BRIEF OVERVIEW TO WELL COMPLETIONS, DESIGN, CLASSIFICATION AND

DESCRIPTION OF AN UNCONVENTIONAL WELL

Javier Felipe Ramirez1
ABSTRACT
Completion is defined as the design, selection and installation of pipe, tools and equipment in a well
for the purpose of convergence, pump and control the production or injection fluids (Leal, 2003). The
well completion process have different phases as definition of objectives and design criteria, well
construction scheme, component completion installation, Production start and evaluation and
monitoring of production. There are many different ways to classify the well completion types
according to different parameters as: hole structure/ reservoir interface, number of pay zones,
production methods and technology applied to completion. According to the technology one of most
advanced systems of well completions is the intelligent well system, an intelligent completion well
may be defined as a completion system capable to collecting, transmitting and analyzing wellbore
production, reservoir and completion-integrity data, then enabling remote action to enhance reservoir
control and well production performance, (Robinson, 2003).
These intelligent completion technologies are currently applied to unconventional reservoirs,
formation and environment requirements push toward limits of materials, completions engineers must
learn new materials, construction methods, and application details that were unknown a few years
before, (King, 2012). Within the petroleum engineering, specifically completion engineering
challenges currently, they are the following, among others: heavy oil, deepwater, tight oil and shale
gas well processes. A brief description of one case about heavy oil well completion facing the new
challenges of the industry and developing new completion techniques to adapt to these changes in
operating conditions is presented.
INTRODUCTION
After a well have been drilled, it need be completed before production time, well completions serve
as an interface between the reservoir formation and the Surface production. Different techniques have
been developed for well completion, The completion of wells involves a process that extends far
beyond the installation of pipeline and equipment in the well; completion is defined as the design,
selection and installation of pipe, tools and equipment in a well for the purpose of convergence, pump
and control the production or injection fluids (Leal, 2003). Understanding all the features of each of
the types of completion is vital for optimal system design production; a brief overview of the different
ways for classifying completions is presented. With the advancement of technology, control of well
completion processes, it is more effective, and the use of technologies such as Smart well system, or
Intelligent Well Completion, processes such as control data are improved and optimized. Within
intelligent systems presented a brief overview of nanotechnology applied to the well completions,
relating these applications primarily using electronic tools that facilitate the transmission and
collection of signals, which converted into data to analyze.
Finally, after studying the basic characteristics of conventional completion, types and technology
applied to completion in the article a study related to the new challenges for engineering completion
is done, emphasizing the Colombian case and finally a description of technology applied to a specific
case involving the completion of wells in unconventional settings (Heavy oil) is presented.

Petroleum Engineer, Bogota-Colombia. - jfelipe.9209@gmail.com

1. WELL COMPLETION DESIGN

A sequential and logical design and implementation of the process approach is required. Since the
final efficiency of completion is determined by the procedures and operations performed during each
phase of the life of the well, a process of review and continuous monitoring is required. Typically,
this can be summarized in table 1.
PHASES OF A WELL COMPLETION DESIGN
1
2
3
4
5

Definition of objectives and design criteria

Well construction scheme
Component completion installation
Production start
Evaluation and monitoring of production
Table 1: Phases of a well completion design (Leal, 2003)

Phase N. 1: Definition of objectives and design criteria

This initial phase can be summarized as the collection of data related to the reservoir, the hole and
production parameters. This Data is considered contingency plan and limitations, which may be
technical or non-technical in nature (e.g., Company policies). Some design criteria are listed below:

Required production rate.

Production mechanisms in areas or fields to complete.
Future needs stimulation.
Requirements for sand control
Future repairs.
Considerations for gas lift, mechanical pumping, etc.
Possibilities for future oil recovery projects
Required investment.

Phase N. 2: Well construction scheme

Well construction must be take into account three processes:
2.1 Drilling:
Drilling and associated tasks (e.g., cementing), must be made with extreme vigilance. It has been
accepted that the prevention of damage formations is easy and cheaper than cure. The fluids used for
drilling or cementing, should be properly selected to minimize any possible damage to the formation.
2.2Evaluation:
Similarly, making accurate data related to the producing area is important, based on some further
discussions on the flexibility of technical and economic variables of the proposed completions depend
on the data that is taken at the time.
2.3 Pre-completion:
Often a simulation treatment pre-completion is carried. This part of the evaluation process is a
program Test- Treatment-test.

The selection and proper installation of the components of completion is imperative. The components
can be classified as table 2 illustrates.
Completion component
These are the essential components needed for a
safe operation of completion

Primary completion components

Wellhead
Xmas tree
Pipe
Packers
Safety valve

Provide system
completion.

Auxiliary completion components

flexibility

and

control

Circulation Accessories
Nipples
Injection mandrels
Seal assemblies
Expansion accessories
Pipe separators

Table 2: Some primary and auxiliary completion components (Leal, 2003)

Phase N. 3: Production start

In most cases, this stage of completion is divided into the following stages:
3.1 Starting to establish flow communication between the reservoir and well
3.2 Defining a suitable cleaning program and to allow optimal rate of production safely and without
formation damage, completion components or surface equipment.
3.3 Design of any stimulation or treatment that may be necessary to enable the restoration of
permeability in the reservoir. These treatments may include the following: well cleaning, matrix
acidification, perforations acidification, fracking, acid washing perforations.
Phase N. 4 Evaluation and monitoring of production
An evaluation of the initial production is needed to confirm that the system conditions meet the
production capabilities required to design intent. Subsequent evaluations and inspections exercises
will give the information of the site, the well and the system.
2. TYPES OF COMPLETION
There are many different ways to classify the well completion types. The most common criteria for
the classification of completions includes:

Hole structure/ reservoir interface

Number of pay zones
Production methods

Technology applied to completion

The choice of completion type should be closely coordinated with the development of the reservoir
management plan. For example, the size, weight, and grade of the tubular goods will be determined
based upon the ultimate use of a wellbore. An injection well may require stronger casing than a
production well. The type of completion adopted will depend on the structural/geological
characteristics of the reservoir, and on the type of mineralization. These parameters are listed below
(Olawale, 2014):

Required production rate.

Production mechanisms in areas or fields to complete.
Future needs stimulation.
Requirements for sand control
Future repairs.
Considerations for gas lift, mechanical pumping, etc.
Possibilities for future oil recovery projects
Required investment.

According to hole structure/reservoir interface completions can be divided into three categories: open
hole completions, liner completions, and perforated casing completions.
2.1. HOLE STRUCTURE/ RESERVOIR INTERFACE
2.1.1.

Open hole completions

In open hole completions the pay rock is kept as it is, and no cemented casing columns are needed,
this type of completion can only be possible in consolidated formations, given the possibility of a
collapse. These completions no way to selectively isolate or produce within the reservoir interval or
open hole section. Normally, casing was run as the hole was drilled. When the formation was
penetrated and oil and gas began to flow, drilling ceased and the well was produced as an open hole
completion. As rotary rigs began to drill the majority of the wells, it was still common to complete a
well using an open hole completion.
Figure 1(a) illustrates a typical wellbore diagram for an open hole completion.

Figure 1: Wellbore diagram of (a) an open hole completion and (b) a slotted liner completion. (Holditch,
1993)

One important disadvantage of an openhole completion is that production casing must be set prior to
drilling and logging the reservoir. If for some geological or engineering reason the target formation
is not productive, then money has been spent to set casing in a well that may be plugged as a dry hole.
Another disadvantage is the lack of control that occurs when an open hole completion is made. One
cannot control the flow of fluids from the reservoir into the wellbore nor the injection profile in an
open hole completion. In addition, if the formation is not competent, sloughing zones can cave into
the wellbore and restrict flow to the Surface (Holditch, 1993).

2.1.2.

Liner completions

According to Holditch (1993) Liner completions are similar to open hole completions in that casing
must be set prior to drilling the producing interval. The advantage of a liner completion is that
the drilling fluid system can be changed and a nondamaging fluid used to drill the pay interval.
Several types of liner completions are commonly employed in well completions. These include:

Slotted liner

Screen and liner

Cemented liner

The slotted liner completion is similar to an open hole completion and has all the major advantages
and disadvantages discussed for open hole completions. The only difference is that a slotted liner is
hung in the open hole interval to minimize sloughing of the formation into the well bore (Figure 1b).
A screen and liner completion is similar to the slotted liner completion in that a screen and liner is set
in the open hole section of the wellbore. The difference is that gravel is sometimes placed behind the
screen (Figure 2a). The advantages and disadvantages are the same as for open hole completions. The
screen and liner completion is used primarily in unconsolidated formations to prevent the movement
of formation materials into the wellbore, restricting the flow of reservoir fluids.

Figure 2: Wellbore diagram of (a) a screen and liner completion and (b) a cement liner completion (Holditch,
1993)

The cemented liner completion is used when intermediate casing is set in a well prior to reaching total
depth (Figure 2b). Many times intermediate casing is used to isolate zones behind pipe such as low
pressured intervals that tend to cause lost circulation problems or to isolate zones such as sloughing
shales or salt layers. Intermediate casing is also set in transition zones between normally pressured
intervals and geopressured intervals. After the casing is set, the weight or chemistry of the drilling
fluid can be changed to continue drilling the well. The cemented liner completion is advantageous
because the particular intervals behind the liner can be selectively perforated. This selection will allow
one to control both the production and injection of fluids in those intervals. The main disadvantage
of a cemented liner is the difficulty encountered in obtaining a good primary cement job across the
liner. If a good cement job is obtained, then a cemented liner completion is very similar to a perforated
casing completion.
2.1.3.

Perforated casing completions

A perforated casing completion, illustrated in Figure 3a. The main advantage of this type of
completion is that the well can be drilled and logged to total depth prior to running and cementing
production casing. By obtaining cores and logs of the potential producing interval, one can estimate
the economic value of that wellbore prior to committing funds to complete the well. Another
advantage of a perforated casing completion is that it is easier to obtain a good cement job, compared
to a liner completion. If the primary cementing job is properly performed, one can selectively produce
from, inject into the reservoir, and isolate intervals as required. The production of an unconsolidated
formation can be accomplished by performing an inside gravel pack. Finally, the perforated casing
completion is quite adaptable to multiple completions and alternate completions. Casing and
cementing wells generally require control methods less complicated pressures during the initial stage
of completion.

Figure 3 Wellbore diagram of (a) a perforated completion and (b) a single completion inside perforated
casing (Holditch, 1993).

2.1.4.

Reservoir interface

One of main problems in well production is related with sand production has been
hypothesized as a combined result of mechanical skeleton collapse and viscousflow drag
force that carries loose sand into a cavity. Theoretical solutions based on Darcys law and the
equilibrium equation have been developed. Once cavity geometry is defined, stresses, plastic
strains, and fluid flow near the cavity can be calculated by use of the equilibrium equation,
massconservation principle, plastic-flow rules, and Darcys law. Bottomhole pressure has
been identified as the parameter to correlate directly with sand production, (Wang, 1999)
Several screen types and gravel-packed completions are used as sand control procedures.
2.2. NUMBER OF PAY ZONES
According to the number of pay zones, well completion can be classified in single completions and
multiple completions.
2.2.1.

Single completion

In single completions, it is relatively straightforward to produce and control the range of interest with
a minimum of equipment underground and / or surface. Single well completion is illustrated in figure
3b. Since typically a conduit or tubing string is used, the objectives of security, installation and
production are easy to reach. . A single completion is simple and results in fewer operating problems
and less cost than multiple completions. Single completions are common on land where the reservoirs
are either shallow or very deep. If the formation is very shallow, then drilling costs are minimal and
single completions are usually best. In very deep wells, single completions are preferred because of
the complexity and expense involved with a dual or triple completion in reservoirs deeper than 10,000
ft.
2.2.2.

Multiple completions

In certain cases, multiple completions may provide the best control of reservoir operations. Multiple
completions include the tubing-casing dual, dual tubing strings, and the typical triple completion
consisting of three tubing strings. Where there are several production layers for one fluid, a single
selective completion is used. This system has only one tubing string and several packers that isolate
the various production levels (Illustrated in figure 4a).
The multiple tubing string completion uses, at the most, two or three tubings, isolated by packers and
producing on different levels at the same time (Fig. 4b), The main advantage of multiple completions
is that two or more reservoirs can be simultaneously produced from a single wellbore. If all goes
properly, the economics of using multiple completions can be attractive; however, operating and
workover costs can be quite high. These operational factors must be considered when considering
multiple completions. This solution is useful when the reservoir presents different layers of
mineralization, for example gas and oil, or different types of oil, because it allows us to produce
selectively according to necessity, while keeping production active on various levels at the same time.
Multiple completion can also be a conventional triple convention, which is similar to dual string
completion (Fig 5).

a)

b)

Figure 4: Wellbore diagram of a) Selective single string completion and b) Dual string completion (Alimonti,
2004)

Figure 5 Wellbore diagram of a conventional triple completion. (Holditch, 1993)

2.2.3.

Special considerations for deviated wells

For deviated wells, the multilateral completion technology is applied, in general, completion
technology for multilateral wells combines selective and multiple functions, and has the particular
characteristic of using several holes, which converge into a main well. In fact, the multilateral system
is based on several wells, all derived from one initial well. The number of wells, their orientation,
disposition and inclination to the vertical, as well as the chosen type of completion and isolation, have
led to the development of a number of systems. Figure 6 illustrates a brief description of the systems
currently available, based on the classification provided by the Technology Advancement of
Multilateral (TAML), a group of experts operating in the field as shown figure 6, (Alimonti, 2004)

Figure 6: Multilateral well completion, (Alimonti, 2004).

2.3. PRODUCTION METHODS

According to production method, completion can be classified as natural flow completions and
artificial lift completions. In general, natural flow wells require fewer components and complicated
equipment. Furthermore, the durability of the bottom components, reliability is generally better than
in pumping completions, (Leal, 2003).
All completions using pumps or any other artificial method requires the installation of special bottom
components. These elements are operated electrically or mechanically, and usually means durability
and reliability completions of artificial Lift is limited. Furthermore, maintenance or repair is generally
greater than those naturally flowing wells. Figure 7 shows some artificial lift systems.

Figure 7: Some artificial lift systems, (Alimonti, 2004).

2.4. TECHNOLOGY APPLIED TO COMPLETION

From another point of view, completion can be classified in two categories: conventional completions
and so-called smart completions. The later were introduced with the aim of allowing production
management to take place directly in the well, thus avoiding maintenance work leading to interrupted
production and additional working costs (Alimonti, 2004). The main difference between smart and
conventional completion lies in the use of technological tools for the general diagnosis remotely.
2.4.1.

Smart well systems and Intelligent well completions

The objective of the intelligent-well system is to maximize value, which could include increased
production, improved reserves recovery, minimized capital and operating expenditures. Systems are
monitored and operated to optimize a given parameter by varying, for example, the inflow profile
from various zones or perhaps the gas lift rate. Remote monitoring and control capabilities include:
pressure and temperature sensors; multiphase flowmeters; flow-control devices. These systems
permit a variety of sensors to be packaged together with the hydraulic control devices to provide a
complete intelligent-well completion.
Presently, one of most advanced systems of well completions is the intelligent well system (Also
known as smart wells), however its beginning is related with Intelligent completion well; an
intelligent completion well may be defined as a completion system capable to collecting,
transmitting and analyzing wellbore production, reservoir and completion-integrity data, then
enabling remote action to enhance reservoir control and well production performance, (Robinson,
2003). According to Olawale (2014) Intelligent well completion system typically comprises of three
major components:
Monitoring component; this consists of downhole gauges, sensors, flowmeters, densiometers.
Downhole flow measurements of pressure, temperature, flowrate, phase properties, etc. as required
can be obtained in real time via monitoring component. The data collected proves useful in making
production allocation decisions.

Analytic component; a dedicated, integrated computer, which serves as database and analysis system
to collect and evaluate received signals.
Control system; interval control valves (set of variable chokes along the tubing), manifold valves,
wellhead choke and lift mandrels.
According to Mohamed et al (2014), the intelligent completion has the following advantages:

Downhole real time monitoring (pressure and temperature) for reservoir management.
Reduced well-cost and decreased number of wells to be drilled.
Reduced well intervention cost (wireline and intervention operations)
Maximized production and ultimate recovery.
Commingled and controlled production from zones.

Mohamed et al presented a success intelligent well completion case, with the first intelligent well
installation in UAE offshore field. The well was equipped with three Interval Control Valves (ICVs)
and four permanent downhole gauges (PDHG) with remote control ability to control the flow from
each zone monitoring the real time gauge data.
Specifically the tools used in UAE case are listed below and illustrated in figure 7

Down Hole Monitoring

Flow control valves (ICV)
Pilot Well ICVs type selection
Feed-through production packers
Flat pack
Control line clamps
Splice subs
Safety valve nipple
Tubing hanger and wellhead
Surface control system

Figure 7: Intelligent completion Sketch of a UAE well. (Mohamed et al, 2014)

2.4.1.1. Nanotechnology applied to well completion

Currently smart well systems is more related with nanotechnology applied to well completion;
nanotechnology is the application of Surface science, organic chemistry, molecular biology,
semiconductor physics, microfabrication, etc., fields of science generally, in the engineering of
functional system built from smaller structures, (Olawale, 2014)
Nanocompletions would be defined as the incorporation or, the adaptation of known applications
of potentially viable nanostructures to the development of the components and functionality of well
completion systems, (Olawale, 2014).
Nanothecnology can be considered in intelligent two of well completion components: monitoring
component with nanoactuators and nanotubes; and analytic component with the use of
nanoelectronics, nanoRAM, nanowires.
With the introduction of nanocomponents, the potential benefits, among other, below are realizable.

Risks and costs due technical difficulty in installing complex are reduced by the introduction
of fibrous nanostructures for communicating received signals through tubing Wall at more
reliable and faster rates.
Faster and more refined processing and analysis of large data sets collected with the use of
computing systems with nanochips.

All the same, advantages of nanocompletion, Olawale (2014) affirm that nanotechnology is a new
tool yet to be used in well completion. More research work need to be done in this aspect.

3. UNCONVENTIONAL WELL COMPLETION DESIGN

As formation and environment requirements push toward limits of materials, completions engineers
must learn new materials, construction methods, and application details that were unknown a few
years before. New and adapted technologies are proven drivers to increase recoverable reserves,
(King, 2012). Comparing costs, the major cost in a conventional well is usually drilling. In contrast,
in an unconventional play, the completion cost can easily be the largest component of the well Budget,
(Ross et al, 2014)
In last years, completion practices have undergone an unprecedented era of experimentations and
evolution. While trying to maximize production and minimize cost, operators make a number of
completion decisions, including, (Ross et al, 2014):

Completion systems: plug and perforate vs. Balldrop (sliding sleeve)

Well configuration: cemented/cased hole, open hole, or production liner
Propant concentration and type (e.g. White sand, resin-coat, ceramics)
Fluid volume and type (e.g. water, hydrocarbon)
Fluid additives (e.g. polymers, surfactants)
Pumping horsepower

Within the petroleum engineering, specifically completion engineering challenges currently, they are
the following, among others: heavy oil, deepwater, tight oil and shale gas well processes. A brief

description of one case about heavy oil well completion facing the new challenges of the industry and
developing new completion techniques to adapt to these changes in operating conditions is presented.
In Colombia there are many matures fields where infill wells experience very rapid rise of water cut,
resulting in high water production. Water injection issues, fluid mobility control and re-vitalization
of highly depleted reservoirs are some of challenges of these mature fields. In ultra-heavy oil thermal
recovery developments, steam injection conformance in existing and conventionally completed wells
is necessary to enhance vertical and areal sweep, while integration of new well designs with advanced
IOR-EOR pilot projects and tertiary recovery processes can be a challenge, (Posturas, 2013).
The annual heavy oil production is more than 15 million tons in China and more than 60% or which
are developed by cyclic steam stimulation (CSS) technology. Vacuum insulated tubing (VIT) with
thermal packer is the mostly adopted thermal insulation manner during steam injection progress. This
usually leads two major problems. One is casing integrity issues like casing crack, casing collapse,
and cement sheath damage induced by thermal packers failure or cyclic casing as well as cement
heating. Another problem is frequent injection and production strings transformation, and this leads
to operation cost increasing and high temperature production time wasting especially when CSS is of
short cycle in super-heavy oil or thin thickness reservoirs, (Yue, 2013)
In order to solve the above problems, the vacuum insulated casing (VIC) and relevant integral
completion technique are researched taking well completion, heat insulation and hereafter production
into consideration simultaneously rather than separately. This completion technique injects steam by
VIC while not by VIT and produces in normal tubing, thus eliminates the thermal packers failure
problems, meanwhile, simplifies the injection and production pipe process and saves production time.
As shown in fig. 8 there are roughly three kinds of steam injection techniques by far: injection steam
by bare tubing, by bare tubing with thermal packer, and by vacuum insulated tubing (VIT) with
thermal packer. Of course, there are some sub inventories for the latter techniques.

a)

b)

c)

Figure 8: Schematic of three kinds of steam injection techniques. a) Injection by bare tubing, b) Injection by
bare tubing with thermal packer, c) Injection by VIT with thermal packer, (Yue, 2013)

Yue et al (2013) present a comparison between VIT and VIC processes using the VIC to replace oil
casing above oil formation, and it is cemented as normal oil casing and it cannot be pulled out as a
VIT, as depicted in fig. 9. Meanwhile, in order to let pump and tubing go through, VIC must has
bigger diameter inner pipe and outer pipe. Nonetheless, A VIC body is quite similar with VIT in very
aspects, such as design theory (pipe-in-pipe), vacuum multilayer insulation systems, materials and
bake out process.
Yue et al (2013) conclude that VIC techniques bridges the connection between thermal insulation and
well completion and view thermal insulation as part of well completion that can be thoroughly
pondered among the well's whole life.

Figure 9. Schematic of VIC as part of Well completion, (Yue, 2013)

CONCLUSIONS
For a well completion design is important to consider all selection parameters given by the
characteristics of the well, reservoir and fluids, there are several options for completing a well and
each has different advantages and disadvantages. The most widely used method for high-pressure
reservoir is perforated casing or liner, as it allows better control over production. There are smart
ways to manage and control the production of a well without affecting their normal development,
these methods are applicable to all mechanical systems that can be configured depending on the
configuration of the hole structure, pay zones and production problems.
Currently, unconventional reservoirs represent a challenge for petroleum engineering, but there are
as mentioned methods that facilitate performing completion operations in, for example heavy oil
wells; With the advancement of technology management and monitoring wells at different
(conventional, unconventional, with production problems, etc.) conditions it can be handled
optimally.

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