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Contents Page Contents Page Introduction .................................................. 1 Single Zone Completions Retrievable Packer ............................ 4 Seal-bore Packer ............................... 5 Packer-Tail-Pipe Attached ................. 6 Casing Seal Receptacle .................... 7 Multiple Zone Completions 2 Zones 1 Packer .............................. 8 2 Zones 2 Packers ............................ 9 3 Zones 3 Packers ............................ 10 4 Zones 4 Packers ............................ 11 Liner Completions Casing Seal Receptacle .................... 12 CSR and Seal-bore Packer ............... 13 Special Service and Remedial Completions Sand Control ..................................... 14 Inhibitor Injection (1) .......................... 15 Inhibitor Injection (2) .......................... 16 Waterflood (1) .................................... 17 Waterflood (2) .................................... 18 Thermal Completion .......................... 19 RemedialScab Liner ........................ 20 Completion Examples Monobore Producer/Injector .............. 21 7 x 5-1/2-in. Produce/Injector ............ 22 Gas Injector ....................................... 23
Introduction
Note: Artificial lift completions, by their nature, require special consideration and the consideration of several detailed design factors. A description of artificial lift systems including configuration examples are shown in Section 5.
An oil or gas well completion should fulfill the technical requirements for the various phases which exist throughout the life of the well or reservoir, e.g., initial production, treatment/stimulation, artificial lift, workover and abandonment. However, in order to fulfill basic safety and economic requirements of any installation some compromise may be necessary. As the performance of wells, and therefore completions, have become more closely scrutinized, the basic design and component selection process has evolved. This evolutionary process has taken account of the following principal factors. Casing protection i.e., protection against erosion and corrosion which could ultimately jeopardize the integrity of the wellbore.
Tubing removal almost every well will require the tubing string to be removed at some point during its life. This process requires the well to be killed, preferably with minimal invasion of wellbore or kill fluid into the producing formation. Safety safety is considered in two principal areas, (i) the provision of a production safety valve to prevent uncontrolled production, (ii) the provision of a means of circulating, i.e., the tubing string, to enable well kill operations to be conducted. Production control for example, the addition of completion components to control flow (nipples and profiles), allow circulation (sliding sleeves) or flexibility in production (side pocket mandrels. The illustrations in Figure 1 through 4 show the basic types of wellbore construction. Figures 1 through 8 show the development of tubing completions.
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Production zone(s) hydraulically isolated by casing cement More options for selective treatment and isolation
Similar to casing production but with savings associated with shorter casing string and smaller hole diameter through reservoir
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Well kill capability but with no control of annular fluid level and possible exposure to corrosion
Well kill capability through circulation around packer once unset Casing string protected from corrosion and production stresses by inhibited packer fluid
As with basic packer production but with: Downhole isolation (plug) capability Facility for downhole instruments (gauges)
As with basic packer production but with: Downhole isolation (plug) capability above and below the packer Circulation capability through the sliding sleeve without unsetting packer. Production safety valve
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Modern completion designs vary considerably but can be categorized into general completion types. The following section illustrates most of the more common completion types. However, in some circumstances, completions may fall into two or more of the categories shown, e.g., multiple-zone sand control completion.
Name Single Zone Retrievable Packer Recovery/Function Primary recovery Frequency of Usage Common Operational Advantages Flow coupling Fully retrievable completion no permanent components. Packer can be set with well flanged up sliding sleeve allows circulation of kick-off or perforating fluids. Thru-tubing perforation possible where size permits. Tail-pipe facility for pressure and temperature gauges located in no-go nipple below perforated spacer. This protects instruments from turbulence during high production rates. Operational Disadvantages Flow coupling Seating nipple Spacer tube Hydro-trip pressure sub Perforated spacer tube No-Go nipple Wireline entry guide Sliding sleeve Flow coupling
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Name Single Zone Seal-bore Packer Recovery/Function Primary recovery Frequency of Usage Common Operational Advantages Seal-bore packer set on electric line or tubing. On-off connector and tubing anchor allows tubing to be retrieved while leaving the packer and tailpipe in place. Tailpipe can be plugged before the tubing is removed to protect formation from kill fluid or workover fluids. Tailpipe can be retrieved with tubing if required. Operational Disadvantages On-off connector Tubing anchor Seal-bore packer Seating nipple Spacer tube Seating nipple Perforated spacer tube No-Go nipple Wireline entry guide
Production tubing
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Name Packer-Tail-Pipe Atached Recovery/Function Primary recovery Frequency of Usage Less Common Production tubing Operational Advantages Tailpipe permanently attached to packer. Tailpipe plug isolates formation during workover/tubing retrieval. Permits safe thru-tubing perforating. Block and kill system facilitates the killing and control of high-pressure, high volume wells. Operational Disadvantages
Block and kill system Sliding sleeve Tubing anchor Seal-bore packer Millout extension Crossover Flow coupling Seating nipple Spacer tube Flow coupling No-go seating nipple Perforated spacer tube Crossover sub Seating nipple Wireline entry guide
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Control line Name Single Zone CSR Recovery/Function Primary recovery Frequency of Usage Infrequent old design Operational Advantages Tailpipe retrievable separately. Protective sleeve run in CSR during primary and remedial cementing operations Expansion joint allows for tubing movement. Safety valve run and retrieved on wireline. Circulation of well fluid/kill fluid facilitated by sliding sleeve. Operational Disadvantages Casing seal receptacle Seating nipple Retrievable tailpipe hanger Expansion joint Flow coupling Safety valve and nipple Flow coupling
Seating nipple Perforated spacer tube No-go seating nipple Spacer tube Wireline entry guide
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Name Multiple Zone Seal-bore Packer Recovery/Function Primary recovery Frequency of Usage Uncommon Operational Advantages Separate or commingled flow through single production tubing string. Upper zone may be produced through the annulus. Blast joint protects tubular integrity across perforated intervals. On-off connector and tubing anchor allows tubing to be retrieved with lower interval isolated. Seating and polished nipples above and below the blast joint provide for contingency repair in the event of blast joint deterioration. Sliding sleeve or the on-off connector facilitates circulation of well fluids and kill fluid. Operational Disadvantages No-go seating nipple Upper zone produced through casing. Lack of casing protection. Wireline entry guide Flow coupling Seating nipple Blast joint
Flow coupling Sliding sleeve Flow coupling Spacer tube On-off sealing connector Anchor tubing seal assembly Seal-bore packer
Spacer tube
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Name Multiple Zone Multiple Packers Recovery/Function Primary recovery Frequency of Usage Uncommon Operational Advantages Independent production through two tubing strings. Both packers are fully retrievable. Tailpipe instrument facility in both strings. Thru-tubing perforation possible on bottom zone. Blast joint protection Operational Disadvantages Complex downhole design and configuration. Multiple packer system retrieval can be difficult to release.
Flow coupling Seating nipple Flow coupling Flow coupling Sliding sleeve Flow coupling
Dual hydrostatic retrievable packer Flow coupling Seating nipple Flow coupling Hydro-trip pressure sub Perforated spacer tube No-go seating nipple Pinned collar Seating nipple Blast joint Polished nipple Sliding sleeve Hydrostatic retrievable packer
Seating nipple Hydro-trip pressure sub Perforated spacer tube No-go seating nipple Spacer tube Wireline entry guide
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Name Multiple Zone Multiple Packers Recovery/Function Primary recovery Frequency of Usage Uncommon Operational Advantages Several zones produced through one tubing string. Flow controlled by wireline retrievable choke/check valves. By-pass sliding sleeve prevents communication during service work. Up to five zones have been produced using this method. Operational Disadvantages Complex downhole design and configuration. Multiple packer retrieval can be difficult to release. Co-mingled flow limits reservoir management options. By-pass sliding sleeve with choke/check valve in place Retrievable packer On-off sealing connector
Retrievable packer
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Flow coupling Name Multiple Zone Multiple Packers Recovery/Function Primary recovery Frequency of Usage Uncommon Operational Advantages Four zone selective production system, two at a time, with the lower two zones alternating or commingled through the long string. Upper zone produced through the short string with remaining zone being produced through either the short or long string. Shear-out safety joints Seating nipple, polished nipple and blast joints Sliding sleeve Safety connector Dual string retrievable packer Dual hydrostatic retrievable packer Seating nipple Sliding sleeve
Operational Disadvantages Complex downhole design and configuration (System contains 28 major downhole components). Multiple packer retrieval can be difficult to release. Flow capabilities may limit reservoir management options. Shear-out safety joint No-go seating nipple
Sliding sleeve Tubing seal nipples Seal-bore packer Seating nipple Polished nipple Siding sleeve Tubing seal nipples Seal-bore packer No-go seating nipple
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Liner Completions
Name Liner Completion CSR Recovery/Function Primary recovery Frequency of Usage Becoming more common Operational Advantages Simplest liner-type hook-up. CSR replaces packer function. Sliding sleeve permits well fluid or kill fluid circulation. Tailpipe retrieved with production tubing Sliding sleeve Fluted locator sub Liner hanger Production tubing
Operational Disadvantages
Tubing seal nipple Casing seal receptacle Seating nipple Spacer tube No-go seating nipple
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Name Liner Completion CSR and Seal-bore Packer Recovery/Function Primary recovery Frequency of Usage Uncommon Operational Advantages Liner lap/top is permanently isolated. Fluid circulation through sliding sleeve. Tailpipe can be plugged to allow retrieval of tubing string with the producing zone isolated. Sliding sleeve Locator tubing seal assembly Seal-bore packer Seal-bore extension Tubing seal nipple Production tubing
Operational Disadvantages
Tubing seal nipple Casing seal receptacle Seating nipple Spacer tube No-go seating nipple Wireline entry guide
Fig. 18. Liner completion casing seal receptacle and seal-bore packer.
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Name Sand Control Recovery/Function Primary recovery Frequency of Usage Common (regional) Operational Advantages Tools and gravel placed using a service tool and tubing workstring. Gravel squeezed into perforation tunnels. Production tubing stung-in to production seal assembly. Operational Disadvantages Can constrain future reservoir or wellbore treatments
Production tubing
Ported housing
Primary screen
Lower tell-tale
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Name Inhibitor Injection Recovery/Function Primary/Secondary Frequency of Usage Uncommon (field requirements) Operational Advantages Side-pocket mandrel injection permits protection inside production tubing above the packer. Injection nipple and small diameter injection line is suitable for shallow injection requirements. Operational Disadvantages
Side-pocket mandrel with injection valve Anchor tubing seal assembly Seal-bore packer
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Name Inhibitor Injection Recovery/Function Primary/Secondary Frequency of Usage Uncommon (field requirements) Operational Advantages Parallel flow tube and seal-bore packer enables inhibitor to be pumped down short string, through the packer body and into annulus below the packer. All flow-wetted completion components are exposed to inhibitor fluid. Inhibitor controlled by surface injection rate. Operational Disadvantages Check valve assembly Sliding sleeve Anchor parallel flow tube
Seal-bore packer
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Name Waterflood Recovery/Function Primary/Secondary Frequency of Usage Common (offshore) Operational Advantages Two injection zones treated with both flow control regulators located at surface. Totally separate injection systems. Operational Disadvantages Casing string exposed to injection pressures Flow coupling Sliding sleeve Flow coupling Upper injection zone
Retrievable packer
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Name Waterflood Recovery/Function Primary/Secondary Frequency of Usage Common (offshore) Operational Advantages Injection efficiency in thick zones is improved by using multiple injection points Downhole flow regulation prevents premature break-through between intra-zonal sections. Operational Disadvantages Limited control on each zone. Retrievable packer Downhole flow regulator Upper injection zone
Retrievable packer
Retrievable packer
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Name Steamflood Recovery/Function Heavy crude special application Frequency of Usage Limited application Operational Advantages Packer incorporates an integral expansion/slip joint assembly Side-pocket mandrel allows insulation material to becirculated into annulus Operational Disadvantages Design critical hostile environment for materials and elastomers. Seating nipple Side-pocket mandrel
Expansion mandrel
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Name Steamflood Recovery/Function Heavy crude special application Frequency of Usage Limited application Operational Advantages Packer incorporates an integral expansion/slip joint assembly Side-pocket mandrel allows insulation material to becirculated into annulus Operational Disadvantages Design critical hostile environment for materials and elastomers. Seating nipple Side-pocket mandrel
Expansion mandrel
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Monobore completion characteristics Seamless integration of completion components (in ideal conditions) Component ID equal or greater than production tubing Designed to facilitate through tubing well intervention Designed to minimize pressure drops for optimized production Safety valve and associated nipples
Liner
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7 x 5-1/2-in. Produce/Injector
Safety valve control line and downhole gauge line 10-3/4-in. casing Flow coupling Safety valve Flow coupling 7-in. tubing Permanent downhole gauge 7-in. nipple 7-in. to 5-1/2-in. tubing crossover Slick plug landing joint Expansion joint 5-1/2-in. tubing Stinger assembly 9-5/8-in. casing Permanent packer Seating nipple Slick plug landing joint
Liner top packer and tieback seal assembly Collar locator sub 5-1/2-in. liner
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Gas Injector
10-3/4-in. casing
7-in. tubing
7-in. nipple 7-in. to 5-1/2-in. tubing crossover Slick plug landing joint Expansion joint 5-1/2-in. tubing Stinger assembly 9-5/8-in. casing Permanent packer Seating nipple Slick plug landing joint
Liner top packer and tieback seal assembly Collar locator sub 5-1/2-in. liner
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