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Completions Basics
Completion Basics – What we will cover
• Part 1
• Part 2
• Completion Space Out Practices
COMPLETIONS BASICS: PART 1
Completion: Definition
• Reservoir
• Surface Facilities
• Casing & Tubing
• Perforating
• Downhole Completion Tools
– Flow Control System
– Sub-Surface Safety System
– Packer System
– Sand Control
– Inflatables
– Liner Hangers
– Instrumentation
– Chemical Injection
• Well Servicing and Workover
Reservoir Definition
A porous, permeable rock body in which
hydrocarbons have accumulated.
Non-Flowing:
• Reservoir pressure is less than hydrostatic
pressure created by the fluids in the
wellbore.
• Various methods used to flow fluid to
surface:
– Decrease hydrostatic head
– Pump fluids to surface
Reservoir Considerations
Artificial Lift
• Generally required
• Supplements reservoir energy
– Sucker Rod Pumping (80%)*
– Gas Lift (10%)*
– Hydraulic Pumping (5%)*
– Electrical Submersible Pump (5%)*
Exception
• Prolific water drive
• Waterflood
• CO2 Flood
• Chemical Injection
• Steam Injection
• Fireflood
Casing & Tubing: Definition
CASING:
Pipe that lines the borehole.
• Prevent caving of the hole.
• Prevent contamination of fresh water zones.
• Provide well control while drilling.
• Provide smooth borehole of known dimensions.
TUBING:
Concentric pipe run inside the casing through which
the hydrocarbons flow.
• Provide isolation of fluid and pressures from the casing.
• Provide well control, production control, stimulation
control.
• Provide a retrievable “replaceable” pipeline.
Casing Types
• Conductor
– OD= 16-30”; Depth= 40-400’
• Surface
– OD= 7-20”; Depth= up to 1500’
• Intermediate
– OD= 7-13-3/8”; Depth= Varies
• Production
– OD= Varies; Depth= Varies
• Liner
– OD= Varies; Depth= Varies
Casing & Tubing: Specifications & Properties
Specifications:
• Joint Length
• Outside / Inside Diameter
• Drift Diameter
• Threaded Connection
• Pipe Thickness
• Steel Grade / Alloy Type (CRA)
– L80: L - type of steel,
80- 80,000 psi MYS
Properties:
• Burst
• Collapse
• Joint Yield Strength
• Corrosion Resistance
Perforating: Function & Types
Provide communication from formation
to cemented and cased wellbore.
Conveyance:
• Wireline
• Electrically Actuated
• Thru-Tubing
• Hollow Tube Carrier Casing Guns
• Tubing Conveyed Perforating (TCP)
Actuation Methods:
• Mechanically
• Pressure Actuated
• Absolute
• Differential
Downhole Tools: Function & Types
Types:
• Flow Control System
• Sub-Surface Safety System
• Packer System
• Sand Control
• Liner Hangers
• Instrumentation
• Chemical Injection
Considerations:
• Temperature, Pressure, & Material
Considerations
• Tubing loads
• Completion Installation
– Actuation/Setting/Retrieving Method
– Degrees of freedom
• Landing flexibility
– Tension, compression or neutral?
• Compatibility
Flow Control Systems: Function & Types
Devices that control the flow of fluids
downhole.
• Functions:
– Plug the tubing.
– Isolate zones.
– Check flow in either direction.
– Choke the flow in either direction.
– Selectively communicate between the
tubing and the annulus.
• Types:
– Tubing Mounted
– Slickline, E-Line, Coiled Tubing
Conveyed
– Running & Pulling Tools
Flow Control: Seating Nipples & Blanking Plugs
Flow Control: Sliding Sleeve
Sub-Surface Safety Systems: Function & Considerations
• Considerations:
– Regulatory requirements
– Setting Depth
• Crater depth
• Hydrate formation depth
• Kick off depth and angles
• “Fail safe” setting depth
– Subsea Completion
• Types:
– Tubing Retrievable
– Wireline Retrievable
Sub-Surface Safety Valve: Tubing Retrievable
Sub-Surface Safety Valve: Wireline Retrievable (Less Lock)
Sub-Surface Safety Valve: Tubing Vs. Wireline Retrievable
Function:
• Production Control
• Production Testing
• Protection of Equipment
• Well Repair and Well
Stimulation
• Safety
Types:
• Retrievable
• Permanent
Packer: Permanents & Seal Assemblies
Packer: Retrievable
Packer: Permanent Vs. Retrievable
Permanents Retrievables
Advantages Advantages
• Performance envelopes • Retrievable without milling
• Generally higher pressure • Reusable
ratings • Some can be resettable
• Packer to tubing seals
retrieved without packer Disadvantages
• Hold pressure from above or • Packer normally retrieved on
below without set-down weight production tubing
or tension • Generally smaller I. D.’s
Disadvantages • Generally lower pressure ratings
• Must be milled over to retrieve
• Not reusable
Packer: Permanents Vs. Retrievables
Other Systems: Functions
Sand Control
• Prevent production of sand by means of a
sand screen or gravel packed screen.
Liner Hanger
• Provide a polished bore receptacle for
future “tieback” with production tubing.
Inflatables
• Provides a versatile sealing system for open
hole, thru-tubing, and for a wide range of
workover operations
Continuous Injection System
• Minimize or prevent corrosion by injection
of chemicals via control line through
downhole mandrel.
Instrumentation
• Manage reservoir by knowing pressure and
temperature obtained from downhole
gauges.
Remedial Systems
• Well Stimulation
– Hydraulic Fracturing
– Acidizing
• Re-perforation
• Fishing
• Remedial Cement Jobs
• Zone Isolation
• Water Shut-Off
• Secondary Recovery
• Plug & Abandon
Completion Basics: Conclusion
To design a completion, you have to be
familiar with a lot of systems and how
they relate to each other.
• Reservoir
• Surface Facilities
• Casing & Tubing
• Perforating
• Downhole Completion Tools
– Flow Control System
– Sub-Surface Safety System
– Packer System
– Sand Control
– Inflatables
– Liner Hangers
– Instrumentation
– Chemical Injection
• Remedial Systems
COMPLETIONS BASICS: PART 2
Completion Design: Reservoir
• Drainage
– Vertical
– Horizontal
– Extended Reach
– Multi-Lateral
• Recovery
– Primary
• Flowing
• Artificial Lift
– Secondary
• Pressure maintenance
• Waterflood
• CO2 flood
• Steam injection
• Well Type
– Production
– Injection
– Disposal
– Storage
Completion Design Well Configuration
• Number of Zones
– Single
– Multiple-
• Selective
• Co-Mingled
• Tubing Strings
– Tubingless
– Single
– Concentric
– Dual
• Formation Interface
– Open Hole
– Slotted Liner
– Sand Exclusion
– Perforated Casing
Completion Design Well Requirements
• Tubulars
– Tensile & Compressive Ratings
– Burst & Collapse Ratings
– Material Requirements
• Wellbore Construction
– Slimhole
– Monobore
– Setting Method
– Number of Trips & Interventions required for setting
• Completion Installation
– Number of Trips Required
– Degrees of Freedom
– Remote Actuation
• "Work-Over” Flexibility
• Intelligent Completions
Applications
• Simple.
• One Trip.
• Injection/Production.
• Limited applications.
• Well control issues
Mechanical Tension Set Packer
• Simple.
• One Trip.
• Set with tubing manipulation.
• Production/Injection mostly.
• Tubemove required.
• Medium to high pressure.
• Moderate temperature.
Mechanical Compression Set Packer
• Simple.
• One Trip.
• Set with tubing manipulation.
• Production mostly.
• Tubemove required.
• Medium to high pressure.
• Moderate temperature.
Hydraulic Set Packer Completion
• Simple.
• One Trip.
• Hydraulic/Hydrostatic.
• Injection/Production.
• Tubemove critical.
• Medium pressure.
• Moderate temperature.
Seal Bore Packer Completion
• Simple.
• Two Trip.
• Packer set with WL or tubing.
• Production/Injection.
• Tubemove required.
• Medium to high pressure.
• Moderate to High temperatures.
Fracturing/Stimulation Completion
• Simple.
• One Trip.
• Packer set with WL or
tubing.
• High tensile loads.
• High differential
pressures.
• Tubemove required.
• Normally run with an On-
Off Tool above packer.
Fracturing Requiring Zone Isolation Completion
• Several options on
packers.
• Mechanically actuated
shut-off valve above
packer.
• No slick line required, no
plastic coating.
Applications
MULTIPLE ZONE
COMPLETIONS
Multizone Waterflood Injector Completion
• Multiple Packer.
• Top tension packers just for
isolation.
• Waterflood mandrels and
regulators between packers.
• Low cost.
Single String Selective Completion
DUAL COMPLETIONS
One Trip Dual Completion
• One Trip
• Hydraulic set Packer.
• Multiple GLM’s.
• SCSSSV.
Chemical Injection
HP/HT COMPLETIONS
HP/ HT Single Zone Completion
ESP COMPLETIONS
Single Zone ESP Completion
• Non-Feedthru Packer.
• Multiple trip completion.
• Q-22 SS to control
formation when retrieving
ESP.
Single Zone ESP With Wireline Access
Topics covered:
• Measurements
• Pipe stretch
• Neutral, compression and tension space outs
• Space out procedures
• Specific tool space outs
• Examples and problems
Completion Space Out Practices
• Completion Equipment
– Measure OD, ID and Length off all tools being ran including
setting tools.
– Draw and dimension a sketch for complicated hookups.
– Measure internal lengths, how far will the seals sting into a
packer?
Completion Space Out Practices
Pipe Stretch
• Tension Space Out means the entire tubing string will be in tension.
The tubing hanger will be loaded by the string weight plus the tensile
force applied to the packer.
• Calculate on what joint you should tag the packer, Record Pick
• Up and Slack Off weight a couple of stands before tagging up.
• Slack Off until you see the seals enter packer bore then measure in
the seal length, or slack off until you see the weight indicator drop
off, set down to engage the anchor. Pull tension to verify that anchor
is latched. Pull the required tension over the Pick Up weight. Mark the
pipe and test the annulus.
• Release anchor and space out to mark.
Completion Space Out Practices
Space Out Procedures
• The pipe should be marked at the slips/rotary from the previous operation.
• Measure the elevation (distance between the slips/rotary to the hanger hold
down pins on the spool). Record this distance.
• Pull the joint you tagged up with and measure from your space out mark to
the last thread shouldered on the pin.
• Pull 2-3 joints depending on elevation, number and measure them.
• Pull one more joint to be used as a slick joint and measure it also.
• Total up all joints pulled including the partial length of the joint marked for
space out.
• Subtract the elevation, length of the slick joint, the portion of the tubing
hanger from the pins down (if used), and the double pin sub if used.
• The remaining length will be compromised of pup joints. Add up various
combinations of pup joints to get the required length.
Completion Space Out Practices
• On neutral or compression space outs when you land the tubing hanger your last
motion will be down. Always mark your tubing for space out after you have made your
last motion down. Especially in deviated holes with large differences between pick up
and slack off.
• With a tension space out you cannot install the tubing hanger until after the anchor is
latched up. You have to latch up the anchor and then pull tension into the string. Set
the slips, break out the landing joint, install the hanger and the landing joint.
• To space out high, mark the pipe and space it out like the neutral space out. Subtract
how far you want to space out high from your required length before you figure in the
pup joints. Treat the desired high space out like a pup joint.
• Most mechanical set packers are spaced out to the nearest joint. Mechanical set
packers also require a certain amount of stroke to set. The stroke needs to be added
on to the required compression. This will tell you how “high” you need to start setting
the packer.
Completion Space Out Practices
Examples and Problems:
• Elevation: 64.50’
• hanger: 0.89’
• Double pin sub: 1.33’
• tagged up 29.30’ in joint 365
• 364: 31.60
• 363: 31.48
• 362: 31.51
• Lay out #1- 29.30
– #2-31.60
– #3-31.48
– #4- 31.51 (slick joint)
– total=123.89
– elev 64.50
– subtract the slick joint 31.51 and hanger 0.89 and DPS 1.33
– total 25.66’ of pup joints
Completion Space Out Practices
Examples and Problems
How far above the bowl on the wellhead should the hanger
be when we slack off to set the packer?
SPACE OUT PROBLEMS
1. How many joints of tubing & how many pup joints of what length should be used?
2. How much stretch will there be in tubing when landed? Disregard any effects of tension & temperature on tubing length.
This is purely an exercise in working with Tubing Tally, pup joints, correction, etc. We recognize that there are a great many
variations in procedures, all of which are customized to well conditions and customer requirements.
NIPPLE-UP PROBLEM #1
• In general we would normally latch into packer, pull
required tension, mark tubing at landing point, get loose
from packer, substitute appropriate pups for marked
landing joint, latch into packer again with landing joint,
pull required tension, install the hanger, land tubing, & lay
down landing joint.
• PLEASE SHOW ALL CALCULATIONS!
NIPPLE-UP PROBLEM #2
BCD Oil Company Lease B Well #2
Packer is set at 7810.00' RKB (RKB 22' AGL). Top of solid Doughnut Hanger to be set at ground level.
7" 23 lb/ft Casing..
2-3/8" 4.7 lb/ft N-80 Tubing.
And a Locator Tubing Seal Assembly.
Top of Tubing Seal Assembly to Locator 1.52 ft
Top of Seals to bottom of Production Tube 7.25 ft
We want 6000 lb↓ on packer.
Tubing Hanger .5' below surface level.
Total tubing on location 7919.5', a total of 259 joints.
The last column of Tally Sheet looks like this.
Pups on location are 4.62, 4.78, 8.12, 10.07, 2.04.
Locator Seal Assembly to be landed on Model "D" Set at 6344.45' RKB, then tubing landed in neutral at packer when
tubing is landed in surface tubing hanger.
This is purely an exercise in working with Tubing Tally, pup joints, etc. We recognize that there are a great many
variations in procedures, all of which are customized to well conditions and customer requirements.
NIPPLE-UP PROBLEM #3
Problem is:
1. How much slack-off, in inches, is necessary on surface
to get 6000 lb↓ on packer? Give the weight (lb)
necessary on surface?
2. How many joints in hole?
3. How many pups of what length should be used