Completion:

Basics

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 Completion Basics:
Part I

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 Completion
Definition

The objective of a completion is to convey fluids from the

reservoir to the surface, in a safe and efficient manner.

Completion design requires knowledge of many systems:

• 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
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 Reservoir
Definition

WELLHEAD
TO PROCESSING
A porous, permeable rock body in which
AND TREATING
STILL LOWER
PRESSURE
hydrocarbons have accumulated.

• Geology determines the porosity,

permeability and the type of trap in
which the hydrocarbons
accumulate.

• Reservoir drive is the force that

causes fluids to flow from the
reservoir into the wellbore

MEDIUM
PRESSURE
• A hole drilled into the reservoir
F LU
ID HIGHER
PRESSURE
provides a conduit for flow to the
surface.

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 Reservoir
Considerations

• Drainage
– Vertical
– Horizontal
– Extended Reach
– Multi-Lateral

• Number of Zones
– Single
– Multiple-
• Selective
• Co-Mingled

• Formation Interface
– Open Hole
– Slotted Liner
– Sand Exclusion
– Perforated Casing

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 Reservoir
Considerations

• Flowing:
Reservoir pressure is greater than
hydrostatic pressure created by
the fluids in the wellbore.
Various methods used to maintain
reservoir pressure:
– water injection
– gas injection

• 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
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 Reservoir
Considerations

Artificial Lift
Generally required

ARMORED CONTROL
METERING
EQUPMENT Supplements reservoir
EQUIPMENT
CABLE
energy
ROD PUMP
PUMP
GAS LIFT VALVE Exception
TUBING ANCHOR
HYDRAULIC
ELECTRIC
MOTOR Prolific water drive
PUMP
PACKER

STANDING VALVE
(OPTIONAL)
– Sucker Rod Pumping
ROD PUMP
SUBMERSIBLE
ELECTRIC
PUMP
(80%)*
HYDRAULIC
PUMP GAS LIFT
– Gas Lift
(10%)
– Hydraulic Pumping
(5%)*
– Electrical
Submersible Pump
(5%)*

* Percentage of Worldwide
Artificial Lift Use
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 Artificial Lift Methods
Sucker Rod Pumping

A method using a downhole plunger pump

which is driven by the surface pumping unit.

– Rods are attached to the plunger pump. On the

surface, the rods are connected to walking beam.
The beam pivots back and forth, resembling a
horse nodding it’s head, and moves the sucker
rods in an up and down motion. This motion is
transferred to the pump downhole. Movement of
the plunger causes the well to unload its fluid.

Operation (Pumping Cycle):

– The downward stroke of the rods, the standing
valve closes, the traveling valve opens, and fluid
is forced from the working barrel through the
plunger and into the tubing.
– The upward stroke of the rods pulls plunger up
through working barrel. The traveling valve
closes, the standing valve in the working barrel
opens and fluid enters the working barrel from
the well.

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 Artificial Lift Methods
Sub-Surface Hydraulic Pumping

A method using a bottomhole pump without

sucker rods.

The system of hydraulic pumping uses two strings

of tubing:
– Two strings installed beside each other.
– A small string installed inside another.
• Clean crude oil from the high pressure surface
pump goes downward through the larger size
tubing to the down-hole engine which moves a
power piston connected to the production plunger
in the bottom-hole pump.
• Fluid from the well and the exhausted power oil
become mixed and return to the surface storage
through the smaller diameter tubing

Operation:
– Surface power is supplied from a standard
engine-driven high pressure pump.
– Bottom-hole production unit consists of a
down-hole hydraulic engine directly
connected to a plunger pump.

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 Artificial Lift Methods
Electrical Submersible Pumping

A method of pumping oil using a downhole

electrical pump.

– Specially design gas lift valves installed

on the tubing string provide openings
between the casing and tubing.
– Gas lift valves can also be ran in side
pocket mandrels and pulled and replaced
by means of a wireline unit.

Operation:
– Downhole is a centrifugal pump and shaft
that is directly connected to an electric
motor.
– Electric motor causes pump to revolve so
that impellers in the pump apply pressure
upon the liquid in it forcing that fluid
through the tubing to the surface.

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 Artificial Lift Methods
Gas Lift

A method of producing oil in which gas

under pressure is used to lift the well fluids.

– Specially design gas lift valves installed

on the tubing string provide openings
between the casing and tubing.
– Gas lift valves can also be ran in side
pocket mandrels and pulled and replaced
by means of a wireline unit.

Operation:
– Downhole is a centrifugal pump and shaft
that is directly connected to an electric
motor.
– Fluid that is standing in the tubing above
the gas-inlet port is displaced, lightened
by mixing with the injected gas and is
raised to the surface by the expanding
gas.

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 Reservoir
Considerations

Secondary Recovery
Recover more hydrocarbons by
increasing reservoir pressure, injection,
displacement, or by means of creating a
downhole reaction.

– Waterflood
– CO2 Flood
– Chemical Injection
– Steam Injection
– Fireflood

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 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.

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 Casing
Types

TVD in Ft.

• Conductor
– OD= 16-30”; Depth= 40-400’
30" 800' 30"
• Surface
– OD= 7-20”; Depth= up to 1500’
16" 1600' 20"

• Intermediate
4300' 13 3/8"
– OD= 7-13-3/8”; Depth= Varies

10 3/4" 6300'
• Production
– OD= Varies; Depth= Varies
• Liner
9650' – OD= Varies; Depth= Varies

10350'

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 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

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 Perforating
Function & Types

Explosive

Conical Liner
Provide communication from formation to
Before Firing cemented and cased wellbore.

Shaped Charge

Explosive

•Conveyance:
–Wireline
–Electrically Actuated
Detonation
Well Debris –Thru-Tubing
–Casing
After Perforating
Before Flow –Tubing Conveyed Perforating (TCP)
Dirty Perforation

•Actuation Methods:
–Electrically
–Mechanically
Clean Perforation
–Hydraulically

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 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
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 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

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 Flow Control
Seating Nipples & Blanking Plugs
Lock Recess No-Go Shoulder Polished Bore

Tubing Mounted Nipple Allows for the

Installation, Locking, and Sealing of Downhole
Flow Control Devices Within the Tubing String
Equalizing Mandrel Lock Mandrel Packing Sub Equalizing Plug Bottom

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 Flow Control
Sliding Sleeve

Nipple Profile Inclded for Inner Sleeve is Positioned Up

Instalation of Flow Control or Down by Wireline to Prevent
Devices or Allow Communication From
Tubing to Annulus (Sleeve is
Shown Closed)

Inner Sleeve Flow Slots Equalizing Slots Housing with

or Insert Flow Ports

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 Sub-Surface Safety Systems
Function & Considerations

Surface Controlled Sub-Surface Safety Valve (SCSSSV)-

Designed to shut-off tubing flow in the event of a catastrophe.

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

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 Sub-Surface Safety Valve
Tubing Retrievable

Control Port Annular Piston Flow Tube Flapper Valve

In a Safety Valve, Pressure Applied Via a Control Line from the Surface to
the Control Port Causes a Piston to Move Down Against a Spring . The
Piston is Connected to the Flow Tube which, as it Moves Down Cams the
Flapper Valve Open, Allowing Flow. When Control Line Pressure is
Released, as in the Case of a Disaster, the Spring Forces the Flow Tube Up
and The Flapper Valve Shuts Off Against Flow. (This Valve is Shown Closed)

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 Sub-Surface Safety Valve
Wireline Retrievable (Less Lock)

Top Sub

Set Screw

Chevron Packing Unit

Packing Sub
(See Detail "A")
(See Detail "B")

Chevron Packing Unit

Set Screw
O-Ring

Spring Washer

Spring Washer

Power Spring

Flow Tube

Spring Stop
C-Ring
O-Ring

Set Screw

Intermediate Sub

Set Screw
Resilient Seal
Set Screw
Flapper Pin

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Flapper Housing
 Sub-Surface Safety Valve
Tubing Vs. Wireline Retrievable

Tubing Retrievable Wireline Retrievable

• Advantages • Advantages
– Largest cross sectional flow – Retrievable w/o rig
area – Less expensive
– Allows insertion of wireline
retrievable SCSSSV • Disadvantages
– More reliable than wireline – Reduced flow area
type
– Must be removed during well
servicing, leaving well
• Disadvantages unprotected
– Requires rig to remove – May be stuck due to scale
– May suffer from erosion build-up
during stimulation

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 Packer Systems
Function & Types

Provides a seal between tubing and annulus at a fixed

depth.

Function:
– Production Control
– Production Testing
– Protection of Equipment
– Well Repair and Well Stimulation
– Safety

Types:
– Retrievable
– Permanent

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 Packer
Permanents & Seal Assemblies
Left Hand Square Thread (For Back Up Rings Extend Out
Running and Anchor Tubing Against Casing when Packer is
Seal Assembly) Set Giving an Excellent
Extrusion Barrier for the
Packing Element

Cast Iron Slips Give Smooth Bore for

360 Deg. Support Seal Assembly
when Set

Locator Seal Assembly with Extra Seal Units for Extended Seal Bore Packer

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Anchor Tubing Seal Assembly
 Packer
Retrievable

J-Pin Slip Cone Element Gage Ring

Drag Pad J- Slot Packing Element

Rocker Type Slips with Built in Drag Pads

are on Carrier Sub Which Rides in J-Slot.
When Slips are Un-Jayed They Ride Down
Over the Mandrel and Over the Cone Out
Against the Casing

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 Packer
Permanent Vs. Retrievable

Permanents Retrievables
• Advantages • Advantages
– Performance envelopes – Retrievable without milling
– Generally higher pressure – Reusable
ratings – Can be resettable
– Packer to tubing seals
retrieved without packer • Disadvantage
– Hold pressure from above or – Packer normally retrieved on
below without set-down production tubing
weight or tension
– Generally smaller I. D.’s
• Disadvantage – Generally lower pressure
ratings
– Must be milled over to retrieve
– Not reusable

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 Packer
Permanents Vs. Retrievables
Expanding Metal Back-Up
Rings Provide Zero
Extrusion Gap

PERMANET PACKER PACKING ELEMENT

Extrusion gap limits casing range

and pressure rating

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 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

• Chemical Injection
– 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.

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 Well Servicing and Workover

• Well Stimulation
– Hydraulic Fracturing
– Acidizing
• Re-perforation
• Fishing
• Remedial Cement Jobs
• Zone Isolation
• Water Shut-Off
• Secondary Recovery
• Plug & Abandon

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 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
• Well Servicing and Workover

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