Well completion-ENI-3

Agip KCO
G R O U P
TRAINING SPECIAL PROJECT

Intermediate Hydrocarbons Production Course
WELL COMPLETION
BOOKLET N° 3
Code: COM031-EAO Rev:04 Date:25/06/2004 Page number.: 81

Agip KCO Well completion
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GENERAL INDEX
1 INTRODUCTION TO THE TOPICS AND PROGRAMME BOOKLET N°1

2 COMPLETION OBJECTIVE AND FUNCTIONS BOOKLET N°1
3 COMPLETION DESIGN BOOKLET N°1
4 COMPLETION CONFIGURATIONS BOOKLET N°1
5 TUBINGS BOOKLET N°1
6 PACKERS BOOKLET N°1
7 SAFETY VALVE BOOKLET N°1
8 AUXILIARY EQUIPMENTS BOOKLET N°1
9 COMPLETION FLUIDS BOOKLET N°2
10 CASING PERFORATION BOOKLET N°2
11 WELLHEAD AND CHRISTMAS TREE BOOKLET N°2
12 GATE VALVES BOOKLET N°2
13 WELL UNLOADING BOOKLET N°3
14 SURFACE TESTING EQUIPMENT BOOKLET N°3
15 ARTIFICIAL LIFT (WIRE LINE INSTALLATION) BOOKLET N°3
16 WELL INTERVENTION BOOKLET N°3
Training Special Project

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BOOKLET INDEX
13 WELL UNLOADING 5
13.1 DISPLACEMENT FLUID 5
13.2 DISPLACEMENT SYSTEMS 6
14 SURFACE TESTING EQUIPMENT 10

14.1 GENERAL 10
14.2 EMERGENCY SHUT-DOWN SYSTEM 12
14.3 FLOWHEAD OR SURFACE TEST TREE 14
14.4 CHOKE MANIFOLD 15
14.5 TEST SEPARATOR 16
14.6 GAUGE THANK 17
14.7 TRANSFER CENTRIFUGAL PUMP 18
14.8 BURNERS 19
15 ARTIFICIAL LIFTING 20
15.1 CHOICE TYPE OF LIFTING 20
15.2 ARTIFICIAL LIFTING METHODS 23
15.3 GAS LIFT 23
15.4 SUCKER ROD PUMP 27
15.5 CENTRIFUGAL SUBMERSIBLE PUMP (ESP) 32
15.6 HYDRAULIC PUMPS 37
15.7 JET PUMPS 38
16 WELL INTERVENTION 39
16.1 CONDITIONS REQUIRING WORKOVER 39

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16.2 WIRE LINE SLICK LINE 41
16.3 WIRE LINE SURFACE EQUIPMENTS 43
16.4 ELECTRIC WIRE LINE 60
16.5 COILED TUBING UNIT 61
16.6 CONVENTIONAL WORKOVER 72

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13 WELL UNLOADING
In conventional completions, undertaken without using artificial lifting
systems, in order to be able to flow the well at the end of the completion
operation, the hydrostatic load applied by the completion fluid at the
formation level, should be reduced.
The normal practice in order to obtain this result is to replace the completion
fluid with a lighter one.
13.1 DISPLACEMENT FLUID
The density of the fluid used to displace the completion fluid from the tubing
is chosen in order to create an acceptable bottom hole pressure differential
with the minimum cost.
Fluid choice
Many elements concur in the choice of the most suitable displacement fluid;
the first is the completion fluid’s density, which is normally greater than the
water’s.
Usually water is used as a displacement fluid; also light mud may be used,
depending on the availability, cost and environmental impact of the different
fluids and bearing in mind, in case of discharges to the atmosphere, both
their disposal and dispersion in the atmosphere and surrounding
environment.
If a lower density is required, the most widely used fluid is diesel, with the
above mentioned limits, or otherwise a total or partial displacement of the
string with a specific type of gas, maybe methane or nitrogen.

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13.2 DISPLACEMENT SYSTEMS
The most common systems used in order to replace the fluid in the well are:
- Through formation absorption (bull heading)
- in circulation
- in lift with Coiled Tubing
Displacement through absorption

The Displacement through Absorption of the Formation System (bull
heading) is the simplest and most economical Although less used, due to
the fact that it may be applied only in specific cases and, in particular, when
the injected fluid does not damage the formation.
13.1 Typical Displacement draw

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Permeability to Hydrocarbons
In some formations the permeability to hydrocarbons deteriorates when the

rock is dampened with a watery fluid, or certain formation elements are not
compatible with the fluids that are to be injected.
Formation permeability
Another choice determining element for the displacement in bull heading,

is that the formation’s permeability should be high, in order to allow for the
injection operations at low pressure levels and rapidity.
Volume string displacement
The displacement of the string through absorption may be partial or total

and may be carried out with a fluid or gas (maybe methane or nitrogen).
Displacement in circulation
The displacement in circulation method is the most widely used, due to the
fact of being as effective as the displacement through absorption, and with
the advantage that the operation is carried out without affecting the
formation.
Circulation Procedure
The displacement in circulation consists in directly pumping the light fluid

inside the string, recovering an equivalent returned volume from the
annulus, passing through a bottom hole valve that connects tubing and
annulus, or otherwise directly from the tubing shoe.

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Completion fluid replacement with packer fluid
Whenever the completion programme provides for the Completion Fluid

replacement with the Packer Fluid, the tubing string’s displacement in
circulation, with the choice of the fluid fit for cleaning operations is granted.
13.2 Replacement with packers fluid

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Displacement through Coiled Tubing
This system is used for bringing-in the well, using light fluid displacement or
a gas lift, continuous or intermittent, through Coiled Tubing.
The Coiled Tubing let down inside the tubing string is used when the well
has absorbed great quantities of fluid during the perforation and/or
completion phases. The system of displacement in circulation should be
repeated many times, implying then a strong impact on operational costs, or
in case of very depleted formations it may become necessary.
13.3 Gas lift

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14 SURFACE TESTING EQUIPMENT

14.1 GENERAL
The main objective when drilling a well is to test and evaluate the target
formation. The normal method of investigating the reservoir is to conduct a
well test. There are two types of well test methods available:
- Drill Stem Test (DST). The scope is to define the quality of the formation
fluid.
Where drillpipe/tubing in combination with downhole tools is used as a
short term test to evaluate the reservoir. The formation fluid may not
reach, or only just reach the surface during the flowing time.
- Production Test. The scope is to define the quality and quantity of the
formation fluid. Many options of string design are available depending on
the requirements of the test and the nature of the well.
Fig. 14.1 Surface safety system

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Fig. 14.2 Surface equipment layout

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14.2 EMERGENCY SHUT-DOWN SYSTEM
The Emergency Shut-Down (ESD) is used when quick closure is necessary

due to a pipe leak or burst, equipment malfunction, fire, or similar
emergency. The ESD system allows a flow line valve to be safely closed
from a remote station or from the ESD console.
In well testing operations, the ESD controls the hydraulically-operated flow

line valve on the flow-head. If required by the surface testing setup, it can
also control an additional safety valve which is sometimes located upstream
of the choke.
Pressure is applied from the ESD to open valves and release to close
valves.
The ESD is push-button activated from ESD stations located at the
separator, the heater/steam exchanger, and the tank. An additional station
is commonly positioned at an escape route. To back up these stations, hi/lo-
pressure pilots are located on the flowline upstream of the choke manifold,
upstream of heater/steam exchanger, and upstream of the separator. The
hi-pressure pilot initiates well closure when the pressure in the flow line
rises above a high-level threshold (line plugged), and the low-pressure pilot
initiates well closure when the pressure falls below a low-level threshold
(flow line rupture or leak).

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Fig. 14.3 Emergency shut down system

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A standard surface testing equipment set is usually composed of:
- Emergency shut down (ESD) system

- Flowhead
- Choke manifold
- Heat exchanger
- Separator
- Tank
- Transfer pump
- Burners and booms
14.3 FLOWHEAD OR SURFACE TEST TREE
Modern flowheads are of solid block construction, i.e. as a single steel

block, as opposed to the earlier modular unit, which was assembled from
various separate components. Irrespective of the type, both should contain:
- Upper Master Valve for emergency use only.

- Lower Master Valve situated below the swivel for
emergency use only.
- Kill Wing Valve on the kill wing outlet connected
to the cement pump or the rig manifold.
- Flow Wing Valve on the flow wing outlet,
connected to the choke manifold, which is the ESD
actuated valve.
- Swab Valve for isolation of the vertical wireline or
coil tubing access.
- Handling Sub which is the lubricator connection
for wireline or coiled tubing and is also for lifting
the tree.

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- Pressure Swivel which allows string rotation with the flow and kill lines
connected.
14.4 CHOKE MANIFOLD
The choke manifold is a system of valves and chokes for controlling well
flow and usually has one adjustable and one fixed choke. Some choke
manifolds may also incorporate a bypass line. The valves are used to direct
the flow through either of the chokes or the bypass. They also provide
isolation from pressure so that choke changes can be made.
Fig.14.4 Choke manifold

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14.5 TEST SEPARATOR

The test separator is required to:
- Separate the well flow into maybe three phases; oil, gas and water
- Meter the flow rate of each phase, at known conditions
- Measure the shrinkage factor to correct standard conditions
- Sample each phase at known temperature and pressure.
The standard offshore separator is a horizontal three phase, 1,440psi

working pressure unit. This can handle up to 60mmscf/day of dry gas or up
to 10,000bopd and associated gas at its working pressure. Other types of
separator, such as the vertical or spherical models and two-phase units
may be used.
Fig.14.5 Test separator

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14.6 GAUGE THANK
A gauge tank is an atmospheric vessel whereas a surge tank is usually

rated to 50psi WP and is vented to the flare.
Tanks are used for checking the oil meter/shrinkage factors and for
measuring volumes at rates that are too low for accurate flow meter
measurement. They usually have a capacity of one hundred barrels and
some with twin compartments so that one compartment can be filled while
the other is pumped to the burner via the transfer pump.
Tanks can also be used for collecting large atmospheric samples of crude
for analysis or used as a secondary separator for crudes that require longer
separation times. Some tanks can have special features such as steam
heating elements for heavy/viscous oil production tests, etc.
Fig 14.6 Gauge tank

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14.7 TRANSFER CENTRIFUGAL PUMP
A transfer pump, connected to the gauge tank outlet, is used when it is

necessary to empty one compartment of the gauge tank as the other is
being filled.
Generally, the pump is electrically driven, but diesel-driven pumps are also
available. If the oil must be reinjected from the separator into an existing
flowline, a high capacity, high-pressure transfer pump is used.
Other uses of transfer pumps include pressure boosting when there is
insufficient pressure to achieve atomization at the burner. Different types of
pump used in the field:
- the centrifugal transfer pumps

- the screw type transfer pumps
- the gear type transfer pumps
Fig. 14.7 Transfer centrifugal pumps

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14.8 BURNERS
Burner heads are mounted on the end of the booms which are usually
installed on opposing sides of the rig to take maximum advantage of wind
direction changes, i.e. to keep at least one burner heading downwind. The
oil and gas flowlines, including the tank and relief vent lines, from the test
area to the booms, must have diverter manifolds for directing flow to the
leeward boom.
Most recent designs of burners are promoted as ‘green’ or ‘clean’ type
burners. This is indicative of them being less polluting to the environment by
having superior burning technology. Although still not ‘ideal’ their ability is
much improved over previous models.
Fig.14.8 Burners

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15 ARTIFICIAL LIFTING
The intention of installing artificial lift is to reduce the hydrostatic head and,
therefore, bottom-hole pressure. Energy can also be introduced by reservoir
pressure maintenance.
In some fields, both pressure maintenance and artificial lift are used which
defers the installation. In other cases, artificial lift from the outset is
necessary to achieve the production and economic targets. Just as tubing
size is critical to high PI wells, then minimisation of the FBHP is critical to
low PI, low pressure wells.
Reasons for the installation of artificial lift are to:
• Reduce the effects of declining bottom-hole pressures.

• Offset the effects of increasing water production.
• Overcome high friction effects of heavy viscous or waxy crudes.
• Meet with targeted high offtake rates.
• Kick off high GLR wells that die when shut-in.
15.1 CHOICE TYPE OF LIFTING

The choice of the type of lifting is determined by various factors:
- The type of completion: conventional or multiple and according to the
physical and dimensional limitations inside the well.
- Well location (on / off-shore): Another determinant choice factor is the
location of the well: either on shore or off-shore. Under similar well
conditions, the best system for an onshore well may not be implemented
offshore due to available supply and space limits.
- Source of supply: The eventual availability of a source of supply, i.e.
gas or electric energy supply

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- Environmental conditions: The planning of the lifting system should be

carried out bearing in mind environmental conditions; extreme cold and
heat, wind or snow limit the choice of the lifting system.
- Corrosive and solid fluid presence: Corrosive and solid factors present
in the fluid, such as sand, salts or paraffin, are primary conditioning
elements.
- Gas / oil and water / oil ratios: The gas/oil and water/oil ratios limit the
range of applicable types of lifting.
- Well productivity: Another very important element is the well’s
productivity. For significant capacities ESP and Gas Lifts are preferred.
- Formation Pressure: Another choice determining factor, is the formation
pressure level compared to its hydrostatic pressure.
If the difference is significant, the Gas Lift may require significant
quantities of gas and ESP and Sucker Rod are hence preferable.
- Formation Depth: Formation depth is a limit for certain systems, since
Hydraulic Pump and ESP are more effective in installations at significant
depths.
Deviated wells exclude the use of Sucker Rod Pumps in favour, i.e., of
Gas Lifts.
- Well depth: The viscosity of the fluid that should be produced.
The viscosity of the fluid that should be produced and the possibility to
form emulsions or foams (in particular through gas lift)
- Fluid viscosity and formation sand:
Highly viscous fluids maybe controlled better with Gas Lifts or Hydraulic
Pumps.
Formation sand is better managed with the Gas Lift system.

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- Other elements: Other elements concurring to the choice of the lifting

system are:
- Gas or electric energy availability.
- Availability of compression or pumping units
- Well disposition: isolated or multiple, in clusters or platforms.
- Environmental restrictions.
- Workover costs on wells either on-shore or off-shore.
Conclusions
In conclusion, all conditions relevant to reservoir, wells and fluids to be

produced, as well as environmental, should be taken into consideration, in
order to identify the best applicable lifting system.
The choice of the lifting system is also based on operational costs and
workover frequency and costs.

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15.2 ARTIFICIAL LIFTING METHODS
The most common methods are the following:

- Gas Lift
- Sucker Rod (or Beam Pumping)
- Electrical Submersible Pump
- Hydraulic Pump
- Jet Pump
15.3 GAS LIFT

The continuous gas lift method adds gas into the producing fluids which
reduces the hydrostatic head and, hence the back-pressure on the
formation.
The injection gas is supplied in a closed loop system in which it is taken

from the separators and then compressed, dried if necessary and then
delivered to the well
The lift gas is normally pumped into the annulus and into the tubing through
gas lift valves installed in Side Pocket Mandrels (SPMs). Occasionally the
gas is pumped into the tubing and the production taken up the annulus or in
the annular space in a concentric completion.

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SPM Positioning
The depth of SPMs is obtained studying their disposition and is specified in

the completion programme.
It is important to position SPMs accurately in order to optimise well
performances.
Fig. 15.1 Continuos ann. flow
Installation and valve extraction
When mandrels are installed in the completion string, valves may be

installed and extracted by wire line operations when the artificial lifting of a
well is needed or in order to modify valve set-up parameters

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Fig.15.2 Side String gas lift
Side String Gas Lift
This type of installation allows for the injection of gas in the service string
through the valve and inside the tubing. It also allows the isolation of the
casing from the pressure of the injection gas.
As mentioned above it is possible to cross the packer and carry out

injections in the bottom where wide perforated intervals are found.

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Chemical injection
Similar to Side String Gas Lift, Chemical Injection provides controlled

injection of a chemical substance at bottom hole.
A capillary line from the surface to the valve, allows for an exact control of
product injection. Using a different configuration, it is possible to inject the
product under the packer.
Fig. 15.4 Chemical Injection

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15.4 SUCKER ROD PUMP

Introduction to Rod Pump Completions
It is the most common pumping system for onshore wells with a low
supplying capacity.
Usually the depth limit is approximately 3000 meters and capacities do not
exceed 300 mc/per day (approximately 2000 bbl/d)
Main elements
The system consists of three main elements:
- the Down Hole Pump assembly

- the Sucker Rod
- the Surface Pumping Unit
Fig.15.5 Rod pump

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Fig 15.6 Tubing pump

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Fig.15.7 Rod pumping scheme

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Characteristics
The annulus is usually open and is used to dispatch gas flows, separating
at bottom hole. The produced fluid reaches the Well Head through the
tubing, including the Sucker Rods.
Usually, tubing’s are anchored to the casing at bottom hole and fixed live, in
order to reduce movements during the pumping activity (breathing) as well
as rod frictions and consumption.
Types of pumps
There are two types of Pumps, the Tubing Retrievable pumps and the
Rod Retrievable Barrel pumps.
With the Tubing Pumps it is necessary to pull out the tubing string to
replace the Barrel while, using Rod Pumps, the Barrel is retrieved with the
Sucker Rods.
The Tubing Pumps have a greater pumping capacity but require more
complex and costly maintenance interventions.
TUBING PUMP ROD PUMP
Fig. 15.8 Basic Rod pump Operations

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Fig.15.9 Basic rod pump operations

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15.5 CENTRIFUGAL SUBMERSIBLE PUMP (ESP)
General
ESP is an easy operation lift method applicable in any location except

where the cost of workover is high.
Most pump installations are on the end of tubing and positioned above the
perforations or open hole.
The motor is situated at the bottom of the assembly so that the well flow
around the motor will dissipate the heat generated.
If the pump has to be positioned below the interval, a shroud is used to
draw the produced fluid down past the motor.
Bottom discharge pumps are used in powered dump flood wells.
The pump characteristics are based on constant rotational speed which is

dependent on the AC supply frequency, 3,500 rpm at 60 Hertz and 2,915 at
50 Hertz.
Due to these high speeds and pump construction, it is obvious that sand
production is very detrimental and that emulsions are easily formed.
To prevent sand production it is sometimes necessary to install a gravel
pack or pre-packed screen for pump protection.
If possible, the installation should be designed to facilitate down hole

separation of free gas and vent up the annulus, which is necessary when
the gas volume exceeds the pump operating limit (typically +/-10% of the
total fluid volume).
On offshore installations, gas production up the annulus may be a
significant problem.
Annular safety valves or dual string with SCSSV’s shall be considered

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Fig. 15.10 ESP System Layout

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ESP MOTOR INTAKE ESP PUMP

GAS SEPARATOR
Fig. 15.11 ESP motor, Intake Gas Separator, ESP pump

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Most common ESP installation
A B C D E
A- ON-SHORE -No Packer, no safety valve

B- OFF-SHORE LINE Y SPOOL - Packer, safety valve and wire
C- WITH SHROUD - Packer
D- OFF-SHORE - Packer, safety valve
E- CABLE/ COILED T. CONVEYED - Packer
Fig.15.16 ESP Installation

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Equipment preparation
Pumping system components
Pumping system components with ESP electric engines, motor, pump,

protector and intake are generally delivered in metal containers with the top
placed in the side of the box highlighted with coloured paint
Equipment handling
The handling of boxes should be carried out carefully in order to avoid

damaging the equipment.
In particular, pumps and Motors should never be lifted only from the centre.
The electric cable Reels should be lifted with ropes anchored to a pivot
passing through the Reel’s axle, and never lifted with the fork-lift truck’s
arms placed on the electric cable.
API Regulations
Other information on the installation procedures of ESP equipment are

found in the “API Recommended Practices for Electric Submersible Pump
Installation’.

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15.6 HYDRAULIC PUMPS

Introduction
Subsurface Hydraulic pumps are down-hole pumps powered by high

pressure fluid directed to them from the surface. There are two types in
common use; the positive displacement piston pump driven by a hydraulic
reciprocating subsurface engine directly connected to the pump, and the jet
pump.
Piston type hydraulic pump.
Fig 15.17 Typical hydraulic subsurface pump installation

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15.7 JET PUMPS
The jet pump is a hydrodynamic rather than hydrostatic type of pump and
operates principally through momentum transfer between two adjacent fluid
streams.
The jet pump uses no moving parts and imparts momentum into the fluid
using the Venturi effect with a jet, throat and diffuser. The size of these can
be varied to pump volumes of 100-15,000stb/d although free pump systems
are limited to 8,000stb/d with 41/2” tubing.
Power fluid
Pump tubing
Casing
Suction AN AT
PS , QS
Nozzle
Throat Nozzle Diffuser
Throat
PN , QN PD , QD
Diffuser
AS = (AT - AN)
Combined fluid return
Well production
Fig 15.18 Nomenclature for jet pump design

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High pressure power fluid passing through the nozzle has its potential
energy (pressure energy) calculations as illustrated, converted to kinetic
energy in a jet of fluid at high velocity.
Well fluid mixes with the power fluid in a constant area throat or mixing
tube, and momentum is transferred to the well fluid, causing an energy rise
in it.
As the mixed fluids exit the throat, they are still at a high velocity, and thus
contain substantial kinetic energy.
The fluids are slowed in an expanding area diffuser that converts the
remaining kinetic energy to static pressure sufficient to lift fluids to the
surface.
Design variables include sizes of nozzle and throat and the ratio of their
flow areas, as well as component shapes, angles, lengths, spacing, finishes
and materials.
Through selection of appropriate flow areas and ratios, pump configuration
can be optimized to match well conditions.
Such a pump is suited to deep wells with high lifts.
16 WELL INTERVENTION
A workover is an operation to be performed on a well that for a certain
amount of time will be shut in to production, causing a production loss to the
company.
A lot of different aspects have to be evaluated to select the most
convenient compromise in term of cost and efficiency.
16.1 CONDITIONS REQUIRING WORKOVER
Following there is a list of motivations which would address to recommend a

workover.

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Mechanical Problems
• Tubing collapsed or leaking.

• Production casing broken or damaged.
• Tubing obstructed (sand, paraffin, asphaltene scales).
• Packer leaking.
• Gravel pack damaged.
Reservoir Problems
• Sand movement.
• Water coning.
• Gas coning.
• Perforations plugged.
• Emulsion and water blocking.
• Clay swelling and silt problems.

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Well Conversion
This is applicable to production wells.

• Artificial lift installation.
• Water injection.
• Gas injection.
The well intervention could be performed:
- Rigless with coiled tubing unity, electric line.

- Workover with service rig (Pulling Unit or Work-over rig), if the operation
includes the completion pulling out of hole.
16.2 WIRE LINE SLICK LINE
Utilized to set mechanical plugs and operate a Circulating Valve. A wire line
set bridge plug can be run in hole. The correct setting depth will be
determined by CCL utilization. The dumping of cement, by cement bailer,
will increment sealing and resistance to differential pressure. However,
limitations may be due to hole deviation while running in hole, and also to
the bridge plug itself, that has to pass from a small OD, suitable to run
through the tubing ID, to the largest casing ID.

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Fig. 16.1 Wireline slick line

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16.3 WIRE LINE SURFACE EQUIPMENTS
Standard wellhead equipment is shown:
1) Upper sheave
2) Slick line wiper (stuffing box)
3) Liquid chamber
4) Upper lubricator
5) Middle lubricator
6) Quick union
7) Lower lubricator
8) Bleed off valve
9) BOP
Fig. 16.2 Standard wellhead equipments
Wire Line Surface Equipment is defined as the necessary equipment to

perform wireline operations in a pressure well, included connection with the
wellhead, safety equipment and the lifting equipment.
The four-section wireline ginpole used to raise the lubricator, can be fixed to
any type of Christmas tree using two special clamps and guidelines.
The four-section wireline ginpole comprises:

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A. Ginpole
B. Crown block
C. Hay pulley for 0.082- or 0.092-in. line
D. Wireline wellhead platform
Stuffing box
Fig.16.3 Stuffing box
The Stuffing Box is defined as the surface equipment element that

guarantees the hydraulic seal on the wireline cable by means of sealing
elements during the operations in hole
The Stuffing Box must be equipped with a top pulley (Sheave Bracket Assy)
and bottom connection fit to the lubricator upper section connection. The

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type of steel and the elastomeric seals will be corrosion resistant to all the
fluids in hole for quick union seals and packing element as well.
The Stuffing Box WP must be same as the other surface equipment WP.
The quantity and quality of packing elements in the Stuffing box packing
unit shall be changed in accordance with the fluid in hole and with the wire
line steel type. They must be replaced as per the following criteria:
• Characteristics of the fluid in hole.
• HP-HT situations.
• Work typology and duration.
• Packing type versus wire line material compatibility
• Experiences in analogous situations.
Lubricator Riser
The Lubricator is composed of sections of tubes of about 8ft long.
Fig. 16.4 Lubricator Riser

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Wire line BOP
A BOP is defined as the surface equipment element that provides the

emergency shut in of the wire line.
Fig. 16.5 Wire line bop
BOPs are the safety surface equipment elements that provide emergency
shut-in on the wireline in the event of a leak or accidental well flow and are
sometimes referred as “wireline valve”.
The specification of the BOP must be resistant to all corrosion from the well
fluids and the WP must be equal to, or higher than, the Xmas tree WP.
The ID must be compatible with the maximum tool OD to be run during
operations and the bottom connection must be compatible with the adapter
flange and lubricator bottom connection.
The BOP must be equipped with an equalising valve to enable equalisation
of pressure before opening the BOP rams.

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Tool String
• Rope Socket
• Stem
• Jars
• Knuckle Joint
• Running/Pulling Tools
Fig.16.6 Tool String

Toolstring selection
The ‘Wireline String’ is defined as the down hole equipment connected

with the slick line cable, fit to allow the running and the operations with wire
line tools in an oil or gas well, furnishing the weight and the necessary
impact force to operate.

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Rope socket
The disc-type rope socket The wedge-type rock

is designed to connect the socket is designed to
slick line connect the slickline
(0.082, 0.092 and 0.102 in.) (0.102, 0.105 and 0.108 in.)
to the downhole string. to the downhole string.
This stranded-line rope

socket is designed to
connect stranded cable
to the downhole string.
Fig. 16.7 Typical standard rope socket
The ‘Rope socket’ is defined like the upper part of the wireline string
connecting with the wireline cable.
The use of the rope socket ‘Disk-Spring Type’ is suggested for light duty
operations.
For heavy duty operations, for 0.125" OD wireline cable size and with H2S
service wireline cable is suggested the use of the rope socket ‘No-Knot
Type’

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Stem
Fig. 16.8 Typical standard stem
‘Stem’ is defined as the bar used to add weight to the wireline string; they
must be installed immediately under the rope socket, to furnish the
necessary weight to allow the running in hole and the necessary impact
force for the jar action.
The standard lengths of the wireline stem are 1ft, 2ft, 3ft and 5ft length.
Wireline stem are obtained by machining out of a single piece of forged
steel.
In order to obtain a more compact wireline string, the use of ‘Filled Type
Stem’ is suggested.
Operations in high deviated wells may be performed by using ‘Roller Stem’
provided with rollers. The friction reduction of the wireline string is a function
of the number of wheels and size.
The wheels must be made by material compatible with the tubing material.

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JAR
Located below rope socket and stem in tool string

• Mechanical
- Spang (Link)
- Tubular
• Hydraulic
• Aid in installing or retrieving subsurface controlled devices by jarring up
or down
Fig. 16.9 Typical jars

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Link Jar
It is placed in tool string’s middle. Its types are hydraulic and mechanical. It
aids in installing or retrieving subsurface control devices by jarring up or
down. With mechanical jars attached below the stem, the weight of the stem
can be used to ‘jar’ up by quickly pulling up on the wire to rapidly open the
jars to create an upward impact.
To jar downward, the wire would be pulled up slowly to open the jars and
then release the wire quickly to allow the stem to fall, closing the jars and
creating a downward impact.
A greater impact can be obtained while jarring up because the wire can be
pulled up rapidly to move the stem up at a very fast rate of speed. When
jarring downwardly, only the weight of the stem controls the rate of speed at
which it falls. We cannot use the wire to push the stem downward.
Spang jars are available in two different stroke lengths 20” and 30” stroke.
The 20” stroke jars are most commonly used because it is felt that they are
more stout, with less chance of becoming scissored. Tubular jars are used
most often when well conditions or the operation might cause the spang jars
to become fouled.

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Hydraulic Jar
Fig.16.10 Hydraulic Jar
The Hydraulic jar is a tool able to perform only upstroke jar action.
The shot force is related to the applied over pull to the wireline string, at the
jar release moment.

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The hydraulic jar shooting time depends on the hydraulic oil characteristics,
selected according to the well temperature. The choice of an oil with
viscosity such to allow the jar action 15-20secs after the over-pull is applied,
is suggested.
The hydraulic jar external diameter must be the same of rope socket and
stem external diameters. The hydraulic jar must be connected in the
wireline string immediately above the link jar.
Use of the hydraulic jar in gas wells is not recommended. A leakage on the
hydraulic section can produce the ‘gasification’ phenomenon in the
hydraulic oil, loosing the jar action.
Tubing Gauging
Tubing gauging is defined as the operation of tubing calibration, performed

on drilling, workover or production, either onshore or offshore.
The operation could be performed during the completion or well production.
Fig. 16.11Tubing gauging

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Description
The gauge cutter is used to:
• calibrate the tubing

• locate reductions and landing nipples
• remove paraffin and other deposits from the
tubing walls.
Fig 16.12 gauge cutter

Impression Block
The impression block is used to ascertain the shape, position and size of
the top of the fish.
Sand Bailer
Sand bailers are used to:
• Remove sand, mud, salt or small pieces of

debris from the tubing or casing
• Clean fishing necks
• Take samples.
Fig. 16.13 Sand bailer

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Shifting Tool (Standard)
• Releasing keys (one or top)

• Go below sliding sleeve, when come up, 90
degree shoulder of keys catch on recess in
upper (or lower) end of sliding sleeve and
move it fully, then releasing profile on lower
end retracts keys, and tool is released.
Fig.16.14 Typical Shifting tool (standard)
R PULLING TOOL
• Run first
• Extensive jarring downward
• Largest pin
• Dogs
• Shear pin cap
• Cylinder (Skirt)
• B, S, and J cores
B S J
Fig. 16.15 R Pulling tool

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R pulling tools engage external fishing necks and shear by jarring up. R
pulling tool core types are B, S, and J.
B has the longest core, but smallest reach.
J has the shortest core but longest reach.
RB short reach does not allow for engaging fishing neck with pin thread
above it while RS does. Tools use upward jarring to release when
necessary and use line pull to cause dogs to securely engage fishing neck,
reducing possibility of dogs slipping off bottom hole control.
R pulling tool has shear pin cap. Has larger pin than S pulling tool pin due to
motor manipulation compared to gravity manipulation.

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B PULLING TOOL
• Dogs (B and E)
• BB latches rope socket; F tubing and collar
stops and test tools; and B, C, and W slip lock
mandrels
• BE pulls all controls that do not have full
relative motion and fishing in difficult
conditions (crooked tubing or heavy fluid)
• Smaller shear pin than R pulling tool
• In wire fishing, gives one more flexibility in
wire and tool retrieval
Fig. 16.16 B Pulling tool
B pulling tools engage external fishing necks and shear by jarring up.
B pulling tool core types are B and E. B has shorter dogs and shorter reach
while BE has longer dogs and longer reach.
B pulling tools fish for subsurface control devices which have fishing neck
junk and in difficult well conditions crooked tubing and (heavy fluid) if R
pulling tool cannot, due to judgment.

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B pulling tools require less jarring to release due to its smaller shear pin. B
pulling tool has exposed dogs (without skit) that are frequently useful in
extremely sandy or trashy wells.
Being exposed, dogs can move down over fishing neck of mandrel easily.
GS/GR PULLING TOOL
• Fishing or retrieving
• Latches onto internal fishing neck
wire line equipment
Fig. 16.17 GS/GR Pulling tool
G pulling tools engage internal fishing neck. GR pulling tool engages

internal fishing neck and shears by jarring up while GS pulling tool
engages internal fishing neck and shears by jarring down.

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GR pulling tool is GS tool and GU adapter. For GR tool, shear pin in shear
up adapter is used. GS pulling tools are used during wireline operation to
unlock and pull a variety of subsurface controls with internal fishing necks.
Designed to shear with a jarring down action, this pulling tool is used where
excessive jarring upward is necessary to retrieve subsurface controls. In
running position, dogs are designed to seat and lock in internal recess of
mandrel being run until pin is sheared by downward jarring. With this tool
being shear down to release, it can be used in many cases as a running
tool.
GR pulling tool are used during wireline operations to unlock and pull a
variety of subsurface controls with internal fishing necks. Designed to shear
with a jarring up action, this pulling tool is used during routine wireline
operations on controls when sheared down is not possible. GR pulling tool
is assembled by incorporating GS pulling tool with a GU shear up adapter.

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16.4 ELECTRIC WIRE LINE
Fig. 16.18 Wire line set inflatable bridge plug

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16.5 COILED TUBING UNIT
It can be utilized for through tubing operations like:

• To spot cement plugs or sand plugs.
• To set inflatable bridge plugs (IBP). However, limitations due to the
maximum differential pressure to which they can withstand may be due
to the ratio between OD while running and maximum inflated OD.
Another limitation of this technique is the tendency of these tools to slide
inside the casing due to differential pressure.
• Setting of IBP. Cement cup displaced on IBP top, shall ensure seal and
anchoring integrity.
• Lower zones abandoning by setting an IBP and squeezing cement.
• CT and electric wire line run in hole together with the possibility of using
CCL to set IBP at the correct depth.
• Casing perforations with Coiled Tubing Gun Conveyed techniques.
Fig. 16.19 Coiled tubing unit

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POWER UNIT
Fig. 16.20 Coiled tubing system
The power unit consist of a diesel engine which powers a dual hydraulic
pump. One section drives the motors of the injector head while the other is
used to drive the reel assembly. Hydraulic output pressure control valves
are used to control the operation of both the injector and the reel. The
power skid also accommodates a nitrogen pressurised hydraulic oil
accumulator which operates the BOP.

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Coiled Tubing Reel
Fig. 16.21 Coiled Tubing Real
The tubing is stored on a reel and coiled upon itself in the same way as
flexible line on a wireline unit.
The reel is supported on an axle and is rotated by a hydraulic motor through

a chain drive. The drive system has two functions. When injecting tubing
into the well it acts as a constant torque brake keeping the tubing tight on
the reel and in tension between the reel and the injector head. When pulling
out the hole it rotates the reel and coils the tubing as it is lifted out of the
well by the injector head. As it is the injector head which injects and pulls
the coiled tubing into and out of the well, the reel assembly only needs to
exert a small tension to control the tubing when spooling.
The inner end of the coiled tubing is connected to the hub of the reel which
incorporates a rotating joint. Fluids can be pumped through the connecting
pipework, through the rotating joint and down the coiled tubing whilst the

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reel is in motion and to any pressure within the operational limit of the coiled
tubing itself.
Injector Head
Fig. 16.22 Injector head
The injection head injects the coiled tubing into the well, pulls it out of the
well and holds it stationary in the well. It works by gripping the tubing
between contoured blocks which themselves are part of two sets of heavy
double row chains. Over the area of contact between the block and the
tubing, the chains are guided by a train of rollers. These rollers are pulled
together hydraulically in order to expert the required grip on the tubing and
prevent slippage. The chains and their drive system are mounted on a
subframe.
On top of the subframe there is a roller guide, usually called a “gooseneck”,
which supports the coiled tubing in its transition from motion along the
vertical axis of the wellhead to the horizontal axis of the storage reel.

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Stuffing Box (Stripper)
Fig. 16.23 Stuffing Box (Stripper)

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Coiled Tubing Bop
Fig. 16.24 Coiled tubing Bop
The BOP stack is a standard piece of equipment included with the coiled
tubing unit. It is not called into use under normal conditions. However, it is
function and pressure tested before each job. The BOP may have blind
rams which will seal off wellhead pressure when the coiled tubing is out of
the hole, shear rams which will slice through the coiled tubing in an
emergency and affect a seal, and tubing rams which will seal off the
pressure in the annulus between the coiled tubing and the well tubing.

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Coiled Tubing Connectors
Roll-on Multislip Single slip
connector connector connector
Fig. 16.25 Typical Connectors

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Coiled Tubing Check Valves
Fig. 16.26 Check Valves

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Coiled Tubing Applications
Fig. 16.27 Coiled Tubing Valve

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Fig. 16.28 Coiled tubing application
Tubing and / or casing can become plugged with emulsions, or formation

debris. Coiled tubing can be run down to the hold up depth and nitrogen, or
gelled or foamed liquids can be used to circulate the debris to surface.
Should the plugging material be too hard to be removed by this method,
turbine drilling can be carried out. However, if the formation pressure is not
enough to support a full column of gel, turbine drilling can still be carried out
using low weight stable foams as the circulating fluid.

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Coiled Tubing Gas Lifting
Fig. 16.29 Sand Clear out application

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16.6 CONVENTIONAL WORKOVER
Conventional workover are workover in which the well is killed and the
completion string is pulled. The pulling of the completion string is the simple
criterion which differentiates conventional workover from coiled tubing,
wireline and concentric tubing workover, none of which involve removal of
the production tubing from the well. Following the workover, the well is
recompleted in the same way as an initial completion operation is carried
out.
Well Analysis
Before starting any workover programme, the following well analysis shall
be carried out.
Analysis of Well Productivity History
The following data needs to be examined:

• Historical production data.
• Abnormal pressure/rates trend.
• Presence of unexpected fluids (formation water, gas).
• Presence of sand.
Actual Well Status
Following data should be available from the well file:

1. Fluid Composition (last PVT Report): to check for paraffin,
asphaltene, scale or indication of corrosive fluids.
2. Well Status Report, to extract information on:

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• Type of completion.
• Releasing values for packers and anchors.
• Completion scheme (including tubing tally).
• Production casing (including casing tally).
• Gravel pack configuration if any.
• CPI log and production casing CBL, VDL, CET.
Logistic Problems Evaluation
• Area preparation
• Transports
• Waste treatment and disposal management
• Environmental safety requirements
• Equipments storage and handling
Rig Selection Criteria

Depending on the geographic area, on well characteristics and overall
workover requirements, the following considerations shall be made:
• Type, size and availability of rigs

• Well maximum operative depth
• Maximum required over-pull
• Rig move constraints
Sequence of operations
- Well killing
- Removal Christmas Tree
- Pull out Completion
- Level partialization
- Level Change/Remedial Job

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- Fishing and Milling
Well killing
Fig. 16.30 Well killing scheme
Kill the well. This may be archived, for example, by opening a sliding side-
door in the completion string by wireline and circulating kill fluid down the
annulus and up the tubing, displacing the hydrocarbon content of the tubing

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into the surface processing facilities of the offshore platform or onshore

wellsite. Alternatively, the tubing contents can be “bullheaded” into the
formation.
In addition, mechanical plugs may be set in one or more of the landing
nipples of the completion string and a back-pressure valve installed in the
tubing hanger to provide additional security during the period between
removal of the Xmas tree and installation of the BOPs.
Remove Christmas Tree, rig up BOP
Fig. 16.31 Remove Christmas tree, rig up BOP

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Example of Level partialization
1) Well flowing
2) Increase water cut
3) Shut off water zone
4) Well re-completed
Fig 16.32 Level Partialization

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Example of cross flow between levels
1) Levels cross flow due to lack of cement

2) Pull out completion, performed cement squeeze
3) Mill out the cement excess and re-complete the well
Fig. 16.33 Cross flow between levels

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Example of production casing repair by cement job
1) Leak on casing string

2) Set BP below leak point
3) Perform cement squeeze
4) Mill out cement excess and BP. Re-complete the well
Fig. 16.34 Casing Repairing

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Example of production casing repair by “Internal casing patch”

2) Run in hole Internal casing patch
3) Set in position and gauge casing internal diameter ready for re-
completion
Fig.16.35 Casing repairing

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Example of production casing repair by “External casing patch”

2) Cut casing string below leak point
3) Pull out of hole casing section
4) Re-run casing string with casing patch and latch on casing stub.
Fig 16.36 Casing repair

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Example of re-completion with Gravel Packing
1) Well flowing
2) Formation sand limits well flow rate.
3) Recover completion, clean wellbore and re-complete with Inside
Gravel Pack assembly
4) Re-complete with Open Hole Gravel Pack after section mill the casing
string and under-ream the open hole.
Fig.16.37 Completion with gravel pack

Well completion-ENI-3

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Agip KCO

TRAINING SPECIAL PROJECT

Code: COM031-EAO Rev:04 Date:25/06/2004 Page number.: 81

1 INTRODUCTION TO THE TOPICS AND PROGRAMME BOOKLET N°1

Training Special Project

13.2 DISPLACEMENT SYSTEMS 6

14 SURFACE TESTING EQUIPMENT 10

14.2 EMERGENCY SHUT-DOWN SYSTEM 12

14.3 FLOWHEAD OR SURFACE TEST TREE 14

14.4 CHOKE MANIFOLD 15

14.5 TEST SEPARATOR 16

14.6 GAUGE THANK 17

14.7 TRANSFER CENTRIFUGAL PUMP 18

15.2 ARTIFICIAL LIFTING METHODS 23

15.3 GAS LIFT 23

15.4 SUCKER ROD PUMP 27

15.5 CENTRIFUGAL SUBMERSIBLE PUMP (ESP) 32

15.6 HYDRAULIC PUMPS 37

15.7 JET PUMPS 38

Training Special Project

16.2 WIRE LINE SLICK LINE 41

16.3 WIRE LINE SURFACE EQUIPMENTS 43

16.4 ELECTRIC WIRE LINE 60

16.5 COILED TUBING UNIT 61

16.6 CONVENTIONAL WORKOVER 72

Training Special Project

13.1 DISPLACEMENT FLUID

Training Special Project

13.2 DISPLACEMENT SYSTEMS

Displacement through absorption

13.1 Typical Displacement draw

Training Special Project

In some formations the permeability to hydrocarbons deteriorates when the

Another choice determining element for the displacement in bull heading,

Volume string displacement

The displacement of the string through absorption may be partial or total

The displacement in circulation consists in directly pumping the light fluid

Training Special Project

Completion fluid replacement with packer fluid

Whenever the completion programme provides for the Completion Fluid

13.2 Replacement with packers fluid

Training Special Project

Displacement through Coiled Tubing

13.3 Gas lift

Training Special Project

14 SURFACE TESTING EQUIPMENT

Fig. 14.1 Surface safety system

Training Special Project

Fig. 14.2 Surface equipment layout

Training Special Project

14.2 EMERGENCY SHUT-DOWN SYSTEM

The Emergency Shut-Down (ESD) is used when quick closure is necessary

In well testing operations, the ESD controls the hydraulically-operated flow

Training Special Project

Fig. 14.3 Emergency shut down system

Training Special Project

A standard surface testing equipment set is usually composed of:

- Emergency shut down (ESD) system

14.3 FLOWHEAD OR SURFACE TEST TREE

Modern flowheads are of solid block construction, i.e. as a single steel

- Upper Master Valve for emergency use only.

Training Special Project

14.4 CHOKE MANIFOLD