282483987-IWCF-WI-1-Well-Completion.pdf

CAN PREVENT THIS

WELL INTERVENTION CERTIFICATION COURSE

Chapter 1

COMPLETION EQUIPMENT

Well Completion

Last process of completing a petroleum well after the installation of casing, cementing job & perforation.

• Series of tubular (tubing & completion accessories) are run & placed to

enable the well to produce or inject, accordingly.

• Xmas tree is positioned on top to regulate or isolate flow. • Single or multiple string determined by the reservoirs.

• Vertical or horizontal completion determined by reservoir geological

aspects.

• Conventional or monobore completion determined by the fields

economics.

Completion Equipment

Various type of equipment installed with production tubing string & each of them with its specific function.

The essential type of equipments install in completion string are:

1. Production Packer 2. Circulation Device

3. Sub-Surface Safety Valve (SSSV) 4. Landing Nipple

5. Other Accessories 6. Tubing Hanger

7. Wellhead & Xmas Tree NOTE:

All illustration are not to scale

PRODUCTION PACKER

4

A mechanical device connected with

Production Packer

Function

• Seal between tubing & casing.

• Prevent fluids movement due to pressure differential. • Seal between multiple zones

• Contained reservoir fluid within tubing.

• Isolates casing from reservoir fluids & corrosion from well effluents or injection fluids

Application

• Use in high pressure & highly corrosive reservoirs.

Placement

• Position above perforation & away from casing collar. • NEVER set packer across casing collar.

• EOT of tailpipe shall be ±10ft above perforation.

5 Perforation Casing Casing Collar Tubing Packer

Production Packer

6 Slips Slips Packer Seal Element Body Construction • Body • Hardened Slips • Packing Element • Shear Pins Setting Mechanism

• Mechanical (Manipulation of string) • Wireline Set (Electrical & Explosive) • Hydraulically Set (Using Pressure)

Production Packer

7 Permanent Packer

Single Retrievable Packer

Dual Retrievable Packer

Production Packer Variant

1. Permanent Packer • Single String 2. Retrievable Packer • Single String • Dual Strings Permanent Packer

• Integral part of casing.

• Removed by milling operation. • Wireline set.

Retrievable Packer

• Integral part of tubing.

• Can be retrieved & redressed. • Hydraulically set

Packer Installations

8 Single Zone

Completion

Single String Multi Zones Completion

Retrievable Packer Accessory

Travel Joint

• To compensate tubing movement due to

temperature and/or pressure changes during treating or production.

• Install on the short string for dual completion.

Permanent Packer Accessories

10

ATA LTS PBR TSR

Locator Tubing Seal (LTS)

• Seals assembly with locator providing effective tubing/packer seal.

Anchor Tubing Assemblies (ATA)

• Seal assembly with anchoring feature.

Polished Bore Receptacle (PBR)

• Polished ID tubular installed on top of packer to accept male

tubing seal assembly.

Tubing Seals Receptacles (TSR)

• PBR Inverted version attached on top of packer to accept female tubing seal

assembly.

Seal Bore Extension

• Same packer ID tubular connected to the bottom of packer to accept male seal assembly & milling spear or tool.

CIRCULATION DEVICE

11

A mechanical device serves to provide

communication between tubing & annulus.

Circulation Device

Function

• Provide communication between tubing & annulus or reservoir. • Eliminate false production data.

Application • Fluids circulation. • Fluids displacement. • Gas lift. • Production access. • Well killing.

• Production data acquisition

Variants of Circulation Devices

1. Sliding Side Door (SSD).

2. Side Pocket Mandrel (SPM). 3. Perforated Joint. 4. Ported Nipple. 13 SPM Ported Nipple SSD PERFORATED JOINT

Circulation Device

Function

• Provide communication between tubing & annulus or reservoir. Application • Fluids Circulation • Fluids Displacement • Well Killing • Production Access. Construction • Seal Bores • Inner Sleeve • Nipple Profile

• Self Equalizing Ports

Placement

• As close as possible above top production packer. • Above each reservoir’s perforation

SSD

14 SSD Nipple Profile Seal Bore Equalizing Port Flow Port Inner Sleeve Seal Bore

SSD

15 Straddle Tool Equalizing Sub Mandrel Extension Lower Packing Assembly Lock Mandrel Assembly Isolation Tool Isolation Sub Variants • Jar ↓ To Open • Jar ↑ To Open • Larger Flow Ports • Smaller Flow Ports

Disadvantage

• Inner sleeve may stuck due to sand or other substance sticking.

Advantage

• More than one SSD can be installed in one tubing string.

• Can set Straddle Tool. • Can set Isolation Tool.

Straddle Tool

• Blank off top zone & bottom zone to flow.

Tool Construction:

• Lock Mandrel • Equalizing Sub

• Mandrel Extension

• Lower Packing Assembly

Separation Tool

• Blank off bottom zone & top zone to flow.

Tool Construction:

• Lock Mandrel • Separation Sub • Mandrel Extension

• Lower Packing Assembly

Side Pocket Mandrel

Originally designed for gas lift system but it also used for communication device.

Feature:

• Full tubing bore • Orientating sleeve • Discriminator

• 1” or 1½” valve pocket Valve Type:

• Dummy Valve (DV) • Gas Lift Valve (GLV)

• Chemical Injection Valve (CIV) • Circulation Valve (CV)

• Differential Dump Kill Valve (DDKV) • Equalizing Valve (EV)

All valve utilize Latch to lock in pocket. 17

SPM

Full Tubing Bore & Pocket

Orientating Sleeve Discriminator Receptacle DV GLV LATCH

Perforated Joint

Function

• Eliminate flow restrictions.

• Provide true downhole readings. • Prevent instrument vibration.

Application

• True production data acquisition

Construction

• Tubing pup joint perforated with greater flow areas than tubing.

Placement

• Installed above gauge hanger landing nipple.

18 Perforated Holes

Collar

Perforated Joint Application

19

With Perforated Joint With Out Perforated Joint

Gauge Gauge

Nipple Nipple

Flow Flow

• Flow turbulence created in nipple. • Gauge vibrate (gauge damage). • False data acquisition.

• Flow thru nipple & perforated joint. • No vibration (gauge safe).

• True data acquisition. Flow Flow

Ported Nipple

Function

• Provide communication between tubing & reservoir.

Application

• Production access in sand accumulation zones. .

Construction • Short Tubular • Nipple Profile • Seal Bores • Flow Ports Placement

• Installed above sand accumulation zones reservoir’s perforation 20 PORTED NIPPLE Port Seal Bore Seal Bore Profile

DHSV

21

A mechanical downhole barrier serves to

prevent uncontrollable hydrocarbon flow

possible cause by surface impact or explosion

Downhole Safety Valve

Function

• Permit flow during normal conditions but would isolate

formation pressure from wellhead to prevent damage during emergency.

Application

• Medium or high pressure well.

DHSV Type • DCSSV • SCSSV Valve Closure • Ball • Flapper • Poppet 22 Remote controlled by hydraulic pressure, set only in

designated nipple & can be integrated with pilots, ESD & surface safety manifolds.

–

– Direct activated by surrounding pressure & can be set anywhere in tubing string.

Closed Open

BALL TYPE

Closed

Open

FLAPPER TYPE POPPET TYPE

DCSSV

These valves are installed in appropriate landing nipples with wireline lock mandrel.

Types of DCSSV (Closure Mechanism - Poppet or Ball Valve )

1. Pressure Differential Safety Valve

2. Ambient Safety Valve

3. Injection Valve

4. Bottom Hole Regulator

23 A “Normally Open” valve utilizes pressure-differential to close valve.

Pressure differential exceeded pre-set spring & forces it to close. Adjustable bean size can be set for pressure differential. Surface pressure will equalize & open valve.

A “Fail Safe” valve utilizes pre-charged dome pressure. Well pressure reaches the pre-set dome pressure & open the valve. When well pressure drops below pre-set dome pressure the valve will close.

A “Normally Close” valve. It serves like a check valve allowing passage of injected fluid but close when injection ceased.

A throttling valve installed downhole to enhance overall well safety where high surface pressure & hydrates formation present problems. In gas well it increase downhole temperature & prevent hydrates formation. In oil well it liberate gas & lighten oil column to increase flow velocity. STORM CHOKE Pre-Charge Connection Spring Ball Valve Lock Mandrel Connection

SCSSV

24 SCSSV Variants • WRSV • TRSV SCSSV Construction • Body • Piston • Spring • Flow Tube

• Valve (Ball or Flapper)

SCSSV Placement

• Set below crater depth

• Above control line hydraulic fluid hydrostatic head. WRSV Lock Mandrel Piston Spring Flow Tube Flapper Packing

WRSV

25

TRSV

26

TRSV With Insert Valve TRSV Close TRSV Open TRSV Lock Open

Flapper Spring

Flow Tube

Lock Open Sleeve Lock Open Profile Ratchet Profile

Nipple Profile

Safety Valve Integrity Test

Integrity Test

Leak test are performed immediately after DHSV are installed & periodically to accomplish 3 functions;

1. Integrity of safety valve seals 2. Integrity of WRSV lock assembly

3. To cycle valve prevent “freezing” after setting for extended periods of time.

NOTE:

Only authorized personnel should conduct all the above test on all SSSV.

Annulus Safety Valve

A “Fail Safe Close” device that isolate flow of gas between above & below the tubing/casing annulus.

Function

• Provide control in annulus if tubing hanger is breached.

Application

• Artificial lift or secondary recovery production wells.

Closure Mechanism

• Sliding sleeve • Poppet

• Flapper

29

Surface Control Manifold

Function

• Provide & control the hydraulic pressure required to hold SCSSV & SSV open.

Construction & Operation

• One or more pneumatic hydraulic pumps to maintain hydraulic operating pressure for the safety valve.

• 3 way valve controlled by remote pressure pilots & fire sensors which is controlling the safety valve hydraulic pressure

• Pilots, sensors or manual activation removes the hydraulic pressure thus close the safety valve.

Sequential Opening & closing Logic

1. Closing • SSV 1st • SCSSV 2nd 30 2. Re-Opening • SCSSV 1st • SSV 2nd

LANDING NIPPLE

31

Landing Nipple

Function

• Receptacle for Flow Control Device (FCD).

Application

• Production wells.

Construction

• Profile (to secure locking mechanism) • Seal Bore

• No-Go shoulder (provide positive location in highly deviated well).

Type

• Non-Selective Nipple • Selective Nipple

• Ported Nipple

• Safety Valve Nipple

32

NON SELECTIVE NIPPLE

(Bottom No-Go) Profile Seal Bore No-Go Shoulder SELECTIVE NIPPLE (Top No-Go) PORTED NIPPLE Port SV NIPPLE Contro l Line Port

Landing Nipple

Non-Selective Type

• Smallest ID in tubing string. • Only one installed in tubing • Bottom No-Go

Selective Type

• Several nipples of same size installed • Top No-Go

Placement

• Non-Selective

• Bottom most nipple • Selective

• Strategic point for FCD

• Immediately below production packer

OTHER ACCESSORY

Wireline Entry Guide

35

HALF MULE SHOE WEG

45 Angle

BELL GUIDE WEG

45 Taper

Function

• Provides safe re-entry of WL tools.

Construction

• Its chamfered internal end prevent tool hung-up.

Placement

• Attached at the end of tubing or tail pipe.

Type

1. Half Mule Shoe

• Incorporate large 45° angle cut on one side to facilitate entry of permanent packer top.

2. Bell Guide

• Incorporate 45° lead in taper to allow re-entry of WL tools into tubing.

Blast Joint

Function

• Withstand external abrasive action from formation fluids.

Construction

• Medium length (20’) with SS heavy-wall.

Placement

• Installed opposite perforations (for non-gravel pack

completion).

36

Flow Coupling

Function

• Withstand internal corrosion caused by flow turbulence.

Construction

• Short tubular with SS heavy wall.

Placement

• Installed DS FCD which caused turbulence e.g. Nipple, SSD, SCSSV. • High velocity & high pressures wells

installed both US & DS.

37 FLOW COUPLING DS Flow Coupling US Flow Coupling Landing Nipple with FCD

Control Line

Function

• 1¼” conduit connected to SVLN or TRSV that supplies hydraulic fluid to SCSSV & terminated at tubing hanger.

Application

• Clamp to tubing external by protector

Materials

• 316 SS for sweet service

• INCONEL or ELGILOY alloys for sour service

Note

• NOT recommended to splice control line.

Tubing

Function

• Medium to convey well fluids from wellbore to surface or vise versa & prevent well effluents expose to casing.

Thread Connections

API: Tapered thread & rely on thread compound to effect seal

Premium: Metal-to-Metal seal

Tubing Selection Governed By:

• Well peak production rate • Well depth

• Use of WL tools

• Pressure & temperature

• Annulus differential pressure etc

39

HYDRIL CS Connection

Metal to Metal Seal

API EUE Connection

TUBING HANGER

Function

• Suspend tubing string with threaded connection

• Isolate casing tubing annular

• Provide access to annular space (‘A’

annulus) & control line.

• Receptacle for BPV

Hanger Type

1. Bowl & Mandrel Tubing Hanger

• Combination of Tubing Head & Hanger

2. Multiple Mandrel Tubing Hanger

• Use in multiple completion. • Similar to No 1

3. Ram Tubing Hanger

• Tubing manipulation is necessary to

locate/latch & maintain tension 41

TUBING SPOOL TUBING HANGER RAM TUBING HANGER

Tubing Hanger

Feature

1. Landing Threads

• Uppermost threads on the hanger & support the entire tubing string weight during landing operations.

2. Bottom Thread

• Support entire tubing string weight & seal producing conduit from the tubing/casing annulus.

3. Sealing Area

• Provide compression type sealing between hanger seal OD & tubing spool ID. Sealing is accomplished by energizing elastomer seals or metal-to-metal seals by tubing weight action on various load bearing surfaces,

42 Seal Neck

Seal

Tubing Connection Profile

Control Line Connection

Tubing Spool Features

1. Connections

• Size & pressure rating must be compatible of joining connections.

2. Upper Bowl

• Provides seal area for tubing hanger 3. Lower Bowl

• Provide isolation seal 4. Tie Down Bolt

• Secure & prevent upward movement due to pressure surges.

• Energizes body seal on tubing hanger. 5. Outlets

• Access to ‘A’ annulus (pressure monitoring or gas lift).

6. Test Port

• Permit pressure testing to hanger seal, lock-down screw packing connection between flanges & secondary (isolation) seal.

TUBING SPOOL

Upper Bowl

Lower Bowl Outlet

Test Port Tie Down Bolts

Tubing Spool

WELLHEAD & XMAS TREE

Wellhead

Wellhead is the assembly of casing spools & tubing spool on top of a well.

Functions

• Anchor & connections for each individual casing • Pressure isolation of individual casing

• Connection for Xmas tree

• Connections for completion string • Isolation of production annulus

• Access to annulus for pressure monitoring and/or pumping.

Wellhead Types

• Conventional Wellhead (modular) • Compact Wellhead (sub-sea)

Casing

At drilling stage, various casing strings are run & cemented in a well.

1. Conductor 2. Surface Casing 3. Intermediate Casing 4. Production Casing 5. Liner Function of Casing

• Protect against borehole collapse

• Prevent unwanted leakage into or from formations • Provide concentric bore for future operations

• Provide wellhead foundation

Each type of casing string is suspended in CHH & assembled on module stack that forms wellhead.

Casing Type

1 Conductor Pipe

• Prevents unconsolidated formations being eroded.

• Provides flow path for drilling fluids.

• Cemented in pre-drilled hole or pile driven.

• Sizes ranging from 16” – 30” OD.

• Depth varies from surface to 40’ – 400’.

Surface Casing

2 Surface Casing

• Protection in case of blowout & Acts as wellhead foundation.

• Isolates shallow consolidated & fresh water formations.

• Cemented along its whole length.

• Sizes ranging from 13 ⅜” – 20” OD.

• Setting depth up to 1 500’ below surface.

48

Intermediate Casing

3 Intermediate Casing

• Seals off problem zones, loss circulation zones, high pressure gas pockets & soft formations encountered.

• Protects production casing from corrosive fluids.

• Cemented up to surface casing shoe.

• Sizes ranging from 7” – 13 ⅜” OD.

• Depth depends on total well depth &

conditions encountered, shallow wells not necessary to set this.

49

Production Casing

4 Production Casing

• Isolates reservoir from other fluid bearing formations.

• Set above or through producing formations.

• Cemented from intermediate casing shoe to its bottom.

• Sizes ranging from 5” – 9⅝” OD.

50

Liner

5 Liner

• Used when geological & pressure

conditions make it hazardous to penetrate the producing formation without the hole being protected by casing.

• Shortened casing hangs from bottom of previous casing through producing

formations.

• Cemented along its length.

• Cost effective 51 Liner Production casing Intermediate Casing Conductor Pipe Surface Casing

Conventional (Modular) Wellhead

It’s a built up of casing spools. During drilling, drilling BOP is installed above this casing spool. The drilling BOP must be removed each time a new casing

spool to be installed for next stage of drilling & position the drilling BOP on top of this new casing spool before drilling commence.

Features:

1 Starter Spool (Conductor Pipe) 2 Surface Casing Spool

3 Surface Casing Hanger 4 Production Casing Spool 5 Production Casing Hanger 6 Tubing Spool

7 Tubing Hanger “A” Annulus

“B” Annulus “C” Annulus

VETCOGRAY Subsea Wellhead MS-800 Advantages:

• Utilized in shallow water and deep wells

• Full-Bore enables to run one extra casing string under BOP control • Option to run 18” and 16” casing

strings below the mud line.

• Larger completion options, by reaching total depth with a larger production

string. 53 Energizing Ring Retainer Nut Wicker Profile Support Ring Casing Hanger

Debris Trap Area

Surface valves manifold to control flow of well fluids & access for well intervention activities.

Features

1 Lower Master Valve (LMV)

• Manual, NOT working valve optimum conditions.

2 Upper Master Valve (UMV or SSV)

• Emergency valve

3 Flow Wing Valve (FWV)

• Permits passage of well fluids to CV.

4 Choke Valve (CV)

• Restrict, control or regulate flow of well fluids.

5 Kill Wing Valve (KWV)

• Permits entry of kill fluids into tubing or equalize.

6 Swab Valve (SV)

• Permits entry of well interventions.

Xmas Tree

The valves used in Xmas tree are invariably of the gate type providing full bore access to the well. These valves must be operated in the fully open or fully closed position.

Xmas Tree Type

1 Solid Block

2 Composite Block

3 Horizontal Xmas Tree

Solid Block Xmas Tree

• Contains fewer components (for high

pressure gas wells).

SV KWV WV CV LMV UMV Tree Cap

Composite Block Xmas Tree

• Valves are located on separate block & jointed by API flange (for medium

pressure oil well).

56 SV LMV UMV KWV _WV CV Tree Cap

Horizontal Xmas Tree

• New concept used for subsea completion.

57 2nd_MV KV CV Tree Cap Wellhead Tubing Hanger with double plugs 1st_MV AV

Xmas Tree

Wellhead spools, valves, chokes etc are installed by means of the following connection types:

1 Screwed Type

• Low pressure application (<1 000 psi). 2 Combination Screwed & Flange Type

• Medium pressure application (1000 psi – 3000 psi). 3 API Flanged Type

• High pressure application (>5000 psi)

API Flanged type are mostly used by Oil Companies even in low pressure application because it’s less susceptible to leakage & easier oriented. What does API Flange specification of “9⅛” – 5000 psi” means?

 9⅛” is the ID of the flange & 5000 psi is the WP

Xmas Tree Valve Operating Sequence

Sequence during RIH & POOH 1 RIH • Close WV & KWV • Open UMV • Open LMV • Open SV 2 POOH • Close SV • Close LMV • Close UMV 59

End of Chapter 1

Any Question?