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Well Completions
Completion Definition
Completion ‐
• After a well is drilled and the hydrocarbon bearing reservoirs have been
After a well is drilled and the hydrocarbon bearing reservoirs have been
established, it needs to be completed to allow the hydrocarbons to flow
from the reservoir to surface.
• Completions are the interface between the reservoir and surface
Completions are the interface between the reservoir and surface
production. The role of the completion designer is to take a well that has
been drilled and convert it into a safe and efficient production or injection
conduit.
•
• The ideal completion is the lowest cost completion (considering initial and
operating cost) that meets or nearly meets the demands placed upon for
most of it life.
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• The aim of completion design is obviously to deliver optimal quantities of
fluid with maximum safety and efficiency throughout the life of the well.
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Completion design is a mix of physics, chemistry, mathematics,
l i d i i i f h i h i h i
engineering, geology, hydraulics, material science and practical hands‐on
wellsite experience.
Completion Categories
Completion ‐
• Completions are categorised in several ways,
common criteria include:
• Wellbore/reservoir interface
– Open hole or cased hole
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• Production method
– Natural flowing or pumped production
• Number of producing zones
Number of producing zones
– Single or multiple zone completion
Open Hole Completion
Open Hole Completion
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The term open hole covers a variety of completion techniques:
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a – Open Hole Completion
Open Hole Completion Complex open hole
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b – Open hole with slotted liner with multi‐laterals
Open Hole Completion
Open Hole Completion
Long Horizontal Section completed Open Hole
Cased Hole Completion
Cased Hole Completion
IIn the cased and perforated completion, Casing is set into or through the
th d d f t d l ti C i i ti t th h th
producing formation and cemented. The casing is then perforated to
provide communication between the well bore and formation.
• Advantages of the Cased Hole Completion
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– Ease of selective completion and work over operation in the producing
intervals.
– Can effectively control gas and water producing by selectively
C ff i l l d d i b l i l
perforating and isolating.
– Can effectively control and monitor zonal fluid production.
– Permits multiple completions.
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– Can stimulate selectively.
– Can fracture selectively.
– DST’s Logs and formations samples provided information on casing
setting depth or abandon.
– Can be deepened, but with smaller hole.
– Can be adopted to sand control, selectively, both as pre‐pack or
conventional gravel pack.
Cased Hole Completion
Cased Hole Completion
Limitations of the Cased Hole and Perforated
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Completions
– Long
Long interval perforation can be expensive.
interval perforation can be expensive
– Effectively well bore diameter and productivity may be
reduced.
– Good cement job through production interval required.
– More expensive than open hole completion.
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– Not adoptable to special drilling techniques to minimize
formation damage.
– Log interpretation sometimes critical in order not to miss
commercial sand, yet avoid perforating submarginal zones
Cased Hole Completion
Cased Hole Completion
• Li
Liner completion is a variation to the cased
l ti i i ti t th d
hole completion. In a liner completion, casing
is lowered much above the pay zone and a
liner hanger is set in the casing Liner is
liner hanger is set in the casing. Liner is
extended through the pay zone Liner is used to
control a sloughing formation.
• Completion using a liner is also to reduce
Completion using a liner is also to reduce
casing cost as it does not reach the surface.
• Liner completion will restrict well bore
completion string diameter
completion string diameter.
• Advantages and disadvantages of the
cemented liner are same as the cased and
perforated completion
perforated completion.
Naturally flowing wells
Naturally flowing wells
• These are wells that flow naturally with the reservoir
These are wells that flow naturally with the reservoir
pressure. These do not need any special techniques
to bring the hydrocarbons to the surface. These are
typically economical to produce. However, in high‐
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temperature, high pressure applications, a great deal
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of highly specialized engineering and design work
will be required to ensure that safety requirements
are met.
• In general, naturally flowing wells require less
complex downhole components and equipment. In
addition the long‐term
addition, the long term reliability and longevity of
reliability and longevity of
the downhole components is generally better than
that of pumped completions.
• In many cases, wells may be flowed naturally during
the initial phases of their life, with some assistance
provided by artificial lift methods as the reservoir is
depleted. Such considerations must be reviewed at
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the time of initial completion to avoid unnecessary
expense and interruption of production.
Artificial Lift Completions
Artificial Lift Completions
All pumped, or artificially lifted, completions require the placement of
All d tifi i ll lift d l ti i th l t f
specialized downhole components. Such components are electrically
or mechanically operated, or are precision engineered devices. These
features often mean the longevity or reliable working life of an
features often mean the longevity or reliable working life of an
artificial lift completion is limited. In addition, the maintenance or
periodic workover requirements will generally be greater than that of a
naturally flowing completion.
naturally flowing completion.
Pumped or assisted lift production methods currently in use include
the following:
the following:
– Gas lift
– Electric submersible pump
– Sucker Rod Pump
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– Plunger lift
– Progressive cavity pump (PCP)
Single Zone Completions
Single Zone Completions
• IIn single zone completions, it is relatively straight forward to produce
i l l ti it i l ti l t i ht f dt d
and control the interval of interest with the minimum of specialized
wellbore or surface equipment. Since typically one conduit or tubing
string in involved the safety installation and production
string in involved, the safety, installation and production
requirements can be easily satisfied.
• IIn most single zone completions, a packer (or isolation device) and
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tubing string is used. This provides protection for the casing or liner
strings and allows the use of flow control devices to control
production.
production
• The complexity of the completion is determined by functional
requirements and economic viability. Several contingency features
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may be installed at a relatively minor cost at the time of the initial
installation. Consequently, consideration must be given to such
options during the initial design phase
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Electrical Submersible Pump System
Electrical Submersible Pump System
• Electrical submersible pump systems (ESPs)
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operate at the bottom of the tubing. Power
reaches the motor via an electrical 3‐phase
cable banded to the tubing from the surface
cable banded to the tubing from the surface
down to the motor. The motor is at the
bottom of the assembly for cooling from the
bottom of the assembly for cooling from the
produced well fluids.
Electrical Submersible Pump System
Electrical Submersible Pump System
Electrical Submersible Pump System
Electrical Submersible Pump System
The System comprises of:
– A downhole pump
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– Electrical power cable
– Surface controls
ESP Characteristics
The standard 60Hz producing range from 100 bbl/D up
The standard 60Hz producing range from 100 bbl/D up
to 90,000 bbl/D
• ESP characteristics are based on a constant rotation speed,
which depends on the frequency of the AC supply:
which depends on the frequency of the AC supply:
• 3500 RPM with 60 Hertz
• 2915 RPM with 50 Hertz
• Currently operated in wells with BHT up to 350 degF
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• Efficiently lifts fluids in wells deeper than 12,000ft
• System efficiency ranges from 18 to 68%
• Has a narrow production rate range
• It does not handle free gas
ESP Typical Installation
ESP Typical Installation
Sucker Rod Pumps
Sucker Rod Pumps
Definition:
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• – “ A sucker rod is the linking involving the surface
• pumping unit and the subsurface pump, which is
pumping unit and the subsurface pump which is
• located at or near the bottom of the oil well”
There are two types of sucker rod pumps in use this days:
There are two types of sucker rod pumps in use this days:
• – Steel Rods: which are manufactured in lengths of 25
or 30 ft.
• – Fibre‐glass Reinforced plastic sucker rods: Which are
supplied in 37 ½ ‐ or 30 ft. lengths.
• – Both of the pumps are connected by a 4inch long
coupling.
Sucker Rod Pumping
Sucker Rod Pumping
• This system uses a vertical positive‐displacement pump
consisting of a cylinder and a hollow plunger with a valve
consisting of a cylinder and a hollow plunger with a valve.
• It is run into the tubing screwed onto the end of the rod
string.
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• The system is actuated from the surface by a motor that
drives a walking beam or a hydraulic elevator.
Sucker Rod Pumps
Sucker Rod Pumps
Sucker Rod Pumps
Sucker Rod Pumps
• Beam pumps are the most widely
used artificial lift method in most oil
companies.
• They are best for low to moderate
They are best for low to moderate
production, primarily on land based
installations.
• Figure shows a beam pump system,
with the motor, gear box, pumping
unit, well head, rod string extending
to the bottom hole pump, and the
pump with a travelling valve and
pump with a travelling valve and
standing valve. A tubing anchor is
included to prevent downhole stroke
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shortening due to tubing movement.
Progressive Cavity Pumps (Moineau
Pump Systems)
• PCP
PCP systems have been historically used for viscous crude or
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to handle solids.
• Operation involves a rotating steel rotor inside a rubber
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stator.
• Cavities are generated between the stator and the rotor and
the cavities move upward as the stator is rotated
the cavities move upward as the stator is rotated.
Progressive Cavity Pumps
Progressive Cavity
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The rotor and stator form series
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of sealed cavities 180oapart.
• They progress from suction to
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discharge end of pump.
• As one cavity decreases the other
increases allowing fluid to move
increases allowing fluid to move
at fixed flow rate proportional to
speed
• Construction
– Stator consists of steel tube with
elastomer, moulded in double
elastomer, moulded in double
helix
– Rotor is chrome plated and
machined in stainless steel.
machined in stainless steel.
Progressive Cavity Pumps
Progressive Cavity Pumps
• Environmental benefits
– Smaller size, fewer moving parts
therefore causing minimum injuries.
• Application flexibility
– Ranges from API 35
f o for light oils to API
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o
8 heavy oils.
– Where gas locking or solids create
problems.
– Can be used in regions which are
populated, farms etc.
• Costs
– Typically from $10,000 to $15,000 for
well depths of 2500 to 3000 ft.
• Efficiency
– 60‐80 %
– High volumetric efficiency
– Higher speed greater efficiency
Single Zone Completions
Single Zone Completions
• In single zone completions, it is relatively straight forward to
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produce and control the interval of interest with the
minimum of specialized wellbore or surface equipment.
Since typically one conduit or tubing string in involved, the
Since typically one conduit or tubing string in involved, the
safety, installation and production requirements can be
easily satisfied.
• In most single zone completions, a packer (or isolation
I t i l l ti k ( i l ti
device) and tubing string is used. This provides protection
for the casing or liner strings and allows the use of flow
control devices to control production.
• The complexity of the completion is determined by
functional requirements and economic viability Several
functional requirements and economic viability. Several
contingency features may be installed at a relatively minor
cost at the time of the initial installation. Consequently,
consideration must be given to such options during the
consideration must be given to such options during the
initial design phase.
Single Zone Completions
Single Zone Completions
Single Zone Completions
Single Zone Completions
Multiple Zone Completions
Multiple Zone Completions
• M
Multiple zone completions are designed to produce
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more than one zone of interest. However, there are
many possible configurations of multiple zone
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completion, some of which allow for selective, rather
than simultaneous production.
– Produce the zones sequentially through a single tubing
string.
– Produce several zones simultaneously through multiple
tubing strings.
– Produce several zones, co‐mingled through a single
P d l i l d th h i l
production string. (Often difficult)
Multiple Zone Completions
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