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‫كلية الطاقة – اجخرة‬

‫قسم الهندسة النفطية‬

WELL COMPLETION

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Well Completion
Definition - What does Well Completion mean?
Well Completion is the process of making an oil or gas well ready
for commercial production. Once the Appraisal of a well is complete,
ongoing drilling of the commercial well has to be completed only if
the presence of hydrocarbons prove the project to be feasibly
viable. During Well Completion process, the borehole is prepared as
per the required specifications. Engineers complete the wellbore by
running production tubing deep into the hole along with its
associated downhole tools. Sometimes, cementing the casing is
also included under this process.

Purpose of well completions

The purposes of a well completion are to:

 Connect the reservoir to the surface so that fluids can be


produced from or injected into the reservoir
 Provide a conduit for well stimulation treatments
 Isolate the producing reservoir from other zones
 Protect the integrity of the reservoir, especially in unconsolidated
formations
 Provide a conduit to measure the changes in flow rate and
pressure needed to run a well test

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The wellbore provides the only path from the surface to the
reservoir. To a large extent, the successful production and depletion
of a reservoir depends upon the successful completion
and workover operations applied to a well. In most companies, the
production engineer designs and supervises all completion and
workover operations.

Types of Well Completion

For the oil and gas industry, production of the hydrocarbons in a


surveyed reservoir is the main goal of a petroleum expedition.
After drilling operations, a quick deliberation will be made whether a
well will be prepared for producing hydrocarbons, having fluids
injected in them, or for plugging it in for abandonment.
Engineers will take good care in preparing it so that it could deliver a
reservoir‟s contents safely to the waiting refinery processes in the
surface.
Well completion is a process in which a well is prepared for having
fluids run within it safely and securely. Transforming a drilled well to
a producing one will take steps such as, casing, cementing,
perforating and gravel packing.
There are three kinds of well completion that has been used
throughout the years as technologies of production have evolved.

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Completions can be divided into three categories: open hole
completions, liner completions, and perforated casing completions.
In most wells, conventional single perforated casing completions are
used; however, multiple, alternate, or slim hole completions may be
used under certain conditions. 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.

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1. Openhole Completion:

Openhole well completion is used in thick reservoir sections with


relatively competent rock type where engineers are confident that
the well walls will hold and not collapse into itself and into the
reservoir.

It depends whether the rock formation surrounding the reservoir is


unconsolidated (loosely packed sand or gravel) or consolidated
(metamorphosed or cemented together), and the type of rock that
exists above the reservoir. This means that if a collapsible formation

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Is above the reservoir section of interest, then leaving a well open-
hole might not be the best idea. you must also be aware of the type
of fluid to be produced, particularly if there is H2S present in it.
Some thought must be put in place to avoid a catastrophic incident.
Openhole completions aren‟t used as much as other completion
types in modern days. Although in the pre 1940s to 1950s, almost
all wells were completed openhole. But was quickly phased out
because of how its advantages are outweighed by problems and
challenges that arise in using this type of completion.
2. Liner Completion:
To overcome the problems of collapsing sands plugging the
production system faced in an openhole completion, the early oil
producers placed slotted pipe or screens across the openhole
section. This screens act as a downhole sand filter.

Sand can be a problem in production operations, it not only


becomes a problem in the wellbore, but it also poses problems on
equipment in the surface. It can block flow paths, help weaken
wellbore and equipment walls, and be a headache in refining
processes the use of uncemented liners as a method of sand
control remains popular today in some areas.

This type of well completion requires no perforation in its finishing.


Sand control becomes easier and is adaptable to other sand control
techniques. It also permits easier well deepening.

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A slotted pipe is run into the openhole and slots are cut small
enough that the produced sands bridge off on the opening rather
than passing through.

For very fine sands, the slots cannot be cut small enough so wire-
wrapped screens or sintered bronze is used. This technique is an
effective sand control method in coarse sands with little or no fine
particles however; the uncemented liner completion is no longer in
common use. Sand movement into the wellbore tends to cause
permeability impairment.

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Blockages happen when fine sands plug the slots or screens. The
liner itself can collapse if the formation starts to break because of
the poor support this completion can offer.

3. Perforated Casing Completion

It involves cementing the production casing (or liner) through the


pay zone(s), and subsequently providing a flow path through a
formation by perforating holes through the casing and cement.

These perforations are designed to penetrate any damaged area


around the wellbore and create a clean conduit within the
undamaged formation.

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In using various depth control techniques, engineers can decide
precisely which sections should be perforated and opened to flow.

This avoids undesired fluids (gas, water) that might contaminate the
neighboring pay zones, and weak zones that might produce sand,
and unproductive sections or shale barriers.

This selectivity is completely dependent on a good cement job and


adequate perforating. Tools used for measuring rely on the cement
job.

The selectivity also allows a single wellbore to produce several


separate reservoirs without having these fluids mix in the flow lines.
This is done by setting isolating packers within an un perforated
section of the pipe.

This type of well completion provides safer operations. This is


because the maneuvrability of the well‟s design and increased well
control greatly helps secure a producing well from disaster.

In this type of completion, sensitivity to drilling damage is reduced; it


can facilitate selective stimulation of the well; and multi zone
completions can be possible for this type.

This well completion is generally used unless there is a specific to


prefer openhole or uncemented liner completions.

Perforated casing or liner completion, however, faces challenges


too. The wellbore diameter through the pay zone is restricted.

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Perforations are small in diameter it could restrict fluid flow unlike
that of openhole completions.

Additional costs due to perforation work are involved; additional


cement work and rig time; and formation damage caused by
cementing and perforation work are common problems with this
completion. These are the three fundamental completion types in
preparing a well for the next processes.

Explains Well Completion


Well Completion is one of the primary steps before the
commencement of production from a reservoir. There are various
steps that have to be taken care when converting a drilled well into
a producing well. The following steps needs to be performed to
make the well complete:

1. Casing – Well casing is the primary step in the Well


Completion process. It is the process of protecting a wellbore
from outside incumbents like water or sand once oil or gas is
produced from the well.

2. Cementing – The next step is to pump cement slurry and


additives into the well to remove existing drilling fluids and fill

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The space between the casing and actual sides of a drilled well.
This process is also known as Well Cementing.

3. Perforations – Once casing and cementing is done at the bottom


of the wellbore, perforations are created with the help a
perforation gun so that hydrocarbons can enter into the well
stream.

4. Gravel Pack – Gravel Pack is used to help filtering sand from


Crude oil or gas.

5. Production tree or Christmas tree – This is the last step in


the Well Completion process. A Christmas tree is installed at
the wellhead on the surface of the earth to provide surface
controls in the flow of oil or gas to the surface of earth.

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1-Casing
Casing is the major structural component of a well. Casing is needed to:

 Maintain borehole stability


 Prevent contamination of water sands
 Isolate water from producing formations
 Control well pressures during drilling, production, and workover
operations

Casing provides locations for the installation of:

 Blowout preventers
 Wellhead equipment
 Production packers
 Production tubing

The cost of casing is a major part of the overall well cost, so


selection of casing size, grade, connectors, and setting depth is a
primary engineering and economic consideration.

Casing strings

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There are five basic types of casing strings:
Casing strings
There are five basic types of casing strings:
 Conductor Casing
 Surface Casing
 Intermediate Casing
 Production Casing
 Liner Casing

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Conductor casing

Conductor casing is the first string set below the structural casing
(i.e., drive pipe or marine conductor run to protect loose near-
surface formations and to enable circulation of drilling fluid). The
conductor isolates unconsolidated formations and water sands and
protects against shallow gas. This is usually the string onto which
the casing head is installed. A diverter or a blow out prevention
(BOP) stack may be installed onto this string. When cemented, this
string is typically cemented to the surface or to the mud line in oil
wells.

Surface casing

Surface casing is set to provide blowout protection, isolate water


sands, and prevent lost circulation. It also often provides adequate
shoe strength to drill into high-pressure transition zones. In deviated
wells, the surface casing may cover the build section to prevent
keys eating of the formation during deeper drilling. This string is
typically cemented to the surface or to the mud line in offshore
wells.

Intermediate casing
Intermediate casing is set to isolate:

 Unstable hole sections


 Lost-circulation zones
 Low-pressure zones
 Production zones

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It is often set in the transition zone from normal to abnormal
pressure. The casing cement top must isolate any hydrocarbon
zones. Some wells require multiple intermediate strings. Some
intermediate strings may also be production strings if a liner is run
beneath them.

Production casing
Production casing is used to isolate production zones and contain
formation pressures in the event of a tubing leak. It may also be
exposed to:

 Injection pressures from fracture jobs


 Down casing, gas lift
 The injection of inhibitor oil

A good primary cement job is very critical for this string.

Liner Casing

Liner is a casing string that does not extend back to the wellhead,
but is hung from another casing string. Liners are used instead of
full casing strings to:

 Reduce cost
 Improve hydraulic performance when drilling deeper
 Allow the use of larger tubing above the liner top
 Not represent a tension limitation for a rig

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Liners can be either an intermediate or a production string. Liners
are typically cemented over their entire length.

2- Cementing
Cement is used to hold casing in place and to prevent fluid
migration between subsurface formations. Cementing operations
can be divided into two broad categories: primary cementing and
remedial cementing.

Cementing Principle

1. To support the vertical and radial loads applied to the casing

2. Isolate porous formations from the producing zone formations

3. Exclude unwanted sub-surface fluids from the producing


interval

4. Protect casing from corrosion

5. Resist chemical deterioration of cement

6. Confine abnormal pore pressure

7. To increase the possibility to hit the target

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Primary Cementing
- Process of placing cement in the annulus between
The casing and the wellbore
-Objectives:
• Create Zonal Isolation
• Protect Useable Water
• Provide Structural Support for Casing
• Protect Casing from Corrosion
• Isolate Casing Seat for Subsequent Drilling

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Effective Primary Cementing

flushes

Casing has been cemented in wells for more than 100 years.
• Cementing best practices have been known for more than
60 years.
• Best practices have to be used by everyone to:
• Protect the environment and community.
• Obtain maximum value.

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3- Perforations
A perforation in the context of oil wells refers to a hole punched in
the casing or liner of an oil well to connect it to the reservoir.
Creating a channel between the pay zone and the wellbore to cause
oil and gas to flow to the wellbore easily, In cased hole completions,
the well will be drilled down past the section of the formation desired
for production and will have casing or a liner run in separating the
formation from the well bore. The final stage of the completion will
involve running in perforating guns, a string of shaped charges,
down to the desired depth and firing them to perforate the casing or
liner. A typical perforating gun can carry many dozens of explosive
charges.

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Perforation is a special operation to crease an efficient
communication path between a wellbore and a reservoir by creating
tunnels. The effective paths allow reservoir fluid to flow into the well
with minimum pressure loss (less skin as much as possible).
Several factors influencing perforation performance are as
follows;
 Rock properties – compressive strength, fracture pressure
 Mineral content of the rock metric
 Tectonic stress and overburden pressure of the reservoir
 Reservoir pressure and temperature
 Reservoir fluid
 Completion fluid
 Wellbore configurations such as size and grade of casing,
wellbore deviation and orientation

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The process of perforation involves lowering a perforating gun into
a wellbore to a planned depth and energizing the gun to be safely
fired. When perforating a well, shape charges are fired and then
energy from the explosion will create tunnels through casing, and
cement and then into a reservoir. Length and diameter of
perforation hole are dependent on the objectives which will be
discussed later. Figure 1 shows the cross sectional of perforation.

Types of Perforation Systems


Three perforation systems which are used in oil and gas industry
are casing guns, tubing conveyed guns and through tubing guns.
1- Casing Gun System (Wireline Convey)
The casing gun system is the oldest perforation technique and it
involves running perforation in order to perforate a well before
running a completion. Wellbore conditions can be either
overbalanced or underbalanced when perforating. Additionally, a
wellbore should be neutralized before running the completion
because it will minimize formation damage.

2- Tubing Conveyed Perforation System (TCP)


For this system, the perforation gun is attached and run with a
completion string. This system requires drilling an additional hole
called a “sump” in order to accommodate a perforated gun to be
dropped and left in the well after a gun is fired.

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3- Through Tubing System
Through tubing perforation allows perforation to be performed with
the existing completion string. This system has limitations on size of
charge and perforation gun because the guns must be small
enough to run into a completion string. Typically, the gun size is
smaller than 2-1/8.”

4- Gravel Pack
Gravel packing is a mechanical means of controlling sand
production. If properly designed and applied, this completion
technique can provide adequate sand control throughout the life of
a well. To obtain an effective gravel-packed completion, it is
essential that the pack be properly designed using the proper
gravel, screen, carrier fluid, and placement technique. Choosing the
proper gravel is of utmost importance in obtaining an effective
gravel pack. Both gravel size and quality should be considered in
designing a gravel pack. To determine the optimum gravel size, it is
essential to conduct sand sieve analysis on representative
formation samples. Sieve analysis from conventional cores is
preferable; however, sidewall core samples can also be used. This
chapter discusses some of the methods of gravel-packing.

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A gravel pack is simply a downhole filter designed to prevent the
production of unwanted formation sand. The formation sand is held
in place by properly sized gravel pack sand that, in turn, is held in
place with a properly-sized screen.

To determine what size gravel-pack sand is required, samples of


the formation sand must be evaluated to determine the median
grain size diameter and grain size distribution.

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5- Production tree or Christmas tree
The Christmas tree is the cross-over between the wellhead casing
and the flow line. The wellhead is the cross-over between the
Christmas tree and the various casings.
 controls the wellhead pressure and the flow of hydrocarbon
 enables the well to be shut off in an emergency
 Provides access into the well for well intervention activities.
The selection of the wellhead is normally by the Drilling Engineer in
conjunction with the well structure design.
Both drilling and production requirements need to be addressed in
the wellhead design, as it provides the crossover between the BOP
and the various casings during the drilling phase of the well life
cycle and as mentioned above controls the wellhead pressure and
hydrocarbon flow during the production phase.
There are basically two types of wellhead, the individual spool type
and the compact wellhead. The compact wellhead is a technically
superior design which offers enhanced safety and rig time savings
without incurring a direct cost penalty.
Christmas tree bottom connection
The Christmas tree connection to the wellhead or the tubing head
spool should be rated to the maximum closed-in wellhead pressure.
The connection should be designed to accept the shear loads, the
loads imposed during wireline, coiled tubing and snubbing
operations, such as bending moments of the lubricator, vibration,
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It must be demonstrated by calculation that the tree/wellhead
connection is adequate to meet these demands during its working
life.
A suitable connection between Christmas tree and wellhead is the
multi-segmented clamp. This device is quicker and safer to install
than the more traditional flange and allows the drilling function to
line up the Christmas tree accurately with the flow line. In principle it
is recommended that dual seals are used, generally this is
accomplished by way of extended neck tubing hangers.

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Tubing hangers
During wellhead maintenance and other operations a back pressure
valve is normally installed in the tubing hanger. To accommodate
this, a profile should be machined into the tubing hanger to receive
the valve and/or running tool. This should preferably be a wireline
profile, which allows setting and retrieving the back pressure valve
to be performed under lubricator control.
It is recommended not to use threaded profiles. They may become
corroded or eroded by well fluids and wireline passing across.
The tubing hanger must withstand the forces exerted during well
completion, such as setting the well conduit in tension or
compression, and subsequent forces during well production, well
stimulation etc.

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Well stimulation
Well stimulation is a well intervention performed on an oil or gas
well to increase production by improving the flow of hydrocarbons
from the reservoir into the well bore.
Well stimulation is commonly applied to boost oil or gas production
and, consequently, revenues therefrom. Stimulation is nowadays
commonly associated with hydraulic fracturing, but a number of
other techniques have been used in the past and are still applied
today. It is essential to get an insight into them in order to
understand the origin of techniques used for extraction of
unconventional hydrocarbons.

The purpose and methods of stimulation


The life cycle of any gas or oilfield falls into three distinct stages:
 Initially, production rate is up with the progress of infill drilling.
 In the second stage, production rate is fairly constant and any
potential drops are offset by additional wells.
 Well productivity decreases in the third stage and cannot be
offset by drilling more wells.
At that point in well history stimulation procedures have to be
applied in order to enhance well productivity by removing natural
and drilling-induced barriers to the flow of hydrocarbons. Unlike
enhanced oil recovery techniques, well stimulation has no effect on
reservoir pressure.
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Well productivity can be stimulated in two ways:
 By enhancing permeability of reservoir rocks,
 By lowering viscosity of the crude oil.
The existing techniques are of double action and fall into the
following procedures:
 mechanical: use of explosives and propellants, hydraulic
fracturing,
 thermal: heat flooding, in situ combustion,
 chemical: acidizing.

Technologies that are used today reach way beyond the immediate
vicinity of the well bore and the so-called “skin damage” area, as it
had been the case in early history of oil production. The
improvements were driven by the oil crisis of the 1970's in an effort

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to enhance recovery from indigenous oilfields, then considered as
commercially non-viable, following OPEC‟s decision to increase
dramatically the price of their crude product. Stimulation techniques
were further improved in the 1990's with focus on reservoirs of
medium to high permeability‟s. Nowadays, oil and gas companies
are in disposal of a wide array of stimulation solutions that have
been developed in the past 150 years with good oilfield
management in mind.

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Well Logging
Well logging, also known as borehole logging is the practice of
making a detailed record (a well log) of the geologic formations
penetrated by a borehole. The log may be based either on visual
inspection of samples brought to the surface (geological logs) or on
physical me

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Well logging chronicles the depths, subsurface formations and
events encountered while drilling. Well logs can include visual
observations or be made by instruments lowered into the well during
drilling.
Well logging today means anything recorded having to do with the
drilling versus the depth of the well at that moment, many times
represented by a graph and corresponding notes. Logging tools are
inserted into the well to measure the electrical, acoustic, radioactive
and electromagnetic properties of the subsurface formations.
Sometimes the logging tools are incorporated into the drilling tool,
and sometimes the drilling tools are lowered into the well at regular
intervals to collect data.

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Well production String
To continue with the completion of the well, the tubing and packer
are now installed. The tubing is simply a smaller diameter pipe,
which is lowered inside the casing to a depth somewhere above the
perforations. Attached to the lower end of the tubing, we see the
packer.
The packer carries one or more sets of slips (teeth) and one or
more rubber seal elements which remain retracted until it is lowered
into the casing to the depth at which it is to be set. Once the tubing
and packer are at the desired depth, the slips and the rubber seal
elements on the packer are activated, usually either by rotating the
tubing or by applying hydraulic pressure through the tubing bore.
This causes the slips on the packer to expand and bite into the
casing and also causes the rubber seal elements of the packer to
expand and seal off against the internal diameter of the casing.
The packer is now firmly anchored in place and sealed off in the
casing. The gas and oil entering the casing through the perforations
will flow up to the packer. Where it must now enter the tubing and
flow to the surface.
The tubing - casing annulus is the space between the outside
diameters of the casing above the packer. It is usually filled with a
fluid such as water, mud or diesel. This fluid usually contains a
corrosion inhibitor, which protects the tubing and casing from
corrosion.
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The hydrostatic pressure (weight) of the fluid tends to help hold the
packer in place and also provides a means of „killing‟ the well, when
necessary, by admitting the annular fluid into the tubing string.

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Tubing
As it is always the tubing in which wireline operations are
carried out it is necessary for the wireline Operator to know
more about the tubing.
Size
OD = the outside diameter of the pipe
ID = the internal diameter of the pipe
Nominal = approximate ID rounded up to the nearest full
size.
Grade
Indicates the „strength‟ and type of steel, used to make
the tubing.
It is specified by a letter followed by a number:
e.g.: H-40, J-55, C-75, L-80, N-80, P-105
The lower the number the softer the steel. This
number is the tensile strength in 1,000 lbs. per sq. in
i.e. N-80 with a cross sectional area of 1 sq. in will
take a load of 80,000 lbs.
Weight per foot
Determines the thickness of the tubing.

Drift
Is the „quality control‟ ID which a bar of steel 32” long and
machined to the OD of the drift size will pass without
hanging up in the tubing. ALL tubing and components
run in the well MUST be drifted. For practical
purposes the drifts used on the rigs are shorter than
32” (Wireline Drift is determined by nipple bore size -
refer to chart below.)

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Threads
EU = External Upset has collar on outside and internal
recess
NU= Non upset but otherwise same as EU
Vam = premium type thread seal with collar. No internal
recess
Hydril CS = No collar. Metal to metal 3 point seal. No
internal recess.

Nominal Wt Drilling Wireline


OD ID
size ft Drift Drift
3
2 /8” 4.7 2.375” 1.995” 1.901” 1.875”
7
2 /8” 6.5 2.875” 2.441” 2.347” 2.313”
1
3 /2” 9.3 3.5” 2.992” 2.867” 2.750”
1
4 /2” 12.75 4.5” 3.958” 3.883” 3.813”
1
5 /2” 15.5 5.5” 4.919” 4.825” 4.750”

Wireline Re-Entry Guide


This guide will generally take one of two forms.
• Bell Guide
This guide has a 450 lead in taper to allow easy re-entry into the
tubing of wireline tool strings. This guide will be used in a
completion where the end of the tubing does not need to enter the
top of the liner hanger.

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• Mule Shoe Re-entry Guide
This would be essentially the same as a bell guide but with the
modification of a large 45° angle cut from the outside of the guide.
This 450 chamfer will cause the tubing to orientate and kick over
into the liner, should the tubing land on the liner lip while running
into the liner hanger.

Tubing Protection Joint


This is a single joint of tubing, included for the particular purpose of
protecting pressure/temperature gauges that might be hung off in
the „RN‟ Nipple above.
‘RN’ No-Go Landing Nipple
This nipple would be used exclusively for a wireline set gauge
hanger (bomb hanger).

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Perforated Pup Joint
In wells flowing large volumes, a restriction in the tubing, such as a
gauge hanger, could cause false pressure readings. Vibrations due
to flow, could also cause extensive damage to delicate gauges,
therefore a perforated pup joint (approx. 10 ft long) set above the
bomb hanger nipple, would allow flow to pass unrestricted over the
gauges and hanger, thus giving a more accurate pressure/
temperature recording within the limitations of the gauge.

‘XN’ No-Go Landing Nipple


This nipple is the primary plugging point below the packer and
would be used during the initial completion stage as a receptacle for
a „test tool‟ (a plug which will only hold pressure from above and
does not lock into the nipple), which would hold sufficient pressure
from above to set the hydraulic packer, and test the tubing.
Thereafter, the nipple would be used for plugging with „XN‟ type
locking devices, for instance when tubing above the packer has to
be pulled leaving the packer in the hole.

Pup Joint
Used for spacing out tubing or as a handling joint when completion
equipment is made up into assemblies prior to running.
Crossover
Connects 2 7/8” inch tubing to 31/2 inch tubing.

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