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A well completion system must provide a means of oil or gas production which is: Safe - e.g., well security, environment Efficient -.e.g, production objectives Economic - vs. Revenue 4 Completion History / Evolution 1300 Marco Polo - wells dug at Caspian Sea 1814 First naturally flowing oil well - 475 ft 1822 Rudimentary art of drilling established 1905 casing cemented 1911 First gas lift device 1913
A well completion system must provide a means of oil or gas production which is: Safe - e.g., well security, environment Efficient -.e.g, production objectives Economic - vs. Revenue 4 Completion History / Evolution 1300 Marco Polo - wells dug at Caspian Sea 1814 First naturally flowing oil well - 475 ft 1822 Rudimentary art of drilling established 1905 casing cemented 1911 First gas lift device 1913
A well completion system must provide a means of oil or gas production which is: Safe - e.g., well security, environment Efficient -.e.g, production objectives Economic - vs. Revenue 4 Completion History / Evolution 1300 Marco Polo - wells dug at Caspian Sea 1814 First naturally flowing oil well - 475 ft 1822 Rudimentary art of drilling established 1905 casing cemented 1911 First gas lift device 1913
Completion Definition Definition: The methodology and technology required to produce recoverable reserves (reservoir to surface).
Process: The design, selection and installation of tubulars, tools and equipment, located in the wellbore, for the purpose of conveying, pumping or controlling production (or injection) fluids.
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Fundamental Requirements A completion system must provide a means of oil or gas production which is: Safe e.g., well security, environment Efficient e.g., production objectives Economic e.g., cost vs. revenue 4
Completion History/Evolution 1300 Marco Polo wells dug at Caspian Sea 1814 First naturally flowing oil well 475 ft 1822 Rudimentary art of drilling established 1905 Casing cemented 1911 First gas lift device 1913 First dual completion 1926 First electric submersible pump 1933 First gun perforation job 1969 Commercial coiled tubing services introduced 5
Completion System Design Openhole or Cased Hole Eruptive or Pumped Single or Multiple Zone Gross production rate Well depth and reservoir pressure Formation properties Fluid properties Well location 6
Openhole Completions (Barefoot) Conductor with openhole No ground water protection Casing string with openhole Provides top-hole stability Liner with openhole Cross-flow protection Reservoir Cap Rock Openhole Completion Gravel Pack Completion 7
Perforated Completions Casing or liner Without production tubing Casing or liner with production tubing Production through tubing or annulus Casing or liner with tubing and packer Production through tubing, enables flow control Reservoir Cap Rock Cemented casing Cemented liner 8
Modern Completion Configuration Four zone selective production system Dual production strings Commingled or alternate production controlled by sliding sleeves System contains 28 major downhole components 9
Factors Affecting Well Performance
1 Reservoir boundary Can be estimated 2 Reservoir properties Can be measured 3 Completion Can be controlled 10
Vertical Wellbore Profile Vertical wellbore No great productivity benefit May catch unwanted water or gas Preferred for fracturing Cap rock Basement 11
Deviated Wellbore Profile Cap rock Basement Deviated wellbore Increased productivity especially in thin reservoirs Extends reach within reservoir 12
Horizontal Wellbore Profile Horizontal wellbore Significant increase in productivity Reduced influence of skin Reduced influence on coning Cap rock Water zone 13
Oil and Gas Well Completions Completion Design and Engineering 14
Multiphase Fluid Flow Principal multiphase flow regimes recognised in oil and gas wells: Bubble flow Slug flow Transition or churn flow Annular or mist flow 15
Bubble Flow Bubble flow characterized by: Small evenly distributed gas bubbles Continuous liquid phase Further categorized as: Bubbly flow Dispersed bubble flow Small gas bubbles evenly distributed throughout liquid phase 16
Slug Flow Slug flow characterized by: Series of gas pockets between slugs of liquid Continuous liquid phase Taylor bubbles Bubbles of varying size unevenly distributed throughout liquid phase 17
Annular/Mist Annular/mist flow characterized by: Continuous gas phase Entrained liquid in gas flow (mist) Annular liquid film Continuous gas phase Annular fluid film 18
Transition/Churn Flow Transition flow characterized by: Chaotic flow pattern Neither phase is continuous Liquid appears to move both up and down the conduit Chaotic flow pattern 19
Tubing String Specification Tubing strings specified by the following: Size and dimensions OD Weight and wall thickness Coupling OD Material grade Minimum yield strength Construction Seamless/electric welded pipe Tool joint Nonupset/Upset Premium thread 21
Tubing Connections - Integral EUE Integral Connection Hydril Integral Connection 23
String Design Factors Criteria for string selection/design include: Pressure and tension < 80% of tubing yield strength burst and collapse pressure limitations Production rate flowrate should be compatible with flow area Wellbore environment fluid properties, e.g., corrosion, wellbore deposits Tubular connections and geometry e.g., tool joints and annular clearance Force and stress throughout the life of the completion 24
Tubing Forces Forces and stresses on the completion can be effected by: Temperature temperature changes Pressure pressure changes Weight of components Fluid density and gradients Friction especially in deviated wellbores 25
Tubing Movement- Packers Limited motion No motion Free motion 26
Buoyancy 1 Open tubing 4 Plugged string 3 Tapered string 2 Tapered string A C B D A C B A 27
Length and Force Changes Length and forces changes should be assessed to enable: Selection of an appropriate packer Assessment of potential tubing damage Accurate space out and landing of the completion Four principal causes of length and force changes: Piston effect Buckling effect Ballooning effect Temperature effect 28
Buckling Effect Radial clearance Bowed tubing Compression buckling Neutral point R R = Casing ID - Tubing OD 2 Casing wall contact 29
Pressure Buckling Tubing deflection acts to increase tension High pressure Low pressure 30
Ballooning Effect High pressure Low pressure Acts to shorten the string increasing tension 31
Reverse Ballooning High pressure Low pressure Acts to lengthen the string reducing tension 32
Temperature Effect
H E A T Neutral (As installed) Cooling increases tension Heating reduces tension ICE HEAT 33
Tubing Stress Calculations Completion fluid 1 Installation 3 Treatment 2 Production Completion fluid Mid stroke setting Produced fluid Completion fluid Seal assembly on down-stroke Treatment fluid Completion fluid Seal assembly on up-stroke 34
Material Selection Factors influencing material selection criteria typically include: Mechanical properties e.g., material strength Operating environment e.g., sour or corrosive service Ease of manufacture Cost Availability e.g., in required dimensions 35
Corrosion Failure mechanisms associated with corrosion: Stress corrosion cracking Hydrogen embrittlement, stress cracking Material weight loss CO 2 corrosion, oxidization, treatment fluids Pitting or localised loss Requires three conditions Corrosive media, e.g., oxygen Electrolyte, e.g., moisture Heat or pressure 36
Elastomers and Plastics General definition: An elastomer can be stretched to at least twice its original length and will quickly return to approximately its original length on release. Plastics cannot withstand such strain without permanent damage.
Elastomer and Plastic Limitations Elastomers and plastics should be selected on compatibility with: Corrosive fluids or environment e.g., reservoir or completion fluids Chemical compatibility e.g., stimulation fluids Operating temperature including range and fluctuation Operating pressure including range and fluctuation Dimension e.g., ability to function with extrusion gap 38
Perforating The process of creating a clear channel of communication between the reservoir and wellbore.
Technique selection depends on: Completion type and dimensions Reservoir conditions, e.g., stability/consolidation Local experience and preference 39
Perforation History 40
Perforation Program Design Principal design considerations include: Location of the perforated interval Shot density Perforation phasing Penetration Perforating debris Gun conveyance method Gun recoverability Bottom hole perforating pressure 41
Perforating Gun Components Principal perforation gun/system components: Charge carrier recoverable, disposable Detonator electrical or percussion (dependent on conveyance) Detonating cord provides link between charges Shaped charge generates high pressure jet 42
Perforation Charge Charge components Damaged zone Reservoir formation Cement Stand-off Charge liner Explosive charge Primer and detonator cord Charge case Gun body 43
Perforation Process Perforation sequence Crushed zone Perforation debris Clean, stable perforation tunnel Extremely high- pressure jet 44
Perforating Gun Systems Perforating gun or system options include: Gun conveyance method wireline, TCP or coiled tubing Thru-tubing gun systems small OD systems Casing gun systems large OD systems Tubing conveyed gun systems recovered or dropped suitable for long intervals no verification 45
Perforation Phasing Perforation phasing describes the angle between shots. Key considerations include: Five common configurations - 0 o , 60 o , 90 o , 120 o , 180 o
phased guns require decentralizing Near wellbore flow characteristics effected by phasing Oriented phasing may be desirable, e.g., hydraulic fracturing treatments 47
Penetration, Stand Off and Debris Penetration - effective length of perforation channel Should bypass damaged zone Effected by stand-off Stand Off - distance between gun and casing/liner Charge efficiency diminishes with distance Effects accentuated at high pressures Perforation size effected by stand off Perforation debris - left in place after perforating Some debris inevitable - dependent on gun/charge type Should be removed by back flush after/during perforating 48
Bottomhole Perforation Pressure Two basic bottom hole pressure conditions associated with perforating: Overbalanced - perforating with kill weight fluid column in wellbore Surge following perforation acts to compact debris Requires less complex equipment and techniques Underbalanced Removes perforation debris at time of perforation Reduces likelihood of near-wellbore damage Requires special equipment and techniques A third Pressure condition is being used in the last years: Extreme Overbalanced Perforation ( EOB ); The wellbore pressure in the wellbore is higher than the Frac Gradient. 49
Oil and Gas Well Completions Types of Completion 50
Completion Design Factors Principal completion design factor include: Casing protection e.g., protection against erosion, corrosion Tubing string removal e.g., for replacement or workover Safety or contingency e.g., requirements for safety valves and well kill Production control e.g., components providing flexibility and control of production (nipples, profiles and sliding sleeves 51
Basic Production Configurations Majority of completions are based on the following completion configurations Reservoir interface Openhole Casing production Liner production Gravel pack wellbore Production conduit Suspended tubing Basic packer Packer and tailpipe Packer with additional safety and production devices 52
Key points No downhole flow control or isolation Producing formation is unsupported Casing provides isolation between shallower formations Open Hole Production 53
Casing Production Key points No downhole flow control or isolation Casing provides isolation between shallower formations with potential for remedial work to isolate sections of perforated interval 54
Liner Production Key points Similar to casing production but with smaller (and shorter) tubulars set through the reservoir 55
Gravel Pack Wellbore Key points Special application - requirement determined by formation type May require special operation (underreaming) during well construction phase 56
Simple Tubing Completion Key features Circulation capability (well kill or kick-off) Improves hydraulic performance Limited protection for casing 57
Basic Packer Completion Key features Circulation capability (determined by design and setting of packer) Casing string protected from fluid and pressure effects 58
Packer with Tailpipe Key features Additional flexibility for downhole production (flow)control, e.g., plugs Facility for downhole instruments (gauges) 59
Enhanced Packer Installation Key features Improved flexibility for downhole production control, e.g., plugs above or below packer Circulation capability independent of packer Safety facility (SSSV) 60
Completion Examples The following completion examples are extracted from design files for: Single zone completions Multiple zone completions Liner completions Special completions Sand control Inhibitor injection Waterflood Thermal Remedial (scab liner) 61
Single Zone Retrievable Packer Key Features Tail-pipe facility for pressure and temperature gauges Fully retrievable completion Packer can be set with well flanged up Thru-tubing perforation possible where size permits 62
Single Zone Seal-Bore Packer Key Features Seal-bore packer set on electric- line or tubing On-off connector and tubing anchor allows tubing to be retrieved Tailpipe plugged and left in wellbore or retrieved with production tubing 63
Single Zone Packer and Tailpipe Key Features Tailpipe plugged and left in wellbore when production tubing is retrieved Permits safe thru-tubing perforating Block and kill system facilitates the killing of high-pressure, high- flowrate wells 64
Single Zone Casing Seal Receptacle Key Features Expansion joint allows for tubing movement Tailpipe retrievable (separately) Protective sleeve run in CSR during primary and remedial cementing 65
Multiple Zones 2 Zones 1 Packer Key Features Separate or commingled production through single tubing string Blast joint protection across upper interval On-off connector and tubing anchor permits tubing retrieval with lower interval isolated
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Multiple Zones 2 Zones 2 Packers Key Features Independent production through dual tubing strings Blast joint protection across upper interval Both packers retrievable Tailpipe instrument facility on both strings Thru-tubing perforation of lower zone possible
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Multiple Zones 3 Zones 3 Packers Key Features 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 68
Multiple Zones 4 Zones 4 Packers Key Features Four zone selective production system Dual production strings Commingled or alternate production controlled by sliding sleeves System contains 28 major downhole components 69
Liner CSR Key Features Most simple liner hook-up CSR replaces packer Fluid circulation through sliding sleeve above the liner hanger Tailpipe retrieved with production tubing 70
CSR and Seal-Bore Packer Key Features Liner top/lap is permanently isolated Fluid circulation through sliding sleeve above the packer Tailpipe can be plugged to allow retrieval of the production tubing 71
Special Service Completions Special completion examples include: Sand control Inhibitor injection Waterflood Tubing/casing repair 72
Gravel Pack Completion Key Features Tools set and gravel placed using a service tool and tubing workstring Gravel squeezed into perforation tunnels Production tubing stung-in to production seal-assembly Specialised service typically involving dedicated service equipment and personnel 73
Inhibitor Injection Key Features Side pocket mandrel injection permits protection inside production tubing above the packer Injection nipple and small diameter injection line is suitable for shallow applications 74
Inhibitor Complete Protection Key Features Parallel flow tube and seal-bore packer enables inhibitor to be pumped down short string All flow-wetted completion components are exposed to inhibitor fluid Inhibitor flow controlled at surface 75
Waterflood Key Features Two injection zones treated with both flow control regulators located at surface Totally separate injection systems 76
Waterflood Thick Injection Zone Key Features Injection efficiency in thick zones is improved by using multiple injection points Downhole flow regulation helps prevent premature breakthrough between intra-zonal sections 77
Thermal Completion Steam Injection Key Features Packer incorporates an integral expansion/slip joint assembly SPM allows insulation material to be circulated into annulus 78
Remedial Completion Scab Liner Key Features Isolation of damaged casing/liner or abandonment of a depleted zone Hydraulic set packers at top and bottom of scab liner On-off connector on lower seal- bore packer allowed installation with the lower perforations isolated throughout the operation 79
Monbore Completion Key Features Designed to meet criteria for: appropriate production rates flexibility/contingency safety monitoring (reservoir management) longevity Safety valve Packer/hanger assembly Liner 80
Multi-Zone Completion Zone 1 Zone 2 Tubing Retreivable Surface Controled Subsurface Safety Valve (TRSCSSV) Annular Safety Valve (ASV) System with Wet Disconnect Gas Lift Mandrel Production Packer w/ TEC bypass 10 3/4 Casing 5-1/2 Production Tubing Isolation Packer w/ TEC feedthru Flow Control Device w/ Integral Pressure/ Temperature sensor Venturi Flowmeter 9-5/8 Liner Example of a Multi Zone Completion using a Standard Configuration for each Zone (thi s can be repeated for any number of zones) Hydraulic Control Line for the TRSCSSV Hydraulic Control Line for the ASV Plug Tubing Encased Conductor (TEC) Cross Coupling Clamp 81
Artificial Lift Objectives The primary purpose of installing an artificial lift system is to maintain a reduced bottom hole pressure (drawdown) to enable the desired reservoir fluids to be produced at an acceptable rate. 82
Reasons for Artificial Lift Compensate for declining reservoir pressure i.e., maintain an acceptable production rate Offsetting the effect of increasing water production Overcome high friction pressures associated with the production of viscous or waxy crudes Kick-off high gas-liquid ratio wells that die when shut in Reduce the effect of flowline back pressure Maintaining a production rate which reduces wax or scale deposition 83
Artificial Lift Selection The selection of an appropriate (optimal) artificial lift system is dependent on: Inflow performance of the well/reservoir Capacity and operation of the artificial lift system(s) Capital cost Operating cost Servicing frequency (maintenance cost) 84
Artificial Lift TPC 85
Artificial Lift Methods Commonly used artificial lift methods include: Rod pump Gas lift Electric submersible pump Piston pump Jet pump Plunger lift Other specialist or adapted systems 86
Rod Pump Rod pumps account for approximately 60% of onshore artificial lift completions Industry accepted Economic in ideal field Not gas dependent Limited efficiency Maintenance intensive Vertical wellbores Rods Productio n tubing Rod pump Tubing anchor 87
Rod Pump - Surface Equipment Stuffing box and polished rod Horsehead Prime mover Gearbox and counterbalance Production valve Walking beam 88
Gas Lift Gas lift accounts for approximately 90% of offshore artificial lift completions System may be designed to suit most wells Wireline serviceable Few mechanical parts Sand and fill tolerant Production tubing Production tubing Gas lift valve installed inside pocket mandrel Retrievable packer No-go seating nipple Wireline entry guide 89
Electric Submersible Pump Extremely high liquid production capability High installation and operating cost Suitable for low gas-to-oil ratio applications only Electrical components easily damaged Armored cable Cable guard Sliding sleeve Dual string retrievable packer (modified) Sliding sleeve No-go seating nipple Pump assembly (various) Pump Intake Protector Motor 90
Hydraulic Systems Hydraulic pumping systems - two main categories Piston pump close coupled engine/pump assembly with positive displacement pump performance determined by the pump/engine size Hydraulic jet pump imparts energy to the production fluid relatively tolerant of lower quality power fluid or produced fluids 91
Hydraulic Pumping Systems Piston pump system Jet pump system 92
Plunger Lift Suited to high GLR wells (low liquid production) Efficiency decreases with depth and PI Efficiency increase in larger tubing sizes (where liquid slippage is more prevalent) Other Systems Screw pump operates on same principle as PDM Turbine pump similar to ESP installations 93
Plunger Lift System Plunger (with liquid load Tubing stop Standing valve Tubing stop Injection gas Production Plunger catcher Intermitter or controller Surface Equipment Downhole Equipment