SPE MISAN CHAPTER

The Fundamentals of
Well Completion Design
Ali Kareem Al-Delfi

Workover & Completion Engineer

PetroChina International Iraq

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 Contents

 Well Life Cycle

 Why To Complete a Well?
 Completion Types
 Number of Completed Zones
 Tubing Specifications
 Lower Completion Assembly

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 Well Life Cycle

1 2 3 4 5 6

Exploration Drilling Plugging &

Completion Production Intervention
Abandonment
• Creating a borehole • The process of • Extracting oil or gas • The final stage of
• Seismic data, that reaches the converting a drilled from the reservoir • The process of
permanently shutting
geological model, target reservoir well into production and transporting it maintaining and
down the well when it
drilled wells data, using a drilling rig. or injection system . to a processing repairing a well.
is no longer
production data. • Involves several • Completion involves facility. • Using a variety of economical or safe to
• Select the well steps, such as site several steps: • Production involves techniques, such as produce.
location. preparation, RM,RU perforating, RIH several steps: wireline, coiled • P&A involves several
• Identify the well drilling, MW, casing, tubing, packers, monitoring, tubing, and steps, such as
type: vertical, cementing, logging, valves, and other measuring, slickline, to access isolating the reservoir
the wellbore and from the wellbore by
horizobtal testing, and downhole and optimizing,
make repairs. setting plugs or
evaluation. surface equipment. maintaining.
cement across it.

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 Well Schematic

36'' Hole 30'' Conductor

26'' Hole 20'' Surface Casing

17 1/2'' Hole 13 3/8'' Intermediate

Casing

12 1/4'' Hole 9 5/8'‘ Intermediate

Casing

8 1/2'' Hole 7'' Production Casing

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 Well Completion

 After the well is drilled, casing ran and cemented in place,

the well is ready for the completion process to begin.

 Well Completion: it is the process of converting a drilled

hole into a safe and efficient production or injection system.

 It consists of a series of operations that are necessary to

enable well to produce and to sustain the production.

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 Why To Complete a Well?

 Protect the casing

 Provide optimum flowing conditions
 Enable tubing to annulus circulation
 Enable down hole chemical injection
 Enable killing the well

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 Completion Design Considerations

 Reservoir characteristics
 Well depth
 Stimulation Requirements
 Desired production rates
 Budget
 Workover Requirements

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 Completion Types

1. Open Hole Completion

2. Cased hole completion
3. Liner completion

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 Open Hole Completion

• Simplest type of completion.

• The production casing shoe set above the

reservoir section.

• The well is produced directly from the

open hole.

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 Open Hole Completion
Advantages Disadvantages
 It is the least expensive completion technique, as it x Difficult to control the excessive gas or water
avoids the cost and complexity of perforating, casing, production because the entire interval is open to flow.
and cementing. x Separate zones within the completion cannot be
 The entire pay zone is open to the wellbore stimulated selectively.
 Log interpretation is not critical since the entire x It is difficult to perform selective well stimulation.
Interval is open to flow x It is prone to sand production.
 Maximum wellbore diameter is opposite the pay zone
 The well can easily be deepened
 Easy conversion to liner or perforated casing
completion
 No formation damage caused by cement and
perforation

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 Cased hole completion

• The most Completion used type

• Running a production casing

across the producing formation

and cementing it in place, then

perforate.

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 Cased hole completion
Advantages Disadvantages
 It provides better zonal isolation. x It is more expensive and complex than open
 Excessive water or gas production may be hole completion, as it requires perforating,
controlled or eliminated. casing, and cementing operations.
 Formation can be selectively stimulated. x It may create skin damage around the
 Protection against hole collapse. perforation zone
x Well bore diameter through the pay zone(s) is
restricted.
x Log interpretation critical.

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 Liner completion

o Liner completions are a type of well completion that involves running a

liner, which is a short section of casing, across the producing formation
and attaching it to the production casing with a liner hanger.
o Un-cemented liner is installed across the pay zone.
o Types of Liner Completion are:
• Slotted Liner
• Wire Wrapped Screen Liner
• Pre-Packed Screen Liner

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 Liner completion
Advantages Disadvantages
 It can reduce the cost and complexity of x Selective stimulation is not possible
perforating, casing, and cementing operations. x Excessive water or gas difficult to control
 It protects the formation from damage caused x Diameter across the pay zone is reduced.
by drilling fluids, cement, or perforations. x Liner completions are more complex to install
 Entire pay zone is open to the wellbore.
 It can provide some protection and support to
the formation, especially in unconsolidated or
sloughing zones.
 Reduced sand production by providing a barrier
between the casing and the formation.

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 Slotted Liner

• Act as filters to prevent or reduce

the sand production from the

reservoir.

• Simple and inexpensive

• Only partial sand control.

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 Wire Wrapped Screen Liner

 It uses a screen that is wrapped

with wire.
 The wire wrapped screen acts as
a filter to prevent or reduce the
sand production from the
reservoir.

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17
 Pre-Packed Screen Liner
• It is a liner with pre-milled holes covered with
wire mesh or metal plates, with gravel pre-
packed between two concentric screens
across the producing formation without any
cement.
• The gravel acts as a filter for the formation
sand and the screen prevents the gravel from
entering the wellbore.
• This type of completion provides better sand
control than a slotted liner or a screen
completion, as it prevents finer particles from
entering the wellbore.

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Pre-Packed Screen Liner

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 Number of Completed Zones

1. Single Zone

2. Multiple Zone

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Single Zone / Single String

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Interval Co-Mingling

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Dual Zone / Single String

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Dual Zone / Dual String

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Dual Zone / Dual String

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Multi Zone / Multi String

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Interval Segregation

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Completion String

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 Tubing
o Tubing is a small-diameter pipe that is run into a well to serve as a conduit for the passage
of oil and gas to the surface or to inject fluids into the reservoir.
o The tubing makes up the largest portion of the completion tubing string.

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 Tubing
Functions:
 It transports the production fluids from the reservoir to the surface or the
injects fluids from the surface to the reservoir.
 It isolates the production fluids from the casing which protects it from
corrosion, erosion, scaling.
 It allows the installation and operation of various artificial lift methods, such
as gas lift, ESP, or others.
 It enables the control and measurement of the flow rate, pressure,
temperature, and other properties of the production or injection fluids.
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 Tubing
Why we don’t produce from casing?
Tubing has a smaller diameter than casing, this can increase the production
rate.
Tubing is easier to install and remove than casing. It can be replaced or
repaired more quickly and cheaply if it gets damaged or corroded.
Tubing isolates the production fluids from the casing, which protects the casing
from corrosion, erosion, scaling,
Tubing allows to use various artificial lift methods, such as gas lift, ESP.
Tubing is less expensive than casing.

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 Tubing Specifications
Size Weight Range

Tubing, 3 ½", L-80, 9.3 PPF, EUE, R2

Grade Connection

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 Tubing Specifications
Size:
 The outside diameter of the tubing, usually measured in inches.
 The most common sizes are 2-3/8", 2-7/8", 3-1/2" and 4-1/2”

Weight:
 This is the average linear weight of the tubing, including the connection,
usually measured in pounds per foot (lb/ft).
 The weight determines the wall thickness and the mechanical strength of
the tubing.
 The weight can vary depending on the grade and type of the tubing. For
example, a 3-1/2" tubing can have a weight of 9.3 lb/ft for L-80 grade or
12.95 lb/ft for P-110 grade

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 Tubing Specifications

Grade:
 The steel grade of the tubing, which indicates its chemical composition and
mechanical properties, such as yield strength, tensile strength, hardness,
and ductility.
 The grade affects the resistance and performance of the tubing under
different well conditions, such as pressure, temperature, corrosion, erosion,
or fatigue.
 API grades of steel: H-40, J-55, K-55, C-75, L-80, N-80, C-95, P-105, and
P-110. (character + two digit figure) (Two digit figure X 1000 PSI = yield strength)
 Yield Strength: is the max. stress which the tubing can withstand before
permanent deformation (Don’t Exceed 80% of tubing yield strength)

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 Tubing Specifications
Connection:
 This is the type of joint and connector used to connect each tubing joint.
 The tubing connection thread can be either API or non API (Premium),
depending on the type and specification of the tubing.
 API connections can be either non-upset (NUE) or external upset (EUE).
 Some examples of non API connections are VAM TOP, Hydril joint, and VA
Superior….
Range
 This is the length range of each tubing joint, excluding the pin thread.
 Range 1: from 20 to 24 ft
 Range 2: from 28 to 32 ft
 Range 3: from 38 to 42 ft

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 Tubing Pup Joint
• A tubing pup joint is a short piece of tubing that is used to
connect the production to adjust the length of the tubing string.
• It is also called a spacer or a saver sub.
• It can have different sizes, diameters, and lengths.
• It has the same Tubing specifications.
• Lengths of pup joints are: 0.5, 1, 1.2, 1.5, 2, 2.5,.. m

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 Tubing Crossover
• A tubing crossover (X-over) is a type of crossover that is used
to connect two different sizes or types of tubing in a well
completion.

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 Packer
 A production packer is a sub-surface component used to provide a seal
between the casing and the tubing in a well.

Slips

Packing Element

Slips

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 Packer
Packer Functions:
 To protect the casing from the corrosive effects of the fluids in the
reservoir.
 To isolate different zones in the reservoir.
 To prevent downhole movement of the tubing string. (anchor the
tubing)
 To allow fluids from a reservoir to be produced to surface facilities
through the production tubing.
 To test the well (DST)
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Packer

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 Packer
Packer Types:

Retrievable Packers 01 Permanent Packers 02

Permanent –
03 Retrievable Packers 04 Inflatable Packers

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 Packer
Packer Setting:
O1

Mechanical-set Packers
02

03 Hydraulic-set Packers

Wireline-set Packers

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 SSD
• A sliding side door allows communication between the tubing and the annulus.
• Consist of two concentric sleeves, each with slots or holes. The inner sleeve
can be moved to align the openings to provide a communication path for the
circulation of fluids.
Inner
Sleeve

Port

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 SSD
SSD Functions:
 Selective Zone Isolation
 Dual well production
 Kill / circulation path above packer

SSD Types:
 Jar up to open
 Jar down to open

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 SSD

Closed Position

Open Position

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 SSSV

• Sub-Surface Safety Valve (SSSV) is a device that designed to

automatically shut in the well in the event of a potential disaster.
• Such scenarios could involve severe:
 Damage to the wellhead
 Malfunction of surface equipment
 Fire at the surface
• It is placed at a depth which varies from 100 ft to 2,000 ft below the
seabed.
• It is generally recommended that a safety valve is installed in a well that is
capable of sustaining natural flow.

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SSSV

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 SSSV
Valve Closure Types:
 Ball Closure Mechanism
 Flapper Closure Mechanism

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 SSSV
SSSV Types:
 Wireline Retrievable Safety Valve (WRSV):
• retrieved for inspection, changed by wireline
(rigless operation)
• restricted bore, short service life
 Tubing Retrievable Safety Valve (TRSV):
• Part of the tubing, larger flow area, allows wireline
and CT to pass, Provision secondary WLRSV in the
event the TRSV fails
• If TRSV failure need to POOH all string

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 Flow Coupling

 A flow coupling is a short, heavy-walled component that is installed in areas

where turbulence is expected in the flow of fluids from the reservoir to the
surface.
 The flow coupling has a thicker wall than the tubing to prevent erosion and
failure due to the high-velocity flow.
 Flow couplings are usually placed above and below devices that may affect the
flow, such as SSSV.

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 Nipple
• A landing nipple is a device that is installed in the well
completion tubing to provide a specific location for
subsurface flow control equipment.
• It is run below the packer.
• It is has internally profile which can accommodate and
secure a locking device called a lock mandrel
• It has a reduced bore that prevents the flow control
devices from passing through and a locking recess
that allows the devices to lock and seal in the nipple.
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 Nipple
Nipple Functions:
• To set hydraulic packers
• To isolate the tubing
• To test the tubing
• To land wireline retrievable flow controls, such as plugs, tubing safety
valves, bottom-hole chokes, and regulators
• To plug the well if the X-tree must be removed
• To land bottom-hole pressure gauges
• To temporarily plug the well while the rig is moved on or off the well

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 Ball Seat

• A ball seat is a pressure actuated device installed in

tubing string below the packer.
• It is designed to provide a temporary tubing plug in
order to set the hydraulic packer.
• One tubing ID after shearing.

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 WREG

• Wireline reentry guide is used for safe reentry of

wireline tools from the casing into the tubing string.
• The lowest component in the tubing string.
• Threaded on the top end only.
• It has internal bevel.

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 Tubing Hanger

• A device attached to the topmost tubing joint in the

wellhead to support the tubing string.
• The tubing hanger typically is located in the tubing
head, with both components incorporating a sealing
system to ensure that the tubing conduit and
annulus are hydraulically isolated.

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Completion String

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Hydraulic-set Packer

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 THANK YOU

Does anyone have any questions?

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