve
The lubricator valve is a tubing shut-off valve which is used to close off flow in the tubing.
Its applications are:
 Shutting off flow between zones
 Shutting off flow to surface
 As a barrier to enable long well intervention toolstrings to be deployed

A typical LV application is shown in Figure 9.50 below.

Figure 9.50 – Lubricator Valve (courtesy of Halliburton)

Page 74
9.8.4 Gas Lift Valve
The I-Well gas lift valve is a variable valve which can be operated from surface usually through an
electric cable.
The application is:
 To enable optimisation of gas lift systems

This is achieved by it being able to vary the amount of gas injected at the mandrel depth to suit
varying well parameters. The valve is effectively a downhole choke which is opened or closed by an
electric motor.
This application saves costly well interventions to change out operating valves and also enables
valves to be installed at high angles where well intervention is not possible.

9.9 I-Well Technology Reliability

Refer to OTC paper: 13031 - Engineered Reliability for Intelligent Well Systems and SPE paper
62955 – Reliability Qualification Testing for Permanently Installed Wellbore Equipment. However
for more recent reliability information regarding surveillance systems including the newer
technology fibre optics, reference should be made to the BP ISIS surveillance report found on the
web at:
http://ebrochure.bpweb.bp.com/index.asp?id=7369643D312669643D30
The information in this report is sensitive and, hence the results are not included in this section. The
data has also been gathered and analysed solely by the ISIS group thereby providing a much more
balanced picture than other data such as ICON which includes companies that have commercial
interests. To understand how the data contained in the data base for the report can be used to aid
individual asset groups, they can request specific interrogations of the data base to tune the general
report findings.

Page 75
 9.10 References
Introduction To Completion Design Jonathon Bellarby
An Introduction To The Basics Of Well Completions, Workovers & Stimulation 2nd Edition
George King
George King’s ‘An Introduction To The Basics Of Well Completions, Workovers & Stimulation’
2nd Edition
The Justification and Application of SmartWell Technology Well Dynamics
http://houston.bpweb.bp.com/iwells/shared.files/articles/Welldynamics-value-of-iwells.pdf
Intelligent Wells, Now and the Future Brock Williams
http://houston.bpweb.bp.com/iwells/shared.files/articles/Well-Connected.Iwells-Now-Future.PDF
Oilfield Review Article, Winter 1999-2000 - Downhole Monitoring Schlumberger
http://houston.bpweb.bp.com/iwells/shared.files/articles/Downhole_Monitoring.pdf
Justification and Value of Permanent Downhole Pressure Gauges Report Mike Webster
http://houston.bpweb.bp.com/iwells/shared.files/articles/Gauge Justification.doc
ISIS Project Permanent Downhole Sensor Survivability Report Mike Webster
http://ebrochure.bpweb.bp.com/index.asp?id=7369643D312669643D30
Fundamentals of Bragg Grating Fibre Optic Sensors
http://houston.bpweb.bp.com/iwells/optical.projects/bragg.grating/page1.htm
SPE Paper 71529 The Optic Oilfield – Deployment and Application of Permanent In-well Fibre
Optic Sensing Systems for Production and Reservoir Monitoring
http://houston.bpweb.bp.com/iwells/shared.files/articles/SPE71529.pdf
SPE Paper 71677 Installation of Advanced Completions in the Oseberg 30/9 38B Well
http://houston.bpweb.bp.com/iwells/shared.files/articles/SPE71677_Oseberg.pdf
Oilfield Review Article, Autum 1999 – Controlling Reservoirs from Afar Schlumberger
http://houston.bpweb.bp.com/iwells/shared.files/articles/controlling.pdf
SmartWell Technology Reservoir Management Systems Well Dynamics
http://houston.bpweb.bp.com/iwells/shared.files/articles/welldynamics.pdf
Intelligent Well Systems
Baker Oil Tools
http://houston.bpweb.bp.com/iwells/shared.files/articles/BOT-IWS.pdf
OTC paper: 13031 - Engineered Reliability for Intelligent Well Systems

SPE paper 62955 – Reliability Qualification Testing for Permanently Installed Wellbore Equipment

Page 76

View publication stats