SPE 161947

A Break Through In Monobore Completion System by Using New Design

"One Run" Upper Completion System
T.Ghayoomi, M.H.Hashemi, P.Karami and M.Javadian , Petropars Limited (PPL); G.Ueland, A.Ibragimov and
A.Delavar , Completion Technology Resources (CTR)

Copyright 2012, Society of Petroleum Engineers

This paper was prepared for presentation at the Abu Dhabi International Petroleum Exhibition & Conference held in Abu Dhabi, UAE, 11–14 November 2012.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers is prohibited. Permission to
reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract

Majority of the high rate gas wells in the world are completed with Monobore completion system. The conventional sequences
of running Monobore completion in giant gas field of SouthPars are in three steps: Run No. 1 which includes running Liner
and liner hanger by drill pipes (DP) and normally followed by cementing behind liner, Run No. 2 which includes Running Tie
Back production Packer with 15 ft Polished Bore Receptacle (PBR)by setting tool and DP and finally Run No. 3 which
includes running completion string with upper seal stem and at the end complete the well with proper space out. Running of
tie back production packer with setting tool and DP in one step and running upper seal stem by tubing in last step has some
concerns (More Rig time, cost, safety, etc).
Feasibility Study and research was carried out to check the possibility of combining the run No. 2 and 3 together.
A new method has been developed and after successful surface test it was run in one of gas wells in South Pars giant gas field
in Persian Gulf. All pressure tests after installation were satisfactory. This procedure saved almost 1.5 day of rig time and
protected seals against mechanical damage while running in the hole.

Introduction

SouthPars gas field is located offshore Iran in the Persian Gulf shared between Iran and Qatar. It is gas condensate reservoir
with highly prolific gas wells with average production of 80 MMscf/day, hence it calls for Monobore completion with 7”
tubing and 7” cemented liner. The Monobore completion design has advantages of high rate gas production without any
diameter restriction that can cause downhole equipment erosion due to the production fluid’s turbulency.
The liner has to be run without an integral packer, due to concerns regarding reliability and gas tight (pressure container),
accordingly, tieback packer is recommended on a separate run into the liner Polished Bore Receptacle (6ft PBR). The tieback
packer features an extension for Monobore anchor seal (15ft Upper PBR) and seal assembly in the bottom (6ft lower seal
stem) for pressure integrity with the liner hanger PBR. The upper completion should then tie into the tieback packer by means
of a mechanical anchor latch and seal stem (15ft upper seal stem). The anchor latch fixes the completion string downhole to
avoid seal stem movement during production and injection until when sheer off forces exceeds 200 Klb upward.
Therefore, operationally speaking, the conventional Monobore completion design in SouthPars gasfield includes 3 main stages
of operation. In first stage, liner and liner hanger are run, set and cemented. The liner hanger is equipped with lower PBR of 6
ft length. Upon successful liner run, the hole clean out will be accomplished by running bit, polish mill and casing scraper. The
second stage includes running of mechanical set tie back permanent production packer together with long (15 ft) upper PBR
and short (6ft) lower seal stem. The packer is run on drill pipes and setting tool. After successful setting and packer pressure
test, the final run of completion involves running of upper seal stem (15ft) and completion string together with downhole
accessories (i.e. safety valve).

Acquiring the conventional Monobore system, intrinsically, has its own challenges and risk. Upper seal stem mechanical
damage during running and installation, complicated and time consuming space out operation and well control issue due to
long installation period are some main concerns that were promoted Petropars Ltd. completion department to look for
alternative methods, in exemplification, Petropars experienced a catastrophic failure due to seal stem mechanical damage
2 SPE 161947

whilst running hole in one of its development wells which

postponed the completion operation in highly deviated wells till Run 3: Run long seal
further modification onto the conventional system. stem on tubings,
accommodate in upper
PBR, space out and land
Accordingly, a combined two run system that involves tubing hanger.
combination of the second and third stage (Run 2 & 3) of the
conventional method was proposed and investigation about
previous field experiences began. In order to fulfill the objective,
upper long seal stem (15ft) must be protected inside long upper
PBR (15ft) to avoid possible seals mechanical damage during
running and installation. It was found out that all previous
experiences with the same objectives were incorporated
hydrostatic or hydraulic set production packers with the
application of plug setting rather than mechanical setting packers.
Since all of the designated well were highly deviated, plug setting
and retrieval operation sound impossible. Therefore,
brainstorming and research continued on the existing equipment
with hanging the seal stem inside long PBR. Yet, questions raised
“how?”. The new system should involve running packer and
upper seal stem in single run on tubing, setting the packer by
applying required weight, disengaging from the packer to install
the tubing hanger while performing the space out and shoulder out
onto the tubing spool.

This paper argues the challenges involved in the process and

brings the benefits of this new designed system which could
reduce the completion time by 1.5 day and as a result reduces rig
time and cost; it involves more accurate space out and reduces the
source of errors in conventional Monobore completion procedure;
It enables us to complete longer and crooky wells. As an
example, one well has been completed successfully in South pars
giant gas field in Persian Gulf with this new system and more Run 2: Run packer on
wells are planned to be completed in near future. setting tool,
 accommodate seal
stem in lower PBR,
Completion System set and pull out
setting tool.
Three Stage Completion Design/Installation (Conventional
System).
The Monobore completion system is a common completion
design in prolific gas wells as it provides the following
advantages:

1. Larger bore ID and hence reduction of pressure drop and

increase of production capability.
2. Minimizing change of bore ID and hence reduction of
the erosion risk.
3. Better well intervention when required.

The Monobore completion system in gas wells is divided in to

two categories; the lower completion system which includes
running of liner and upper completion system which includes
running of tie back production packer in one run and running the
completion string in another run.
At the first stage the liner string containing Float shoe, Float
Collar, Landing Collar and liner hanger is run in the well. The
liner hangers are mostly hydraulic set and activates by dropping
ball and increasing the pressure to liner hanger setting pressure Run 1: Run liner hanger
(Figure 1). The pressure is increased to release the liner hanger by setting tool, set same
running tool and shear out the ball seat. The liner is cemented in ,release and cement.
next step. The clean out trips are required to assure access to TD
Figure 1.Three stage monobore completion system
SPE 161947 3

and polish mill run is required to clear lower PBR to safe accommodate lower seal stem.
Tie back production packer is the second stage of running the Monobore completion system. Tie back production packer
includes mechanical packer setting system, packing element, lower seal stem and a long Upper Polish Bore Receptacle. Down
ward force application on packer energizes the slips and packing element (Figure 1).
Third stage of the completion involves running of completion string, 15ft Seal Stem, mechanical latch (Figure 1), tubing
string, down hole safety valve and tubing hanger. Upper completion string engages to PBR by means of mechanical latch
which incorporates a sheer ring. The value for this sheering is set to be 200 Klbs upward pull which is based on the
expansion/contraction during stimulation/production. Hence, the system is fixed at both ends (Mechanical latch and tubing
hanger). Detailed tubing stress analysis by Osprey Tubular Designer calculates maximum upward force of 188 klb during cold
acid injection with 3,000 psi injection pressure on a typical vertical well, thereafter, considering safety factors, rupture value
was designed to 200 klbs.
After careful space out which considers all applied forces during well stimulation and production life of the well, the seal stem
is entered to upper polish bore receptacle and tubing hanger lands on wellhead landing shoulder. The space out procedure
includes identification of exact length of completion string in hole by means of pressure and weight indication in order to meet
following criteria:

1. Be able to land the tubing hanger

2. Have the full length of seal stem in PBR during production and well stimulation.
3. Latch the seal stem to PBR to have static sealing.

Pressure indication is the most reliable means to identify the exact position of the seal stem while entering to PBR. The weight
indication shall be identified by utilization of Snap Locator. The snap locator is a bow type strong spring which is energized
when it enters to PBR. The completion integrity is checked by pressure test of annuls and tubing.

There is a big dispute over space out procedure of the upper completion string among the contractors of the field.
Conceptually, in tubing anchored completion design it is thought that, tubing string must be in tension at both fixed ends -
Anchor latch and tubing hanger. Hence, during production, due to temperature expansion, completion string comes back to
neutral state and helical/sinusoidal buckling is avoided. Following this general idea, some adopt a space (i.e. 80cm) between
NO-GO of the mechanical latch and upper PBR during the space out operation and landing of the tubing hanger. Hence, by the
help of reverse ballooning effect (annulus pressure test) they are able to simultaneously latch the system at downhole and holds
it in tension when pressure is bled off in the annulus.

To put in into perspective, although PPL’s detailed stress analysis reveals the possibility of helical/sinusoidal buckling during
steady production and temperature expansion, the chance of mechanically activate the latching mechanism during reverse
ballooning due to medium to high casing to tubing drag is rare. This free, unanchored tubing system allows the seal stem to
travel up and down during well intervention operations which are quite abundant throughout the life cycle of the wells (i.e.
shut ins, stimulation and production logging) and hence high possibility of mechanical damage of the seal stem and annulus
leakage. Considering the cost of workover operation and replacing CRA tubing, it is justified to acquire NO-GO to NO-GO
space out procedure and try to sit the anchor latch on top of PBR when tubing hanger shoulders out; accordingly, latch is
activated by applying annulus pressure. Space out procedure should be much precise to avoid latch activation before landing of
tubing hanger. PPL has adopted this procedure throughout its completion operation and found an activated latch system during
one of its workover operation.

It is worth noting that, although stress analysis shows the possibility of helical/sinusoidal buckling during production, but a
zoom into the calculation reveals the low DLS (Dog Leg Severity) due to buckling. This is reasonable when ones imagine the
low redial clearance between 7” tubing and 9 5/8” casing. Moreover, this compression load exerted during production is still
too less than compression efficiency of tubing connections.

Challenges With Conventional Completion System.

Three stage Monobore completion system has the following challenges:

1. The seal stem is run bare in the hole and seals are subject to mechanical damage while running in long interval.
2. Extreme drag in highly deviated wells misguides in getting the weight indication and correct space out while entering
the seal stem in to PBR.
3. High possibility of seal mechanical damage due to possible repetitive space out operation when indications are under
question especially in highly deviated wells
4. The space out procedure is time consuming. It may take circa three hrs to make sure about precise measurement.
5. It takes much of rig time. The longer the completion string running period the more concern about the well safety.
6. Running of tie back packer by setting tool on drill pipes exerts additional rental cost to the operation; moreover,
applying drill pipe dopes is a menace to clean packer fluid above packer and PBR.
4 SPE 161947

These intrinsic concerns, risks in running and installation of conventional Run 2 &3: Run packer
Monobore completion system together with one catastrophic failure that and long seal stem on
occurred in one of the highly deviated wells at SouthPars gasfield due to tubings, accommodate
lower seal stem in lower
seal stem mechanical damage during running and installation, stipulated PBR, set packer, perform
the Petropars Ltd. Completion team to modify this conventional three run space out and land
system to a two run system which integrates the second and third runs of tubing hanger.
conventional system
to one run upper completion. This methodology involves the combination
of packer run and upper seal stem/mechanical run together to protect the
seal stem from the above mentioned risks.

One Run Upper Completion System.

Initially, a combined two run system that involves combination of the
second and third stage (Run 2 & 3)(Figure 2) of the conventional method
was proposed and investigation about previous field experiences began. It
was quite obvious that to fulfill the goals, upper long seal stem (15ft)
must be protected inside long upper PBR (15ft) to avoid the main concern
of the mechanical damage during running and installation. It was found
out that all previous experiences with the same objectives were
incorporated hydrostatic or hydraulic set production packers with the
application of plug setting rather than mechanical setting packers, which
was the case. Since all of the designated wells were highly deviated, plug
setting and retrieval operation sound impossible to let us think about
changing the packer setting mechanism from mechanical to
hydrostatic/hydraulic. Therefore, brainstorming and research continued
on the existing equipment with hanging the seal stem inside long PBR.

Completion Technology Resources (CTR) is the supplier of the downhole

completion tools in the project, hence after full consideration about the
engagement and disengagement process of the seal stem in and from the
packer PBR together with risk of failure during the process were
investigated. A mechanism was designed onto the seal stem with
application of shear pins. A collet sleeve inside the prep profile of packer
PBR helps to withstand downward movement of the seal stem while
running hole. The locking mechanism should also withstand the
downward force required during packer setting which is around 60 Klb.
The sheer pins holds the collet sleeve attached to PBR during running
hole and overpull testing of the packer after setting up to 60 Klbs
overpull. Eventually the shear pins shear above 60klbs of overpull and
allows the disengagement of seal stem from packer PBR.

Meanwhile, the space out measurement could accurately been performed

during packer setting process when the desired weight was applied on
latch. The operation continues after disengagement with replacing the
landing string (usually drill pipes) with tubing hanger and space out pup
joints to shoulder out the hanger into the tubing spool.

Based on the above intuition, a prototype system was manufactured and

stack up test has been done successfully with minor concerns. Hence,
upon management approval and firm confidence within the engineering
and operation team, the system was successfully run in one of the highly
deviated wells (C-01) in SouthPars gasfield with more than 50 degrees of
inclination at packer depth. This One Run Upper Completion system
saved up to 1.5 days of rig time equals to more than $200,000 on each
well expenditure.
 Run 1: Run liner hanger
by setting tool, set same
,release and cement.

Figure 2.Two stage monobore completion system ,

ORUC, (One Run Upper Completion )
SPE 161947 5

Field Experience

Well C-01 is one of the longest and highly deviated wells drilled by Petropars in SouthPars gasfield. As well plots (Figures
3&4) and directional survey (Table 1) show, it is deeper than 3,000 m TVD with more than 3,000 m step out acquiring DLS of
less than 2 °/30m. One Run Upper Completion system (ORUC) showed in figure 5 and 6 has been run in this well conveyed
with 4,000 m tubing. The ORUC depth was correlated respect to liner hanger using pressure and weight indications when
lower seal stem was pushed into lower PBR; packer was set by applying 50 Kips, and 120 Kips down weight was applied to
assure full packer element squeeze and slips engagement. Accordingly, packer has been over pull tested up to ~40 Kips, and
seal stem released at ~60 Kips overpull out from upper PBR. Meanwhile space out measurement was performed using
recorded data while setting the packer. The tubing hanger was landed in position and pressure tests have been done
successfully up to 4,500 psi. Fortunately, all weight indications and sheerings were observed and recorded according to the
expected values (figure 7).

Measured
Inclination Azimuth TVD DLS
Depth
(deg/30 m
(m) ( deg ) ( deg ) (m)
)
0.00 0.00 0.00 0.00 0.00
256.72 3.31 336.62 256.69 2.19
372.40 12.06 333.07 371.27 3.17
631.47 14.93 338.54 621.28 0.31
719.27 15.01 340.88 706.04 0.15
804.67 15.56 345.93 788.38 0.74
863.68 14.97 346.33 845.31 0.32
1195.98 32.37 343.81 1152.43 1.22
1373.59 39.30 342.04 1296.27 1.33
1489.18 41.95 343.35 1383.20 0.94
1547.59 44.24 343.50 1425.71 0.80
1721.62 50.55 342.26 1542.38 0.92
1780.83 50.49 342.01 1579.87 0.47
1894.81 49.95 342.12 1653.29 0.22
2065.59 49.93 342.48 1763.15 0.10
2123.92 49.58 342.98 1800.94 0.42
2182.40 49.55 342.55 1838.83 0.18
2329.19 51.11 342.75 1932.38 0.30
2497.61 53.09 341.65 2035.70 0.95
2562.01 53.80 341.52 2074.08 0.73
2649.72 54.97 341.90 2125.16 0.41
3001.43 58.71 343.78 2317.77 0.28
3059.81 59.15 343.24 2348.01 0.52
3385.38 61.46 343.81 2509.57 0.17
3471.15 59.46 344.32 2551.94 0.61
3614.88 59.02 343.75 2626.90 0.34
3786.93 59.72 343.45 2714.56 0.68
3898.20 60.92 343.09 2769.85 0.48
4047.48 61.72 343.25 2839.95 1.26
4105.38 59.65 343.30 2868.26 1.19
4222.95 56.15 343.94 2931.06 0.35
4258.50 54.94 344.44 2951.17 1.08
4324.34 56.14 343.86 2989.16 2.09
4440.53 59.98 331.26 3048.24 5.39
4530.00 59.59 336.74 3093.63 1.36
4613.69 60.65 338.80 3135.27 0.29
4650.00 60.13 340.80 3153.24 1.39
4747.68 59.32 343.34 3202.24 0.41
4773.00 59.00 343.15 3215.22 0.44

Table 1. Well C-01 Trajectory

6 SPE 161947

Figure 3. Well plot top view

Figure 4. Well plot, Vertical view

SPE 161947 7

Figure 5.Picking up ORUC, (One Run Upper

Completion, 14 meter length )

Figure 6. Checking ORUC before running in hole

8 SPE 161947

Figure 7. Drilling Log record for

setting the ORUC
SPE 161947 9

Future plans

One Run Upper Completion system (ORUC) has successfully been run in one of the highly deviated wells of SouthPars
gasfield. However, it is under investigation to design a contingency releasing mechanism of the upper seal stem out of
production packer other than overpull and shearing. PPL and CTR are investigating the possibility of having rotational or
extra-overpull releasing mechanism as contingency systems when the primary shearing fails particularly in extremely, tortuous
wells where applied forces are not completely transferred downhole.

Conclusion

Running of Monobore completion in two runs have concerns regarding seals damage, well safety, space out accuracy, well
cleanliness and operation cost. The new One Run Upper Completion design combines packer and upper completion runs to
encounter all these concerns and seems to be more beneficial.

Acknowledgment

The authors of this technical paper would like to acknowledge the management of Petropars Ltd. (PPL) and Completion
Technology Resources(CTR) for permission to publish this paper. The authors also grateful to many skilled engineers and
operation personnel who helped and executed the new design to be a successful achievement.