Professional Documents
Culture Documents
where:
- V
e
= Max allowable Erosional critical velocity
-
f
= Fluid Specific Gravity
- C = Constant (material dependent)
Based on limited AGIP operating experience and some test data from manufacturers, currently
recommendable C factors for various materials are as follows:
Carbon steel : 100.
13%Cr stainless steel : 200.
Duplex stainless steel and over: 250.
The above mentioned formula should be used only as a preliminar screening on erosional velocity; it
does not take into account, infact, concurrent effects due to fines production. More sensible data
can be derived from field experience.
2.1.7 GALVANIC CORROSION
Galvanic corrosion is the preferential corrosion damage which can occur when two dissimilar
materials come into electrical contact via a conducting medium. The susceptibility towards galvanic
attack is influenced by a number of factors. These include:
Conductivity of the aqueous medium
Relative surface area of the materials in contact
Presence of surface films
Comparative positions of the metallic materials in the galvanic series.
2.1.8 CREVICE CORROSION
Crevice corrosion is the preferential localised corrosion damage which can be observed in the
crevices present in hydrocarbon production and processing systems. The local environment
produced within the crevice can be quite different to that in the bulk of the wellstream fluids. The
resulting chemical differences in the crevice provide a concentration effect which promotes the
corrosion damage.
The crevice may be present at a junction between dissimilar materials, a common material or a
combination of metal and non-metal.
2.1.9 CORROSION FATIGUE
Corrosion fatigue, as the name suggests, is the type of fatigue cracking which takes place when
materials are subjected to cyclic stresses in a corrosive environment. The presence of this corrosive
environment can reduce, or even eliminate entirely, the fatigue limit which is exhibited by many
materials in air. As a result, fatigue cracks are likely to initiate at lower stresses and grow more
easily in a corrosive environment.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 9 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.1.10 LIKELIHOOD OF CORROSION MECHANISM
Although a variety of corrosion mechanisms can occur under the fluid conditions present downhole,
in practice some mechanisms are far more common than others. Some possible mechanisms are
very unlikely to be observed.
Corrosion resulting from water or wet gas containing carbon dioxide is probably the most frequently
observed corrosion mechanism in practice. In wet gas systems, the present of CO2 corrosion even
at low partial pressures has led to the extensive use of CRA materials for such conditions (e.g.
13%Cr stainless steel).
Generally, corrosion resulting from the presence of hydrogen sulphide in an aqueous environment is
far less common. However, sulphide stress corrosion cracking (SSC) can occur at very low
concentrations of H2 S downhole because of the high total pressures which can be present. As a
result, materials resistant to SSC are often specified for AGIP tubulars and completion equipment.
Sulphide stress corrosion cracking resistant materials are essentially designed to meet the
requirements of the NACE sour service standards MR-01-75*.
Chloride induced SCC is principally a problem with austenitic stainless steels of the 18% Cr / 8% Ni
type. Materials for downhole tubulars and completion equipment are usually of different generic
types, and chloride is not normally a significant problem.
Corrosion fatigue is not in practice a problem for production tubulars and completion equipment
because the cyclic stressing necessary to produce corrosion fatigue is not normally present.
Corrosion fatigue of drilling tubulars in their threaded tool joints is a significant problem which can be
addressed by reducing the corrosivity of the drilling fluids, reducing working stresses and inspecting
threads more thoroughly for incipient cracks before failure occurs.
Galvanic corrosion is always a possibility with the mixture of materials which can be found in a
downhole design, but in practice, significant problems have not been observed.
Crevice corrosion is also a possibility, but again in practice, major problems have not been reported
under downhole conditions.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 10 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.2 CORROSION EVALUATION
This paragraph evaluates the production fluids corrosivity. Following corrosion conditions are
considered:
1. H2S (S.S.C.)
2. CO2 e Cl
-
3. H2S, CO2, and Cl
-
The effects due to Ph and to souring, which is H2S increase in time inside the reservoir when this
one is depleting, are not considered.
Material selection is based on the application of engineering diagrams, supplied by Sumitomo,
adequately modified and updated (Fig. 3-4).
Proposed material selection is quite conservative also because materials recently available on the
market, like Super 13% Cr, 15% Cr and Superduplex class of material and whose testing is still
undergoing, are not taken into account.
In any case this selection is intended to be a screening guideline which can be easily adopted in
90% of the actual cases; for applications which falls outside of the covered area or at the boundary
of each defined area, AGIP-CORM specialized personnel shall be involved.
2.2.1 H2S CORROSION (SULFIDE STRESS CRACKING - S.S.C.)
H2S when in contact with H2O ion H
+
, and presence of water is essential to have S.S.C; other
important factors are presence of stress (tension) and temperature. Temperature above 80C
inhibits the S.S.C.; temperature gradient can so be used for selecting materials and different
materials can be selected for different depths. Problem evaluation is function of well type. In gas
wells the water saturation is always sufficient to cause water condensation, so the right environment
for S.S.C.
In vertical oil wells it is instead necessary to analyze the water cut evolution during the well
production life; the treshold water cut value generally considered for the corrosion to start is 15%.
In higly deviated oil wells (deviation above 80) the H2S corrosion risk is high because water, even if
in limited quantity, for sure will wet the lower tubing generatrix; the problem can also be extended to
gas wells but in this case the water cut treshold should be reduced to 1%.
In the following chapters formulas will be supplied for calculating pH2S in gas wells, gas &
condensate wells and oil wells; calculation of partial pressures should be done after considering the
combination of well data relevant to water cut and deviation.
2.2.1.1OIL AND GAS & CONDENSATE WELLS
Partial pressure is calculated as:
pH2S = SBHP x Y(H2S)/100
where:
SBHP = atm.
Y(H
2
S) = H
2
S
molar fraction
pH
2
S
= atm
S.S.C. is present if pH2S >.0035 atm
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 11 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.2.1.2OIL WELL
Corrosion problems occurr when water is wetting or, as stated:
- water cut > 15% in vertical wells,
- water cut > 1% in horizontal wells,
- deviation is high (> 80 deg)
- GOR > 800 Nm3/m3
Partial pressure calculation is different in case of under-saturated or over-saturated oils
2.2.1.2.1 UNDER-SATURATED OIL WELLS
Well is classified under-saturated (gas is always dissolved in the oil), when well head and bottom
hole pressures are above the Bubble Point Pressure at reservoir temperature conditions.
There are two methods for calculating the pH2S:
- the Basic Method
- the Material Balance Method.
If the gas H2S content @ bubble point conditions, Y(H2S), is not known or the value is not reliable,
pH2S calculation should be done with both methods and the higher value taken. Otherwise only the
basic method should be applied.
2.2.1.2.1.1 BASIC METHOD
This method should be utilized, without the need of comparing results with the material balance
when H2S value in the separated gas @ bubble point conditions is reliable or better if Y(H2S), molar
fraction measured @ bubble point (Pb) is greater than 2%.
pH2S is calculated as follows:
pH2S = Pb x Y(H2S)/100
where:
- Pb = (bubble point pressure) @ reservoir conditions; atm
- Y(H
2
S) = molar fraction in the separated gas @ bubble point pressure (from PVT)
- pH
2
S = atm
2.2.1.2.1.2 MATERIAL BALANCE METHOD
The method is utilized when production test data are available, and/or when the H2S is present at
very low concentrations (< 2000 ppm) and water cut value measured during production tests is less
than 5%; for higher water cut values this method is not applicable.
H2S measured values shall be well stabilized; infact values obtained from short production tests are
always lower than stabilized values.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 12 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
The Algorithm used for pH2S calculation is as follows:
Step1
Calculate pH2S @ separator conditions (p H2S
sep
):
pH2S
sep
= (P
sep
x H2S
sep
)/10^6
where
P
sep
= Average absolute separator test pressure; atm
H
2
S
sep
= Average ppm H
2
S in separator gas
Step2
Calculate molecular weight of produced oil (PM)
PM
GOR
d
PM
GOR
giac
*
*
.
*( * )
.
1000
1000
23 6
29
23 6
PM
GIAC
= Average oil molecular weight in the reservoir = (
i (i=1,n)
C
i
x M
i
)/100
C
i
= molar percentage of reservoir oil i-component
M
i
= molecular weight of reservoir oil i-component
d = gas density at separator conditions (ref. air =1)
Step3
Calculate H2S as moles/liter dissolved in separator oil:
H2S
oil
= p H2S
sep
/H(1) x ( x 1000)/PM)
where:
H(1) = Henry constant for produced oil at separator temperature (atm/molar fraction). The method is
applicable for separator temperature between 20 C and 200 C (see step 6).
PM = average molecular weight of produced oil
= produced oil specific gravity gr/lt
Step4
Calculate H2S content in the gas at equilibrium at separator conditions (per liter of oil)
H2S
gas
= (GOR/23.6 x H2S
sep
/10^6)
where:
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 13 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
GOR = gas oil ratio Nm3/m3 (from production test)
23.6 = conversion factor
Step5
Calculate pH2S at reservoir conditions:
pH2S = (H2S
oil
+ H2S
gas
/K) x H(2)
where
K = ( x 1000/PM + GOR/23.6) total number of moles inside the iquid phase in the reservoir
H
(2)
= Henry constant for reservoir oil at reservoir temperature (atm/molar fraction) (see step 6).
Generally speaking H2S corrosion can occur at wellhead as well as at bottom hole.
S.S.C. is present if pH2S > .0035 atm e STHP >18.63 atm.
Step 6
Procedure for calculating Henry constant
Henry constant is dependant on temperature. Method is applicable to separator temperature
between 20 C and 200 C. Figure 2 represents H(t) function for the three different oil types,
heptane PM = 100, n-propilbenzine PM = 120 and methylnaftaline PM = 142.
H1 Calculation Method
Having available the average molecular weight of produced oil as per step 2 the reference curve for
calculating the Henry constant is selected using following ranges of values:
a) if PM 142 methylnaftaline H(t) curve shall be used
b) if PM = 120 n-propilbenzine H(t) curve shall be used
c) if PM 100 heptane H(t) curve shall be used
d) if 100 < PM < 120 the average value between n-propilbenzine H(t) curve and methylnaftaline H(t)
curve shall be considered
e) if 120 < PM < 142 the average value between n-propilbenzine H(t) curve and heptane H(t) curve
shall be considered
f) given FTHT, flowing tubing head temperature, H1 value is read on Y axis, drawing an horizontal
line from the intersection of the considered curve/s with the vertical line parallel to Y axis intersecting
X axis at FTHT (this value taken in between the immediately lower and gretaer values on the
diagram.
H2 Calculation Method
After calculating PM GIAC
PM GIAC = Average oil molecular weight in the reservoir = ( i (i=1,n)
Ci x Mi)/100
and using the separator temperature calculation shall proceed like H
(1)
.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 14 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
0
10
20
30
40
50
60
70
80
90
100
110
120
130
2
0
3
5
5
0
6
5
8
0
9
5
1
1
0
1
2
5
1
4
0
1
5
5
1
7
0
1
8
5
Temperature - C
A
t
m
/
F
r
a
z
.
M
o
l
.
Met i l naf t al i na P. M. 142
N _Pr opi l benzene P. M. 120
Ept ano P. M. 100
Figura 2. H(t) reference curve.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 15 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.2.1.2.2 Over-saturated Oil Wells
Well is classified oversaturated (gas is separated from fluid) when system pressure is below the
bubble point pressure. Different situations can occurr:
A case
FTHP < Pb
FBHP > Pb
B case
FTHP < Pb
FBHP < Pb
A case Partial Pressures Calculations
1. Partial Pressures Calculations @ Reservoir conditions
pH2S is to be calculated as per paragraph 1.1.2.1.
2. Partial Pressures Calculations @ Wellhead conditions
Since FTHP < Pb only Basic Method applies.
Partial pressure ( H2S ) is calculated as follows:
pH2S = STHP x Y(H2S)/100
where:
- STHP = Static Tubing Head Pressure; atm
- Y(H
2
S) = molar fraction in the separated gas @ STHP and STHT
- p H
2
S = atm
S.S.C. is present if p H2S > .0035 atm e STHP >18.63 atm
B case Partial Pressures Calculations
1. Partial Pressures Calculations @ Reservoir conditions
In the reservoir FBHP < Pb, gas is already separated and pH2S calculation can be done after
following considerations:
a. PVT data are reliable, Y(H2S) > 0.2%
p H2S = Y(H2S) / 100 x FBHP
where:
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 16 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
- Y(H
2
S) = molar fraction in the separated gas @ FBHP and SBHT (from PVT)
- p H
2
S = atm
b. PVT data are not reliable; Material Balance Method can be applied as in the case of
undersaturated oil; this doing means to assume worse conditions. If Pb >> FBHP error introduced
can be not acceptable.
2. Partial Pressures Calculations @ Wellhead conditions.
Proceed as per Acase (FTHP < Pb).
2.2.2 CO2 E CL
-
CORROSION
CO2 in presence of water causes different corrosion phenomena with respect to H2S. It occurs if CO2
partial pressure is above a certan treshold value. As for S.S.C. this paragraph will evaluate the
possibility for the corrosion to occur as a function of well deviation and type of well. If conditions set
up in paragraph 1.1 applies then pCO2 can be calculated.
2.2.2.1 GAS OR GAS & CONDENSATE WELLS
Partial pressure is calculated as:
pCO2 = SBHP x Y(CO2)/100
where:
- SBHP = atm.
- Y(CO
2
) = CO
2
molar fraction
- pCO
2
= atm
Corrosion is present if pCO2 > .02 atm
2.2.2.2 OIL WELLS
Corrosion problems occurr when water is wetting or, as stated:
- water cut > 15% in vertical wells,
- water cut > 1% in horizontal wells,
- deviation is high (> 80 deg)
Partial pressure calculation is different in case of undersaturated or oversaturated oils
2.2.2.2.1 UNDER-SATURATED OIL WELLS
Partial pressure ( pCO2 ) is calculated as follows:
pCO2 = Pb x Y(CO2)/100
where:
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 17 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
- Pb = (bubble point pressure) @ reservoir conditions; atm
- Y(CO
2
) = molar fraction in the separated gas @ bubble point pressure (from PVT)
- pCO
2
= atm
Corrosion is present if pCO2 > 0.2 atm.
Calculated pCO2 values are to be utilized for corrosion evaluation either at bottom hole or at well
head conditions; that is to say that it is assumed that well head pCO2 corresponds to the one at
reservoir conditions.
2.2.2.2.2 OVERSATURATED OIL WELLS
Well is classified over-saturated (gas is separated from fluid) when system pressure is below the
bubble point pressure. Different situations can occurr:
A case
FTHP < Pb
FBHP > Pb
B case
FTHP < Pb
FBHP < Pb
A case Partial Pressures Calculations
1. Partial Pressures Calculations @ Reservoir conditions
pCO2 is to be calculated as per paragraph 1.2.2.1.
Corrosion is present if pCO2 > 0.2 atm
2. Partial Pressures Calculations @ Wellhead conditions
pCO2 = STHP x Y(CO2)/100
where:
- STHP = Static Tubing Head Pressure; atm
- Y(CO
2
) = molar fraction in the separated gas @ STHP and STHT
- pCO
2
= atm
Corrosion is present if pCO2 > 0.2 atm
B case Partial Pressures Calculations
1. Partial Pressures Calculations @ Reservoir conditions:
pCO2 = FBHP x Y(CO2)/100
where:
- Y(CO
2
) = molar fraction in the separated gas @ FBHP and FBHT (from PVT)
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 18 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
- pCO
2
= atm
2. Partial Pressures Calculations @ Wellhead conditions.
Proceed as per A case.
Corrosion is present if pCO2 > 0.2 atm.
2.2.2.3H2S , CO2 AND CL
-
CORROSION
It is possible to find out H2S, CO2 together with Cl
-
, in this case the problem is more complex and
material selection much more delicate. Partial pressures are calculated as above and then usually
dedicated lab test are required for material characterization in the specific environment. Next
chapters will give indications on materials to chose for those conditions.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 19 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.3 MATERIAL SELECTION
If H2S and CO2 partial pressures are below critical values defined in the above chapter, in this
chapter recommended materials refers to Cabon Steel/Low-Alloy Steel classes; otherwise following
combinations of environmental conditions can occur:
1. only H2S in oil wells
2. only H2S in gas and/or gas condensate wells
3. only CO2 and Cl
-
4. both H2S and CO2 and Cl
-
Following tables will indicate the materials selections for Oil Country Tubular Goods (OCTG), Down
Hole Equipment (DHE) and Well Head & Xmas Tree.
Each step indicates the reference to Figure 3,4, corrosivity conditions in second column and the
minimum cost recommended material in the third column while in the fourth column there is a list of
recommended materials in ordered per increasing cost.
Corrosivity conditions superimpose partial pressure conditions, temperatures, chlorides (Cl
-
), and
refers to engineering diagrams estabilished threshold zones (Fig. 2,3).
Corrosivity conditions are defined when all different statements (partial pressures, chloride content,
temperatures )are all valid at the same time.
Units used in the tables are:
- atm for pH2S
MAX
e pCO2
MAX
,
- C for temperatures,
- ppm for chlorides (Cl
-
).
2.3.1.1 O.C.T.G MATERIALS TABLES
2.3.1.1.1 OCTG MATERIALS - ONLY H2S IN OIL WELLS
Corrosive environment Material First Choice Alternative Choice
1 0.0035< pH
2
S
MAX
0.1
FBHT > 80
J55, K55, N80-1, C95, P110-1 L80-MOD, C90-TYPE1, T95-
TYPE1
2 0.0035< pH
2
S
MAX
0.1
65 < FBHT 80
J55, K55, N80-1 L80-MOD, C90-TYPE1, T95-
TYPE1
3 0.0035< pH
2
S
MAX
0.1
FBHT 65
L80 L80-MOD, C90-TYPE1, T95-
TYPE1
4 pH
2
S
MAX
> 0.1 L80-MOD, C90-TYPE1, T95-
TYPE1
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 20 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.3.1.1.2 OCTG MATERIALS - ONLY H2S IN GAS AND/OR GAS CONDENSATE WELLS
Corrosive environment then Alternative Choice
5 0.0035< pH
2
S
MAX
0.1 e
FBHT > 80
J55, K55, N80-2, C95 L80-MOD, C90-TYPE1, T95-
TYPE1
6 0.0035< pH
2
S
MAX
0.1 e
FBHT 80
L80 L80-MOD, C90-TYPE1, T95-
TYPE1
2.3.1.1.3 OCTG MATREIALS - ONLY CO2 AND CL
-
WELLS
Corrosive environment Material First Choice Alternative Choice
7 0.2< pCO
2
MAX
100
FBHT 150 e Cl- 50000
13%-Cr
8 0.2< pCO
2
MAX
100
150 < FBHT 200
22%-Cr
9 0.2< pCO
2
MAX
100
200 < FBHT 250
25%-Cr-Solution Annealed 25%-Cr
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 21 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.3.1.1.4 OCTG IN H2S , CO2 AND CL
-
WELLS
Corrosive environment Material First Choice Alternative Choice
10 0.2< pCO
2
MAX
100
0.0035< pH
2
S
MAX
0.005
FBHT 150
Cl- 50000
13%-Cr-80Ksi-Max 22%-Cr
25%-Cr
11 0.2< pCO
2
MAX
100
pH
2
S
MAX
0.005
FBHT 200
Cl-> 50000
22%-Cr-Cold Worked
25%-Cr-C.W.
12 0.2< pCO
2
MAX
100
0.0035< pH
2
S
MAX
0.005
150< FBHT 200
Cl- 50000
22%-Cr
25%-Cr
13 0.2< pCO
2
MAX
100
0.0035< pH
2
S
MAX
0.005
200<FBHT 250
Cl-<50000
25%-Cr
14 0.2< pCO
2
MAX
100 0.0035<
pH
2
S
MAX
0.005
200 < FBHT 250
Cl->50000
25%-Cr-C.W.
15 0.2< pCO
2
MAX
100
0.005< pH
2
S
MAX
0.1
FBHT 250
Cl- 20000
25%-Cr
16 pCO
2
MAX
100
0.005< pH
2
S
MAX
0.1
FBHT 250
Cl- 50000
25%-Cr-C.W.
17 0.2< pCO
2
MAX
100
0.005< pH
2
S
MAX
0.1
200 < FBHT 250
Cl- 50000
28%-Cr Incoloy-825
18 0.2< pCO
2
MAX
100
0.1< pH
2
S
MAX
1
FBHT 200
Cl- 50000
22%-Cr-S.A. 25%-Cr-S.A.
28%-Cr
Incoloy-825
19 0.2< pCO
2
MAX
100
0.1< pH
2
S
MAX
1
FBHT 250
Cl- 50000
25%-Cr-S.A. 28%-Cr
Incoloy-825
20 0.2< pCO
2
MAX
100
0.1< pH
2
S
MAX
1
FBHT 200
Cl-> 50000
28%-Cr Incoloy-825
21 0.2< pCO
2
MAX
100
pH
2
S
MAX
> 1
28%-Cr Incoloy-825
2.3.1.2DHE MATERIALS
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 22 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.3.1.2.1 DHE MATERIALS - ONLY H2S IN OIL WELLS
Corrosive environment Material First Choice Alternative Choice
1 pH
2
S
MAX
0.1
FBHT > 80
Carbon Steel-110Ksi-Max AISI-
41XX
2 pH
2
S
MAX
0.1
FBHT > 65
Carbon Steel-80Ksi-Max AISI-
41XX
3 pH
2
S
MAX
0.1
FBHT 65
or pH
2
S
MAX
> 0.1
AISI-41XX-HRC-22-Max
2.3.1.2.2 DHE MATERIALS - ONLY H2S IN GAS WELLS
Corrosive environment Material First Choice Alternative Choice
4 pH
2
S
MAX
0.1
FBHT > 80
Carbon Steel-80Ksi-Max AISI-
41XX
5 pH
2
S
MAX
>0.1
or FBHT > 80
AISI-41XX-HRC-22-Max
2.3.1.2.3 DHE MATERIALS - ONLY CO2 AND CL
-
WELLS
Corrosive environment Material First Choice Alternative Choice
6 pCO
2
MAX
100
FBHT 100
Cl- 50000
9%-Cr-1-Mo
7 pCO
2
MAX
100
100 < FBHT 150
Cl- 50000
13%-Cr-80Ksi-Max
8 pCO
2
MAX
100
150 < FBHT 250
25%-Cr-C.W. 28%-Cr
Inconel 718
Incoloy 825
2.3.1.2.4 DHE MATERIALS - H2S, CO2 AND CL
-
WELLS
Corrosive environment Material First Choice Alternative Choice
9 pCO
2
MAX
100
pH
2
S
MAX
0.005
FBHT 100
Cl- 50000
9%-Cr-1-Mo
10 pCO
2
MAX
100
pH
2
S
MAX
0.005
100 < FBHT 150
Cl- 50000
13%-Cr-80Ksi-Max 22%-Cr
25%-Cr
Incoloy 825
Inconel718
11 pCO
2
MAX
100
pH
2
S
MAX
0.005
22%-Cr
25%-Cr
Incoloy 825
Inconel 718
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 23 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
150 < FBHT 200
Cl- 50000
12 pCO
2
MAX
100
pH
2
S
MAX
0.005
200 < FBHT 250
Cl- 50000
25%-Cr
Incoloy 825
Inconel 718
13 pCO
2
MAX
100
pH
2
S
MAX
0.005
100 < FBHT 200
Cl-> 50000
22%-Cr-C.W.
25%-Cr-C.W.
Incoloy 825
Inconel 718
14 pCO
2
MAX
100
pH
2
S
MAX
0.005
200 < FBHT 250
Cl- > 50000
25%-Cr-C.W. Incoloy 825
Inconel 718
15 pCO
2
MAX
100
pH
2
S
MAX
0.1
200 < FBHT 250
Cl-<=50000
25%-Cr Incoloy 825
Inconel 718
16 pCO
2
MAX
100
pH
2
S
MAX
0.1
200 < FBHT 250
Cl-> 50000
28%-Cr Incoloy 825
Inconel 718
17 pCO
2
MAX
100
pH
2
S
MAX
1
FBHT 200
Cl- 50000
22%-Cr-S.A. 25%-Cr-S.A
28%-Cr
Incoloy 825
Inconel 718
18 pCO
2
MAX
100
pH
2
S
MAX
1
FBHT 250
Cl-50000
25%-Cr-S.A. 28%-Cr
Incoloy 825
Inconel 718
19 pCO
2
MAX
100
pH
2
S
MAX
1
FBHT 250
Cl-> 50000
28%-Cr Incoloy 825
Inconel 718
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 24 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.3.1.3WELL HEAD & XMAS TREE MATERIALS
2.3.1.3.1 WELL HEAD & XMAS TREE MATERIALS - ONLY H2S IN OIL WELLS
Corrosive environment Material First Choice Alternative Choice
1 pH
2
S
MAX
0.035 Tubing-Hanger AISI-4140-HRC-22-Max
Tubing-Head-Adapter AISI-4135-HRC-22-Max
Tbg-Spool AISI-4135-HRC-22-Max
Cross AISI-4135-HRC-22-Max
Top-Adapter AISI-4135-HRC-22-Max
Casing-Spool AISI-4135-HRC-22-Max
Stud ASTM-A193-B7M
Nut ASTM-A194-2M
Automatic-Master-Valve-Materials
Body-Bonnet-Flanges AISI-4135-HRC-22-Max
Gate&Seats AISI-4140-HRC-22-Max
Stem AISI-4140-HRC-22-Max
Manual-Master-Valve-Materials
Body-Bonnet-Flanges AISI-4135-HRC-22-Max
Gate&Seats AISI-4140-HRC-22-Max
Stem AISI-4140-HRC-22-Max
2 pH
2
S
MAX
<0.035 Tubing-Hanger AISI-4140
Tubing-Head-Adapter AISI-4135
Tbg-Spool AISI-4135
Cross AISI-4135
Top-Adapter AISI-4135
Casing-Spool AISI-4135
Stud ASTM-A193-B7
Nut ASTM-A194-2H
Automatic-Master-Valve-Materials
Body-Bonnet-Flanges AISI-4135
Gate&Seats AISI-4140
Stem AISI-4140
Manual-Master-Valve-Materials
Body-Bonnet-Flanges AISI-4135
Gate&Seats AISI-4140
Stem AISI-4140
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 25 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.3.1.3.2 WELL HEAD & XMAS TREE MATERIALS - ONLY CO2 AND CL
-
WELLS
Corrosive environment Material First Choice Alternative Choice
3 0.2< pCO
2
MAX
100
FTHT 150
Cl- 50000
Tubing-Hanger 13%-Cr-80Ksi-Max
F6NM
Tubing-Head-Adapter 13%-Cr-80Ksi-Max
F6NM
Tbg-Spool AISI-4135
Cross 13%-Cr-80Ksi-Max
F6NM
Top-Adapter 13%-Cr-80Ksi-Max
F6NM
Casing-Spool Carbon Steel
AISI-41XX
Bolting-Materials
Stud ASTM-A193-B7
Nut ASTM-A194-2H
Manual-Master-Valve-Materials
Body-Bonnet-Flanges 13%-Cr-80Ksi-Max
F6NM
Gate&Seats 13%-Cr-80Ksi-Max
Stem Monel K 500
17-4-PH
Automatic-Master-Valve-Materials
Body-Bonnet-Flanges 13%-Cr-80Ksi-Max
F6NM
Gate&Seats 13%-Cr-80Ksi-Max
Stem Monel K500
17-4-PH
4 pCO
2
MAX
100
150 < FTHT 200
Cl- 50000
Tubing-Hanger Monel K500
Inconel 718
Tubing-Head-Adapter AISI-4135 & Internal Cladding w/ Inconel 625
Tbg-Spool AISI-4135
Cross AISI-4135 & Internal Cladding w/ Inconel 625
Monel K500
Top-Adapter AISI-4135 & Internal Cladding w/ Inconel 625
Monel K500
Casing-Spool AISI-4135
Bolting-Materials
Stud ASTM-A193-B7
Nut ASTM-A194-2H
Manual-Master-Valve-Materials
Body-Bonnet-Flanges AISI-4135 & Internal Cladding w/ Inconel 625
Gate&Seats Inconel 718
Stem Inconel 718
Automatic-Master-Valve-Materials
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 26 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Body-Bonnet-Flanges AISI-4135 & Internal Cladding w/ Inconel 625
Gate&Seats Inconel 718
Stem Inconel 718
2.3.1.3.3 WELL HEAD & XMAS TREE MATERIALS - H2S, CO2 AND CL-
Corrosive environment Material First Choice Alternative Choice
5 pCO
2
MAX
100
pH
2
S
MAX
0.005
FTHT 150
Cl- 50000
Tubing-Hanger F6NM
Tubing-Head-Adapter 13%-Cr-80Ksi Max
F6NM
Tbg-Spool AISI-4135-HRC-22-Max
Cross 13%-Cr-80Ksi Max
F6NM
Top-Adapter 13%-Cr-80Ksi Max
F6NM
Casing-Spool AISI-4135-HRC-22-MAX
Bolting-Materials
Stud ASTM-A193-B7M
Nut ASTM-A194-2M
Manual-Master-Valve-Materials
Body-Bonnet-Flanges 13%-Cr-80Ksi Max
F6NM
Gate&Seats 13%-Cr-80Ksi Max
Stem 17-4-PH
F6NM
Automatic-Master-Valve-Materials
Body-Bonnet-Flanges 13%-Cr-80Ksi Max
F6NM
Gate&Seats 13%-Cr-80Ksi Max
Stem 17-4-PH
F6NM
6 pCO
2
MAX
100
pH
2
S
MAX
0.2
FTHT 150
Cl- 50000
Tubing-Hanger F6NM
Monel K500
Tubing-Head-Adapter F6NM
Tbg-Spool AISI-4135-HRC-22-Max
Cross F6NM
Top-Adapter F6NM
Casing-Spool AISI-4135-HRC-22-Max
Bolting-Materials
Stud ASTM-A193-B7M
Nut ASTM-A194-2M
Manual-Master-Valve-Materials
Body-Bonnet-Flanges F6NM
Gate&Seats 13%-Cr-80Ksi Max
STELLITE-6
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 27 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Stem Monel K500
Automatic-Master-Valve-Materials
Body-Bonnet-Flanges F6NM
Gate&Seats 13%-Cr-80KSI-Max
Stellite-6
Stem Monel K500
7 pCO
2
MAX
100
pH
2
S
MAX
0.8
FTHT 150
Cl- 50000
Tubing-Hanger Inconel 718
Tubing-Head-Adapter
AISI-4135 & Internal-Cladding
Inconel 625
Tbg-Spool AISI-4135-HRC-22-Max
Cross AISI-4135 & Internal Cladding
Inconel 625
Monel K500
Top-Adapter AISI-4135 & Internal-Cladding
Inconel 625
Monel K500
Bolting-Materials
Stud Monel K500
Nut Monel K500
Automatic-Master-Valve-Materials
Body-Bonnet-Flanges AISI-4135 & Internal-Cladding
Inconel 625
Gate&Seats F6NM
Inconel 718
Stem Monel K500
Manual-Master-Valve-Materials
Body-Bonnet-Flanges AISI-4135 & Internal-Cladding /Inconel 625
Gate&Seats F6NM
Inconel 718
Stem Monel K500
8 pCO
2
MAX
100
pH
2
S
MAX
0.8
Cl-> 50000
or
pCO
2
MAX
100
pH
2
S
MAX
> 0.8
Tubing-Hanger
Inconel 718
Tubing-Head-Adapter AISI-4135 & Internal-Cladding
Inconel 625
Tbg-Spool AISI-4135-HRC-22-Max
Cross AISI-4135 & Internal-Cladding
Inconel 625
Inconel 718
Top-Adapter AISI-4135 & Internal-Cladding
Inconel 625
Inconel 718
Casing-Spool AISI-4135-HRC-22-Max
Bolting-Materials
Stud Inconel 718
Nut Inconel 718
Manual-Master-Valve-Materials
Body-Bonnet-Flanges AISI-4135 & Internal-Cladding
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 28 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Inconel 625
Inconel 718
Gate&Seats Inconel 718
Stem Inconel 718
Automatic-Master-Valve-Materials
Body-Bonnet-Flanges AISI-4135 & Internal-Cladding
Inconel 625
Gate&Seats Inconel 718
Stem Inconel 718
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 29 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
10
-4
10
-3
10
-2
10
-1
1 10 100
10
-4
10
-3
10
-2
10
-1
1
10
100
4
21
10
19
18
20
8
7
9
11
12
13
14
1
2
3
5
6
C-STEEL
16
15
17
p
C
O
2
(
A
T
M
)
pH
2
S (ATM)
FIGURE 2. Diagram material OCTG
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 30 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
10
-4
10
-3
10
-2
10
-1
1 10 100
10
-4
10
-3
10
-2
10
-1
1
10
100
5
6
18
17
19
8
7
9
11
12
13
14
1
2
3
4
C-STEEL
or
AISI 41XX
16
15
28% Cr
or
INCOLOY 825
INCONEL 718
pH
2
S (ATM)
p
C
O
2
(
A
T
M
)
2.4 FIGURE 3. DIAGRAM MATERIAL FOR D.H.E
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 31 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.4 ELASTOMERS
2.4.1 INTRODUCTION
Elastomers (rubbers for sealing) and polymers (engineering plastics for back-ups) are used in many
fluid sealing applications in downhole and surface equipment. This section covers their use in
completion equipment.
A wide range of elastomers and plastics is available, and seal material selection is always a
compromise resulting from consideration of the service duties and the performance needs. This
section is designed to provide help and information to enable the engineer to make a basic material
selection or appraise the material on offer from an equipment manufacturer.
Many of the malfunctions of subsurface oil field equipment have been traced to seal failure. Seal
materials and seal designs, often among the least expensive components, are often the limiting
factors in equipment performance. Failures in elastomer seals downhole can result in high workover
costs. In order to minimize these failures, all the contributing factors should be assessed and the
correct elastomer seal material should be chosen for the intended duties. To do this, the well
conditions need to be defined as fully as possible and the performance of the elastomers, their
properties and environmental resistance should be understood. Working closely with the equipment
supplier or Agip CORM, will ensure the optimum material selection is made.
The selection process detailed in this section is as follows:
Define well conditions.
Select elastomer class for compatibility with:
- Heat resistance.
- Oil resistance.
- Service liquids resistance.
- Gas duties resistance.
Select elastomer grade based on pressure level for required performance properties.
Tables 1, 2 and 3 (pg. 6, 7, 8) provide quick guides to aid elastamer selection
Elastomers (e.g. Nitrile, Viton, Aflas, etc.) possess the ability to recover from applied stress over a
significant deformation range. Plastic material (e.g. PTFE, Ryton, PEEK, etc.) do not possess this
quality and deform irrecoverably by plastic flow. In general, elastomers are used for the sealing
elements and plastics (suitably filled to reduce deformation) are used as back up rings to prevent
extrusion under high pressure service.
The same environmental considerations are applied to the plastic materials as to the elastomeric
material, consequently the term elastomer is used to include both types where appropriate.
The essential quality of elasticity in a rubber allows it to have an advantage over metallic
counterparts in the degree of conformability to a rough or uneven sealing surface. Also, an
elastomer is incompressible and has the ability to deform under constant volume to provide a seal in
constrained housings, whilst still exerting a positive sealing force.
Elastomers can be readily fabricated in a variety of shapes and sizes, e.g. O-Rings, T-seals,
Chevrons and Lip Seals etc., depending on the application requirement, and may be assembled
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 32 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
with relative easy due to their elastic nature. Unlike metals, corrosion is not a significant problem
with elastomeric materials.
2.4.2 DEFINITION OF WELL CONDITIONS
The information required to specify an elastomer is listed below. This data should be collated from
the Statement of Requirements for the well and refined during the conceptual design phase:
Bottom hole temperature
Surface temperature
Temperature extremes
Temperature profile
(closed in/flowing)
(closed in/flowing)
(max./min.)
(static/cyclic, frequency)
Reservoir pressure
Wellhead pressure
Pressure profile
(closed in/flowing)
(variation, frequency, rate)
Production fluid composition
- Hydrocarbons
- Aromatics
- Water
(and variation)
Gas/oil ratio
Injected fluids composition
- Inhibitors
- Control line fluids
- Completion fluids
- Acid and chemicals
(strength, duration, frequency)
(corrosion and scale)
Temperature of injected fluids
downhole
Produced gas composition
- Hydrocarbons
- Hydrogen sulfide
- Carbon dioxide
Differential seal pressure (level, rate, frequency)
Seal movements (level, rate, frequency)
Lifetime required (between workovers
In addition, the seal design in which the elastomer is incorporated should also be considered (i.e. O-
ring, T-seal, V-packing etc.)
2.4.3 EFFECTS OF TYPICAL DOWNHOLE ENVIRONMENTS
2.4.3.1 PRODUCED FLUIDS
Crude oil with natural gas or natural gas with condensate are most typical. High aromatic content
oils and chlorinated hydrocarbons can cause excessive swelling, loss of strength or even dissolution
in some rubbers (e.g. natural rubber, EPDM, butyl, silicones etc.). Absorbed gases at high pressures
could give rise to blistering or rupture in seals when rapidly decompressed. Formation water is
frequently present, as a result of waterflood breakthrough. Seawater may cause hydrolysis
degradation in some elastomers (e.g. acrylics, urethanes).
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 33 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.4.3.2 TEMPERATURE AND PRESSURE
Surface temperatures can be low when the well is shut in (sea temperatures 2 to 6C), but
downhole equipment normally functions at service temperatures between 80F (27C) and 400F
(204C). Temperature is important because materials strength properties generally reduce and
environments become more aggressive with increases in temperature. Two opposite effects on
performance are possible as a result of temperature. Materials may soften and extrude where no
chemical reaction occurs, or they could harden with age and become brittle under chemical attack.
Both mechanisms can lead to failure.
Differential pressures are typically a maximum of 15 000 psi. The level of pressure determines the
mechanical properties required within the grade of elastomer class and whether back up rings are
required.
2.4.3.3 CORROSION AND SCALE
Moderately corrosive environments are typical. Wells often contain significant amounts of carbon
dioxide (CO2) which readily causes blistering in some elastomers when rapidly decompressed. H2S
may chemically attack the cure sites in the elastomer, which can lead to hardening and rupture by
embrittlement. The selection of corrosion resistant alloys is becoming more common, but inhibitors
are often added to injection water and completion fluids. Low levels of inhibitors are normally used
and chemical attack on seal materials by these low levels at low temperatures is normally not a
problem. However, some film forming amine based corrosion inhibitors can be aggressive, and
attention should always be drawn to the assessment of their effect on the seal material (especially
Nitriles and Vitons)
2.4.3.4 CONTROL LINE FLUIDS
Mineral oil hydraulic fluids are common. Low viscosity Arctic grades are frequently used where they
may encounter low surface temperatures. Water based fluids with about 50% glycol are also used.
Appropriate seal material selection can normally overcome any problems with control line fluids, but
there may be a conflict of interests where a seal may experience water based control line fluid on
one side with oily produced fluids on the other, e.g. in subsea safety valves.
2.4.3.5 COMPLETION FLUIDS
Treated seawater is a typical completion fluid. The treating chemicals are normally used at low
concentrations. and CaCl/CaBr systems do not usually affect seal materials. However, care must be
taken when dense acidic systems (e.g. ZnBr) are used because of their very marked hardening
effect on nitrile rubbers. Fluoroelastomers, like Aflas or Viton, are unaffected. Highly alkaline fluids,
such as K2C03, can affect Viton elastomers through hydrolysis.
2.4.3.6 ACIDS AND CHEMICALS
Consideration must be given to the effects on seals materials of future acidization and any other
chemical injection additives. Normal seal exposure is limited to short term but some of the additives
can be very aggressive (acids, surfactants, aromaties, iron chelating agents etc.).
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 34 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.5 PROPERTIES OF ELASTOMERS
Elastomers are essentially long molecular chains in which the development of strength and
recoverability is governed by the level of crosslinks present between the chains. These crosslinks
are formed by curing the rubber using sulfur or peroxide cure systems. The extent of curing, or
molecular length between crosslinks, gives rise to important variations in mechanical properties as
shown in Figure 1.
Figure 1. Effect of degree of curing on Elastomer Mechanical Properties
2.5.1 ELASTOMER TYPES AND COMPOUNDING
A wide range of elastomer material types or classes (e.g. EPDM, Nitrile, Fluoroelastomer etc.) is
available to cope with particular service requirements. Within these classes it is possible to
compound specific grades to yield individual performance characteristics.
An elastomer compound is the term used to describe the rubber grade which is manufactured
from a recipe of ingredients that comprise the base rubber class, reinforcing agents, curing agents
and other additives (e.g. lubricants, anti-oxidants etc.).
Some unreinforced elastomers can undergo crystallization under strain, e.g. natural rubber,
chloroprene, butadiene etc., and have inherent strength as a high plateau value across a wide
range of temperature and strain rate. However, many elastomers are subject to very poor
mechanical strength in their unreinforced state. It is only when some degree of reinforcement is
made through compounding with fillers and curing systems that the majority of elastomers can
achieve serviceable strength and performance over a wide range of conditions
This is why the chemist spends so much time on optimizing his compound recipes to achieve grades
with enhanced performance at operating temperatures.
STATIC MODULUS
EXTRUSION RESISTANCE
BLISTER RESISTANCE
HIGH SPEED
DYNAMIC MODULUS
HARDNESS
TENSILE STRENGHT
TEAR STRENGHT
FATIGUE LIFE
TOUGHNESS
HYSTERESIS
COMPRESSION SET
FRICTION COEFFICIENT
ELONGATION
CROSSLINK DENSITY (DEGREE OF CURE)
M
E
C
H
A
N
I
C
A
N
I
C
A
L
P
R
O
P
E
R
T
I
E
S
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 35 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Table 1 shows a typical compound recipe based on a Nitrile rubber.
TYPICAL NITRILE RUBBER COMPOUNDS
Additive Part by weight Additive Function
Nitrile N28C50 100 Base rubber (28% acrynolite)
Zinc Oxide 5 Activator for sulfur
Stearic Acid 1 Lubricant, retarder
Regal SRF (N 762) 50 Carbon black filler (semi-
reinforcing)
Silica VN3 15 Fine silica filler (for heat resistance)
Flectol H 2 Anti-oxidant
CBS 1.5 Fast curing accelerator
TMT 2.5 Sulfur donot compound
Sulfur MC 0.5 Sulfur accelerator
Dutrex 729 10 Process aid (to give better low
temperature and resilience
properties
Table 1
A large number of possible ingredients are available for compounding, and this leads to an infinite
number of potential compounds. The art of compounding is to optimize the properties of the
compound to suit the particular performance requirements. Various compounding factors influence
material properties, e.g. the molecular weight of the base rubber, the degree of cure, the filler type,
its structure and loading. The effects of these factors on properties are seen in Table 2.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 36 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
CHANGE IN PHYSICAL PROPERTIES OF ELASTOMERS WITH INCREASE IN VARIOUS
FACTORS RELATED TO STRUCTURE AND COMPOUNDING
Property Change
for Increase in:
Mol Wt
Rubber
Degree
of cure
Filler
Load
Filler
S Area
Filler
Structure
Hardness NC UP UP UP UP
Modules UP UP UP UP UP
Tensile Strength UP MAX. MAX. UP NC
Elongation UP DOWN DOWN NC DOWN
Compression Set DOWN DOWN UP UP UP
Tear Strength UP MAX. MAX. UP UP
Fatigue Life UP MAX. MAX. DOWN UP
Abrasive Resistance UP MAX. MAX. UP UP
Impact Strength UP MAX. MAX. UP UP
Extrusion Resistance UP UP UP UP UP
Blister Resistance UP UP UP UP UP
NC No significant change in value
UP Properties increases in value
DOWN Properties decreases in value
MAX. Properties goes through a maximum
Mol Wt Molecular weight of rubber
S Area Surface Area of filler (inverse of particle size)
Table 2
There are, of course, some compatible properties which can be achieved together in compounding
(e.g. high modules and hardness with high filler load and high cure), but equally, there are
properties which can only be obtained at the expense of some other characteristic (e.g. extrusion
resistance cannot be achieved from low strength, soft materials). Consequently, all compounds or
elastomer grades are a compromise of properties.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 37 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.5.2 CLASSIFICATION OF ELASTOMERS
Elastomer seals materials may be classified by their resistance to heat and oil as indicated in Table
3 where the standard ASTM notation system for elastomer class and examples is given.
ELASTOMER CLASSIFICATION BY RESISTANCE TO HEAT AND OIL
ASTM Ref. Elastomer Class Example
1 Non Oil Resistant - General Purpose
NR Natural Rubber SMR
IR Synthetic isoprene Natsyn
BR Butadiene Rubber Cariflex
SBR Styrene-butadiene rubber
2 Non Oil Resistant - Medium Heat
Resistance
IIR Butyl rubber Vistanex
EPM Ethylene-propylene (saturated) Dutral
EPDM Ethylene-propylene-diene (unsaturated) Nordel
3 Oil Resistant - Low Temperature
TR Polysulphide Thiokol
AU/EU Plyurethane (ester/ether) Adiprene
4 Oil Resistant - General Purpose
CR Chloroprene rubber Neoprene
NBR Nitrile rubber Buna-N
HNBR Hydrogenated nitrile rubber Therban
CM Chlorinated plyethilene Duralon
CSM Chlorosulphonated polyethilene Hypalon
CO Epichlorohydrin Hydrin-100
ECO Epichlorohydrin copolymer Hydrin-200
5 Oil and Heat Resistant
ACM Polyacrilic Vamac
FCM Tetrafluoroethylene-propylene Aflas
FKM Fluoroelastomer Viton
FFKM Perfluoroelastomer Kalrez
6 Silicone Rubber
SI Silicone rubber
FSI Fluorosilicone rubber
Table 3
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 38 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
The elastomers indicated in Table 3 are shown graphically in Figure 4 as a function of their heat
resistance (upper service temperature limit) and % volume swell in oil. In most downhole seals
applications 25% to 35% is the maximum volume swell in oil that is tolerable for a static seal.
Dynamic seals will only tolerate considerably less (< 15%). Only those elastomers with volume swell
values of less than 35%. which lie to the right of the dotted line, will be considered as useful for
seals in hydrocarbon duties.
Figure 4. Elastomer classification based on heat and oil resistances
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 39 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.6 ENVIRONMENTAL RESISTANCE OF ELASTOMER CLASSES
This section gives a brief review of properties and environmental resistance for the commercial
elastomers most commonly used in completions equipment. Some of the harder seal materials used
for back-ups are also included.
Under recommended service, reference is made to each elastomers resistance to aliphatic and
aromatic hydrocarbons. The vast majority of produced fluids are aliphatic hydrocarbons. e.g.
methane. Aromatic hydrocarbons occur less frequently and incur benzene ring type compounds.
2.6.1 GROUP 2 ELASTOMERS (MEDIUM HEAT RESISTANCE, NON OIL RESISTANT)
2.6.1.1 EPDM- ETHYLENE-PROPYLENE-DIENE (NORDEL)
Tradenames
Nordel DuPont
Service Temperature
-50C to 150C (200C max in steam)
Recommended Service
EPDM has outstanding resistance to weathering. It is particularly resistant to superheated steam,
water, glycol based control fluids, many organic and inorganic acids, cleaning agents, alkalis,
phosphate ester based hydraulic fluids, silicone oils and greases. Also EPDM has resistance to
many polar solvents such as alcohols, esters and ketones
Not Recommended
EPDM has very poor resistance to hydrocarbons.
Physical Properties
Appropriate compounding of EPDM could result in elastomer systems capable of performing
continuously up to 175C, although 150C is more usual. Intermittent exposures can be tolerated up
to a temperature of 200C.
2.6.2 GROUP 4 ELASTOMERS (GENERAL PURPOSES OIL RESISTANT)
2.6.2.1CR-POLYCHLOROPRENE (NEOPRENE)
Tradenames
Neoprene Dupont
Butaclor Distugil
Service Temperature
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 40 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
(-55C) -45C to 100C (130C short term)
Recommended Service
The chlorine is responsible for the general resistance to oxygen. Outdoor weathering of neoprene
does not have a significant effect on its elastomeric properties. It is unaffected by aliphatic
hydrocarbons, alcohols, glycols and fluorinated hydrocarbons. It has a good resistance to most
inorganic chemicals including dilute acids and concentrated causties. Neoprene also displays
reasonable oil resistance, although this is not as good as that noted for Nitrile rubber.
Neoprene also has good resistance to silicone oils, grease and water.
Not Recommended
Polychloroprene is not resistant to chlorinated hydrocarbons, organic esters, aromatic hydrocarbons,
phenols and ketones. It is also severely attacked by concentrated oxidizing acids like nitric or
sulphuric acids, as well as strongly oxidizing agents such as potassium dichromate.
Physical Properties
Neoprene is a tough, strong, resilient rubber with good resistance to abrasion. It has lower
permeability than natural rubber.
2.6.2.2 NBR - ACRYLONITRILE-BUTADIENE RUBBER (NITRILE RUBBER)
Best known as Nitrile rubber or Buna-N.
Tradenames
Breon BP Chemicals Ltd
Hycar B F Goodrich Chemical Co
Krynac Polysar Ltd
Nysyn Copolymer Corpn
Perbunan Bayer AG
Copolymers of acrylonitrile (ACN) and butadiene were first used as synthetic stocks before World
War II (Buna-N). In NBR the ACN content may vary from 20 to 50%, but more typically 28 to 41% by
weight, and this affects the performance properties.
Service Temperature
(-55C) -30C to 100C (130C short term)
Recommended Service
NBRs are resistant to aliphatic hydrocarbons, vegetable and mineral oils and greases, hydraulic
fluids, many dilute acids, alkalis, salt solutions and water
Not Recommended
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 41 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Nitrile rubbers are not recommended for service in hydrocarbons with a high aromatic content,
chlorinated hydrocarbons, polar solvents such as ketones, acetone, acetic acid, esters, strong acids
or with control fluids based on glycols. Zinc bromide brines also have a very serious hardening
effect on Nitrile rubbers.
Physical Properties
The properties are greatly affected by acrylonitrile content as shown below:
As acrylonitrile content increases:
Tensile strnght
Resilience
Oil resistance
Low Temp. Flexibility
Hardness and Modulus
Compression Set
Brittle Temperature
Abrasion Resistance
Heat Resistance
I
n
c
r
e
a
s
e
D
e
c
r
e
a
s
e
Nitriles are noteworthy because of their resistance to hydrocarbons. They are relatively inexpensive
and are used extensively in applications requiring oil resistance.
2.6.2.3 HNBR - HYDROGENATED NITRILE RUBBER (THERBAN)
Tradenames
Therban Bayer A G
Zetpol Nippon Zeon
Camlast Cameron
Service Temperature
-25C to 150
Recommended Service
HNBR elastomers have better heat ageing characteristics than Nitrile rubbers, but otherwise they
have many similarities on their dependence on acrylonitrile content for their physical properties.
They normally have good resistance to oils, diesel, kerosene, hydraulic fluids and inorganic salts
(except zinc bromide). HNBR has better resistance to sour conditions than conventional Nitrile
rubbers and has very good ageing and weathering properties.
Not Recommended
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 42 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
HNBR elastomers are swollen in highly aromatic oils and are not so resistant to hydrocarbons in
general compared to conventional Nitrile rubbers. They can also be affected by corrosion inhibitors,
zinc bromide brines and strong acids. HNBR is used in seals for valves and BOPs.
2.6.2.4 CO AND ECO EPICHLOROHYDRIN HOMO-AND COPOLYMERS (HYDRIN)
Tradenames
Hydrin B F Goodrich Co
Service Temperature
-40C to 135C
Recommended Service
Both CO and ECO epichlorohydrins are resistant to mineral oils and greases, aliphatic
hydrocarbons, silicone oil, grease and water at room temperature. They are also resistant to ageing
and weathering. Their low permeability to gases make them particularly appropriate for gas
applications.
Not Recommended
Epichlorohydrins are not resistant to aromatic and chlorinated hydrocarbons, ketones and esters,
hydraulic fluids and glycol based control fluids.
2.6.3 GROUP 5 ELASTOMERS (HEAT AND OIL RESISTANT)
2.6.3.1 FKM FLUOROELASTOMER (VITONS)
Tradenames
Viton DuPont
Fluorel 3M Company
Technoflon Montecatini
Fluorocarbon elastomers were the most significant advance to come out of the 1950s and are noted
for their high temperature capabilities and general chemical resistance. It is important to understand
that there are several chemically different types of fluoroelastomers. The Viton group is divided into
three main types: A, B and G.
The Viton-A family consists of copolymers of vinylidene fluoride and hexafluoropropylene. This
general purpose copolymer family is further subdivided into A, E and speciality series and includes
for instance Viton-AHV, a high molecular weight fluoroelastomer, and Viton-E60, an extrusion
resistant grade. Viton A types are cured using amines and exhibit good resistance to compression
set.
The Viton-B family offers improved heat and fluid resistance at some sacrifice in compression set
resistance compared with the A family.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 43 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
In general, the Viton-G family have improved steam and acid resistance compared to conventional
types of Viton. Viton-GF, a newer addition to this range, has received much attention in oil field
applications due to its improved resistance to hydrocarbons, volume change and property retention.
Service Temperature
(-40C) -20C to 200C (250C)
Recommended Service
The fluoroelastomers all have excellent chemical and solvent resistance. They are very resistant to
aliphatic hydrocarbons, chlorinated solvents, animal, vegetable and mineral oils, gasoline, kerosene,
dilute acids, alkaline media and aqueous inorganic salt solutions. They exhibit good weather
resistance.
Physical Properties
These fluoroelastomers retain their physical properties well over a wide temperature range and have
low gas permeability rates and extremely low water absorption. They exhibit good tensile strength
and tear resistance. Special grades are available with improved decompression resistance.
Not Recommended
They have only fair general resistance to alcohols (be careful with methanol dewatering), aldehydes,
ketones, esters and ethers and are not compatible with polar solvents such as acetone,
methylethylketone or ethyl acetate. Certain amines may also cause problems, as will hydraulic fluids
based on glycol, superheated steam and low molecular weight organic acids, e.g. formic and acetic
acids.
If organic amine corrosion inhibitors are to be used, then Viton and Fluorel are not recommended for
seals where there is the possibility of movement. This is because amines were the first curing
systems used for these elastomers, and the presence of added amine corrosion inhibitor will
continue to cure the elastomer until it hardens and becomes brittle. The effect is less marked with
the peroxide cured Viton-GF types.
2.6.3.2 FCM TETRAFLUOROETHYLENE - PROPYLENE COPOLYMER (AFLAS)
Tradenames
Aflas Asahi Glass Co
Fluoraz Greene Tweed
Service Temperature
-40C to 230C (300C short term)
Recommended Service
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 44 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
FCM elastomers are not affected by most strong acids, bases, ketones, alcohols, high temperature
lubricating oils, hydraulic fluids and glycol based control fluids. They have good resistance to sour
petroleum products, steam. waters inorganic salts (including zinc bromide) and sodium hypochlorite.
Some grades have better resistance to amine based corrosion inhibitors than Viton type FKM
elastomers.
Not Recommended
Volume swell in crude oils is somewhat high for a tetrafluoroelastomer (10 to 20%, compared with 1
to 5% for Vitons. Nitrile rubbers swell by some 10 to 35%). This can cause problems when using
Aflas in a dynamic seal. Aflas is not resistant to chlorinated hydrocarbons.
2.6.3.2.1 FFKM PERFLUOROELASTOMER (KALREZ)
Tradenames
Kalrez DuPont
Chemraz Greene Tweed
These compounds have the chemical resistance properties of PTFE (Teflon) and the elastic
properties of Vitons. The processing of both is exceptionally difficult. As a result of this, the price is
much higher than fluoroelastomers. Thus, Kalrez and Chemraz (20% cheaper) are only used in
applications where nothing else will survive.
Service Temperature
0C to 260C Kalrez
-20C to 230C Chemraz
Recommended Service
Kalrez has almost universal chemical resistance. It is resistant to sour petroleum products, acids,
bases, steam and has excellent oxygen and weathering resistance. It has exceptionally low weight
loss in high vacuum applications under high temperatures.
Kalrez has poor strength and should be used with mechanical back up even at low temperatures. It
is extremely difflcult to mould, and it is only recently that larger sections (up to 7.5 in.) have become
available, e.g. for packer elements etc. Both Kalrez and Chemraz are only sold as fabricated units.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 45 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.6.4 HARD POLYMER MATERIALS (FOR BACK-UPS ETC)
The following materials cannot be used as primary seals.
2.6.4.1PEEK POLYETHERETHERKETONE (PEEK)
Tradenames
Victrex ICI Ltd
Kadel Union Carbide
Service Temperature
Up to 250C continuously (315C short term).
Recommended Service
PEEK polymers are resistant to virtually all organic and aqueous chemicals. They exhibit significant
chemical resistance and high performance at elevated temperatures. They are also tough and highly
wear resistant.
Not Recommended
Concentrated nitric or sulphuric acids at elevated temperature.
Physical Properties
PEEK can be fabricated by conventional melt processing methods such as injection moulding,
extrusion and melt spinning. It may be used in the virgin state or reinforced with glass or carbon
fibres.
Recommended Service
This unique combination of properties makes PEEK polymers attractive in a wide range of
demanding applications. They are not elastomeric and are used as hard seals, back up rings, cable
insulation and electrical components. In the oil industry they find uses as casings for various logging
tools, support rings and anti-extrusion rings for downhole V- and O-ring seals.
2.6.4.2 FPM FLUOROCARBON POLYMERS (TEFLON PTFE ETC)
These polymers are plastics rather than elastomers. The most useful of these types are listed
below:
Tradenames
PTFE Teflon DuPont
Fluon Allied Chemical Co
Halon DuPont
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 46 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
FEP, ETFE Tefzel DuPont
PFA Teflon DuPont
PCTFE Kel-F 3M Co
PVDF Foraflon Atochem
Coflon Coflexip
PVDF Furakawa Electric Co
Kynar Pensalt Chemicals
Service Temperature
PTFE -190C to 290C
FEP, ETFE -190C to 200C
PFA -1 90C to 280C
PCTFE -60C to 190C
PVDF -60C to 130C (melts at 143C)
Recommended Service
PTFE, FEP and ETFE can be regarded as chemically inert for all oilfield applications.
The other compounds, although not totally inert, exhibit a high degree of resistance.
Primarily used as back-up rings for elastomer seals.
2.6.4.3 PPS POLYPHENYLENE SULPHIDE (RYTON}
Tradename
Ryton
Service Temperature
Up to 230C
Recommended Service
Polyphenylene sulphide (Ryton) can be compounded with a variety of materials to reduce its brittle
nature and to improve the sealability. It has been used for back up rings for V-packings and O-rings
and, suitably compounded, it may be used as seal elements in V-packings.
2.7 FAILURE MECHANISM
This section outlines some of the failure modes that can occur in seals, how they are caused and
how they can be corrected to prevent future failure.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 47 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
2.7.1 EXTRUSION DAMAGE
The pressure ranges given by the extrusion diagram in Figure 5 below, show allowable pressures
for various degrees of elastomer hardness and indicate when to use back-up rings.
10000
8000
6000
4000
3000
2000
1000
800
600
400
300
200
100
0 0.08 0.16 0.16 0.24 0.32 0.40
EXTRUSION
NO-EXTRUSION
hardness shore
a durometer
70 80 90
Total diamentral clearance, in
F
l
u
i
d
p
r
e
s
s
u
r
e
,
l
b
/
i
n
2
BASIS FOR CURVES
1. No back-up rings
2. Total diametral
clearance must
include cylider
expansion due
to pressure
3. 100,000 cycles
at rate of 150/1
from zero to
indiacated pressure
Figure 5. Extrusion Resistance Related to Pressure and Hardness
In its housing before pressurizing, an unsupported seal sits slightly deformed between the gland and
sealing surface. On pressurizing (100 to 1500 psi), the seal acts like an incompressible fluid,
exerting a pressure on the gland proportional to the system pressure and so forms a closure. If the
system pressure exceeds the seal strength, a small volume of material will be forced into the
clearance gap. This extrusion may lead to seal failure and leakage follows rapidly.
Extrusion is characterised by a 'peeling' or 'nibbling' of the O-ring surface and is the most common
cause of O-ring failure.
This type of failure is exaggerated in dynamic applications where material is clamped in the
clearance gap and sheared off completely. However, it must be remembered that in static
applications, extrusion will occur at high pressures and is accentuated when pressures fluctuate and
the seal housing components stretch under load.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 48 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Resistance to extrusion for differing materials may be compared by using modulus values at 100%
elongation. Alternatively, hardness may be used to select appropriate maximum pressure levels.
For pressures above 1500 to 3000 psi, back up rings should be used. T-seals and V-seals always
have back up rings associated with them, and extrusion is not such a problem as with unsupported
O-rings.
Causes of extrusion failure:
- Unnecessarily large clearances.
- High pressure.
- Soft seal material.
- Physical or chemical changes which weaken/soften seal.
- Eccentricity.
- Sharp edges on seal size.
- Wrong seal size.
Corrective actions:
- Tighten tolerances.
- Use a back up ring.
- Increase seal material hardness.
- Cheek medium compatibility.
- Prevent eccentricity.
- Strengthen machine parts to prevent breathing'.
- Gland radii from 0.10 to 0.40 mm.
- Select T-seal or V-seal geometry with suitable back up.
2.7.2 COMPRESSION SET FAILURE
Compression set, the partial or total loss of elastic memory of an elastomer, is a common failure
mode. It is characterized by a double sided flattening of a seal (radial or axial according to
application) and can be clearly seen after disassembly.
The problem is caused by selection of the wrong compound. The elasticity of a seal depends not
only on the formulation, but also on the working temperature, type and length of deformation and
ageing caused by a medium, e.g. air, steam, acid, petroleum etc.
Compression set damage can be described as the loss of crosslink sites between the molecular
chains or as the creation of new sites, brought about by temperature or chemical changes.
Compression set damage clearly visible at low temperatures is generally reversible, and at higher
temperatures, the elasticity may return to effect a seal again.
The causes of high temperature compression set and loss in sealing power are connected and can
be described as follows:
Causes of compression set failure:
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 49 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
- Seal compound has poor compression set.
- Wrong gland dimensions.
- Working temperature higher than expected.
- Higher deformation through tight gland area.
- Contact with non-compatible medium. (assembly grease or service fluid).
- Poor seal material quality.
Corrective actions:
- Select elastomer with low compression set.
- Select elastomer according to working conditions.
- Reduce system temperature at seal.
- Cheek compatibility of seal with environment.
- Use correct gland dimensions.
2.7.3 EXPLOSIVE DECOMPRESSION DAMAGE
Under high pressure, gases will diffuse into elastomers. On rapid decompression, the absorbed
gases expand quickly causing high levels of internal stress which may cause internal rupture and
blistering to occur on the sealing surface. A seal may also swell on decompression, but with time
may return to its original shape without leaving any external evidence of decompression damage.
This is potentially dangerous since serious internal fissures can be present, but remain undetected,
which will affect the sealing performance.
This problem may be solved or at least reduced in the following ways:
- Lengthen the time for decompression.
- Reduce working pressure at seal.
- Design for smaller seal cross-section.
- Select a seal material with higher strength, higher modulus and higher hardness.
-Use specially compounded grades having known resistance to explosive decompression.
Blister damage has been reported for a wide range of elastomers under hydrocarbon duties,
particularly under gas alone but also in gas/oil mixtures. The presence of carbon dioxide and
hydrogen sulphide is especially prone to causing problems on rapid decompression (they are both
easily liquefiable gases and have solubility parameters approaching those of the elastomer seal
materials).
2.7.4 WEAR
Wear is probably the most understandable form of seal failure in dynamic seals. In a static
application, damage through wear is caused by pulsating pressure which induces the O-ring to
abrade on relatively rough surfaces or edges of the gland.
Causes of wear failure:
- Incorrect surface finish.
- Poor lubrication.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 50 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
- High temperature.
- Too high deformation.
- Impurities in system fluid.
- High or pulsating pressure.
Corrective actions:
- Correct surface finish.
- Use a hard coated surface.
- Select an improved machining process.
- Change system fluid to one with better lubricity.
- Select a compound with higher wear resistance.
- Select a material with internal lubrication or design lubrication pockets or reservoirs.
- Clean system and fllter fluid.
2.7.5 CHEMICAL DEGRADATION
Chemical degradation depends on a number of factors which include temperature, concentration
and duration of exposure. Mechanical properties of a seal material can be seriously changed by a
chemical reaction. The timescale for the change is ultimately a function of the severity of service
conditions and may be slowly progressive to catastrophically fast.
Two different processes can occur when a seal is exposed to a chemical environment:
Bond scission results in chemical bonds being broken in the elastomer causing
softening, weakness and a gummy seal material.
Crosslinking results in bond formation causing a harder, more brittle and often cracked
seal. The elastic properties are often lost beyond a point where the seal ceases to
function. Leak paths through a cracked seal can lead to failure.
The effect of increased temperature will be to speed up the reaction rates, but more
importantly the mechanical properties of an elastomer are normally reduced with increasing
temperature. Hence, it is important to select materials with both sufficiently high chemical
and thermal resistance.
2.7.6 ASSEMBLY FAILURE
Even if all the above hints and rules are observed, failure can still occur due to poor workmanship
practices adopted on assembly of the seal into its housing. A seal is a precision product and should
be treated with respect. Careful assembly will repay the user in trouble free operation. The
alternative is an expensive and possibly dangerous failure.
Causes of assembly failures:
- Using undersized seal.
- Twisting, cutting or shearing of seal.
- Assembly without the correot tool.
- Assembly without lubrication (care - compatibility).
- Assembly in dirty conditions.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 51 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Corrective actions:
- Break all sharp edges.
- Leading edge chamfer in between 15 to 20 degrees.
- Cleanliness.
- Cheek seal size before assembly.
- Assembly as a stack of seals where possible.
2.8 SEALS SELECTION
This section gives a summary description of types of downhole seal arrangements with an example
set of typical seals and notes on materials qualification.
2.8.1 COMPLETION SEALS
The three basic seal types are as follows:
Radial compression seals, e.g. O-rings and T-seals, are used in both static and dynamic
applications. O-rings are typically used as static body connection seals, both with or without back
up rings as dictated by the pressure and temperature. T-seals are normally used as dynamic
seals to take advantage of the unique design to limit rolling in the gland. They always incorporate
back-up rings.
Axial compression seals are used as packer element seals. Elements are set after the packer is
run to the desired depth in the well. The large cross-section of the seals when set, bridge large
extrusion gaps and seals against poor casing surface finishes.
Pressure energized seals. such as V-packing stacks. are used in both static stab and dynamic
applications. such as the external seals on wireline safety valves, lock and gas lift valves.
A typical set of seals for a difficult well is given in the example below. The actual nature and
hardness of the seal material chosen will depend on the application and the service duty.
O-rings Viton 95A durometer with PEEK back-ups
T-Seals Viton with PEEK back-ups
V-Packing Aramid fibre reinforced Nitrile used in combinations with
other rings of molybdenum disulphide reinforced Teflon,
Ryton and PEEK
Soft seats Moly reinforced Teflon or 90A durometer Viton for sandy
service
Packer Elements Nitrile
Many other material and seal options are available.
2.8.2 QUALIFICATION
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 52 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Proven field history is the best qualification.
Laboratory simulation tests are available. Agip TEAP or CORM can make evaluate various material
performance properties after exposure to a wide range of service conditions, for candidate
materials. Facilities are available to screen materials for environmental resistance to both fluids and
gases up to 20 000 psi and 200C with up to 25% H
2
S concentration coupled with decompression
control.
Equipment manufacturers should conduct pressure tests on the final products. For example. API
Standard 14A requires a 10 minute pressure test at 150% of the rated pressure and two growth
tests of 2 hours for stab in or dynamic seals.
Repeated decompression tests may also be carried out. It is better to evaluate the material in the
seal configuration wherever possible.
Quality control is essential to good sealing practice.
Suppliers should be approved by the Quality Assurance Department, should have a QA programme
that meets industry standards and all seals should be traceable to the material batch. Routine
quality control tests should be performed to assure that each shipment of seals meet the
specifications. These should then be verified by the suppliers inspector who will issue certificates of
compliance and actual test reports on each shipment of seals.
The following information should be obtained from the equipment manufacturer for possible future
reference:
Seal equipment type (Unit, maker, drawings)
Seal design (Static/dynamic, O-ring, V-ring,T-ring)
Seal material (Class, grade, supplier, part no, batoh no, cure date shelf life)
2.9 MATERIAL SELECTION CRITERIA
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 53 OF 57
REVISION
TEAP-P-1-R-8791 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
The listed physical properties are desirable in the following applications:
Dynamic seals require:
- Good abrasion resistance.
- Good tear resistance.
- Good compression set resistance.
- Good gas impermeability.
- Good resilience.
Static seals primarily require:
- Good compression set resistance.
Packing elements require:
- Good compression set resistance.
- Resistance to swelling is not most important. Indeed a small degree of swelling may be
beneficial.
MATERIALS SELECTIONS BASED ON HEAT AND OIL RESISTANCES
Temp.
Level
ASTM Ref.
Code
Material Class Upper Lower Oil
Resistance
C F C F
< 150 F NR Natural rubber 65 149 -50 -58 Bad
200 F
to
250 F
CR
AE/AU
NBR
Neoprene
Polyurethane
Nitrile Rubber
100
105
120
212
221
248
-45
-30
-30
-49
-22
-22
Poor
Poor
Good
250F
to
300 F
ECO/CO
PVDF
HBNR
EPDM
Hydrin
Coflon back-up
Therban
Nordel
135
140
150
150
275
284
302
302
-40
-60
-25
-50
-40
-76
-13
-58
Good
Very Good
Fair
Bad
300 F
to
400 F
SI
FSI
FKM
ETFE
Silicone
Fluorosilicone
Viton
Tefzelback-up
175
190
200
200
347
374
392
392
-55
-40
-20
-190
-67
-40
-4
-310
Bad
Good
Very Good
Very Good
400 F
to
500F
FCM
PEEK
FFKM
Aflas
Vyctrex back-
up
Karlez
230
250
260
446
482
500
-40
0
-40
32
Good
Very Good
Very Good
> 500F PTFE Teflon back-up 290 554 -190 -310 Very Good
Table 4
Any equipment which experiences temperature fluctuations of greater than 100 to 150F should
utilize elastomers with good compression set resistance over the range of temperature. Aflas, Kalrez
and Viton GF are particularly prone to failures under these situations.
ARPO
ENI S.p.A.
Divisione Agip
ORGANIZING
DEPARTMENT
TYPE OF
ACTIVITY'
ISSUING
DEPT.
DOC.
TYPE
REF. N. PAG. 54
OF 57
TEAP P 1 R 8791
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
ENVIROMENTAL RESISTANCE AND PHISICAL PROPERTIES FOR COMMON DOWNHOLE SEAL MATERIAL (ELASTOMERIC AND PLASTIC) IN COMPLETION
EQUIPMENT SERVICES
Material CR
Neoprene
AE/AU
Urethane
NBR
Nitrile Rubber
ECO
Hydrin
PVDF
Coflon
HNBR
Therban
EPDM
Nordel
FKM
Viton
ETFE
Tefzel
FCM
Aflas
PEEK
Victrex
FFKM
Kalrez
PTFE
Teflon
Upper Service Temp C
Lower Service Temp C
100
45
105
-30
120
-30
135
-40
140
-60
150
-25
150
-50
200
-20
200
-190
230
-40
250
260
0
290
-190
Oil Aliphatic Hydrocarbons
Aromatic Hydrocarbons
Crude Oil (<120 C)
Crude Oil (>120 C)
Sour Crude Oil
Sour Natural Gas
2
3
2
4
3
3
2
3
2
4
3
3
1
2
1
4
2
2
1
1
1
4
3
3
1
1
1
2
1
1
2
3
2
3
2
2
4
4
4
4
4
3
1
1
1
2
2
2
1
1
1
1
1
1
1
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
Water 2 1 2 1 1 1 1 2 1 1 1 1 1
Steam 3 3 3 2 1 1 1 1 1 1 1 1 1
Inibitors Amines 3 2 2 2 1 2 2 3 1 1 1 1 1
Completion Fluids CaCl/Ca/Br 1 1 1 1 1 1 1 1 1 1 1 1 1
Completion Fluids ZnBr 1 1 4 1 1 3 1 1 1 1 1 1 1
Completion Fluids Kr2CO3 1 2 2 2 2 1 1 1 1 1 1 1 1
Brine Seawater 2 4 1 1 1 1 1 1 1 1 1 1 1
Control Fluid Mineral Oil 2 1 1 1 1 1 3 1 1 2 1 1 1
Control Fluid Glycol based 1 2 1 1 1 1 1 1 1 1 1 1 1
Alcohols Methanol 1 4 1 1 1 1 1 4 1 1 1 1 1
Acids Hcl Acid (diluted) 3 2 3 1 1 2 1 1 1 1 1 1 1
Acids Hcl Acid (concentred) 4 4 4 3 2 4 3 1 1 1 2 1 1
Acids Hcl Acid (<65% cold) 1 x 3 x 3 3 1 1 1 1 2 1 1
Acids Acetic (hot) 4 4 4 2 2 3 3 4 1 3 2 1 1
Surfactants 2 4 1 x 1 3 1 1 1 1 1 1 1
Chlorinated Solvents 1 4 4 4 3 3 4 1 1 3 1 1 1
Mhetane 2 2 1 1 1 1 4 1 1 1 1 1 1
CO2 2 1 1 1 1 1 2 2 1 2 1 1 1
H2S 2 4 4 4 1 3 1 2 1 2 1 1 1
Phisical Properties
Tear resistances Good V. Good Good Good Good Good Poor Good Good Fair V. Good Fair Good
Abrasion Resistances V. Good V. Good Good Good Good Good Good Good Good Fair V. Good Fair Good
Compression Set Resistances Good Good V. Good Fair N/A Good Fair Fair N/A Fair N/A Poor N/A
Resiliences High High Med Med N/A Med Med Low N/A Fair N/A Low N/A
Gas Impermeability Fair Good Fair V. Good Good Good Good V. Good Good Good Good V. Good Good
Key to performances rating
rating Significance rating Significance
1 Good Satisfactory performances in relatively high level of chemical 4 Bad No tollerance to chemical DO NOT USE
2 Fair Performances depends on desidered life and level of chemical x No data avaible
3 Poor Performances depends on desidered life and level of chemica 4 Bad TABLE 5
ARPO
ENI S.p.A.
Divisione Agip
ORGANIZING
DEPARTMENT
TYPE OF
ACTIVITY'
ISSUING
DEPT.
DOC.
TYPE
REF. N.
PAG.
55
OF
57
TEAP P 1 R 8791
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
service duties are shown in Table 5.
The data should be used only as a general guide to the performance of a class of material. Variation
in performance exists across the grades within a class.
Material selection is made by assessing the effects of individual environments and rejecting
unsuitable material classes where there is a definite need for resistance. The selected materials
should have optimum performance across all media.
Up till now, it is only the 'class' of seal material which has been selected. The 'grade' within the class
will be determined by the physical properties required to yield a good sealing performance under the
level of pressure in the service environment. Table 6 gives a guide to the level of properties required
for various sealing pressure ranges. The actual material 'grade' will be determined in conjunction
with the equipment supplier or on recommendation from TEAP.
GUIDE TO PROPERTY LEVELS REQUIRED
IN ELASTOMERS GRADES
FOR VARIOUS SEALING PRESSURE RANGES
Pressure Range 0 to 300 psi 300 to 3000 psi > 3000 psi
Hardness (Shore A) 60 -70 A 70 - 85 A > 85 A
Modulus Low Medium High
Tensile Strength Low - Med Med -High High
Elongation High Medium Low
Compression Set Medium Low Low
Tear Strength Low - Med Medium Low - Med
Abrasion Resistance Low - Med Medium High
Impact Resistance High High Med - Low
Hysteresis Heat-up Low - Med Medium Med -High
Extrusion resistance Low Medium High
Blister Resistance Low Medium High
Table 6
2.10 PRACTICAL GUIDELINES
The effect of a chemical reaction doubles for every 10C temperature rise. The lifetime
roughly doubles for every 10C drop.
Make sure that the upper temperature is within the capability of the seal material.
The seal material must be compatible with the fluid environments.
Do not use Zinc Bromide (ZnBr) brine with Nitriles.
Be careful with Vitons if amine inhibitors are present. It may be better to use Aflas.
Methanol can affect Vitons. Use Aflas or Nitrile if possible.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 56 OF 57
REVISION
TEAP-P-1-R-8791 0
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Do not use EPDM where hydrocarbons are present.
For really aggressive, hot and sour conditions, the best choice is the expensive Kalrez
(to 260C) or Chemraz (20% cheaper and better properties over -20 to 230C).
Pressure level dictates the mechanical properties required.
Critical pressure for blistering is Pb = 5E/6
where E = Youngs Modulus (at service temperature).
Critical pressure for rupture is Pr = 4(Lb x Sb)/3
where: Lb = extension ratio at break (length of stretched material per unit initial
length)
Sb = stress at break (at service temperature)
Consider use of T-seals with back-up rings if pressure exceeds 1500 psi, or pressure
exceeds the modulus of the material.
Consider whether there is likely to be gas dissolved into the seal which may be
subjected to rapid decompression. There are special grades with improved
decompression resistance available.
Seal stacks form good solutions to wide ranging service. They allow use of varying
hardness or differing materials in the stack, and the outer rings may be sacrificial for the
sake of the main inner seal.
Elastomers with higher chemical and temperature resistance, e.g. Aflas and Kalrez,
achieve this resistance often at the expense of elasticity. This compromises their ability
to seal with temperature fluctuations.
In Static Seal Assembly seals (ie Solid Latch Anchor) Molded Seals are recommended
instead of V-seals when important and frequent pressure reversals are expected at seal
level.
2.11 REFERENCES
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 57 OF 57
REVISION
TEAP-P-1-R-8791 0
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
1 NACE Standard MR-01-75-1988: Standard Material
Requirements for Sulphide Stress Cracking Resistant
Materials for Oil Field Equipment, National Association
of Corrosion Engineers, Houston
2 Tuttle, R N and Kane, R D: H2S Corrosion in Oil and Gas Production - A
Compilation of Classic Papers, National Association of Corrosion
Engineers
3 De Ward, C and Milliams, D: 'Predietion of Carbonic
Acid Corrosion in Natural Gas Pipelines', First
International Conference on the Internal and External
Protection of Pipes, University of Durham, 1975
4 Thomas, S, de Ward, C and Smith, L M: 'Controlling Factors in the Rate
of CO2 Corrosion', UK Corrosion, 1 Q97
5 API Recommended Practice RP 14E: Recommended Practice for Design
and Installation of Offshore Production Piping Systems, 4th Edition (April 1984)
ARPO
ENI S.p.A.
Divisione Agip
ORGANIZING
DEPARTMENT
TYPE OF
ACTIVITY'
ISSUING
DEPT.
DOC.
TYPE
REF. N. PAG.
1
OF
40
TEAP P 1 R 8792
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
TITLE
Well Completion & Workover Course Volume 1
CHAPTER 3
- TUBING DESIGN -
DISTRIBUTION LIST
TEAP
STAP Archive
LIST of CONTENTS (authors)
Cap. 01 - Well Completion Design - M. Marangoni
Cap. 02 - Material Selection - M. Marangoni
Cap. 03 - Tubing Design - B. Maggioni
Cap. 04 - Tubing Stress Analysis - B. Maggioni
Cap. 05 - Packers - M. Marangoni
Cap. 06 - Surface Wellhead - M. Marangoni
Cap. 07 - Safety Valves and Miscellaneous - M. Marangoni
Cap. 08 - Perforating - M. Marangoni
Cap. 09 - Formation Damage - M. Viti
Cap. 10 - Sand Control - M. Viti
Cap. 11 - Workover - G. Treglia
Date of issue:
s
=
L
H
L
+
g
( 1 - H
L
)
(dp/dL)
el
= g sin
g
c
4. Calculate an acceleration component (if it is to be considered) and the friction component.
(dp/dL)
f
= (p/L) - (dp/dL)
el
- (dp/dL)
acc
5. Calculate a two-phase friction factor
f
Tp
= 2g
c
d (dp/dL)
f
v
2
m
6. Change test conditions and return to Step 2. H
L
, f
Tp
and flow pattern should be obtained over a
wide range of conditions.
7. Develop empirical correlations for H
L
, f
Tp
and perhaps flow pattern as a function of variables that
will be known for design cases. These variables include v
sL
, v
sg
, d fluid properties, pipe angle, etc.
Many authors have developed mathematical correlation and method to calculate the pressure drop,
some of these are:
Poettmann and Carpenter
It is the first serious attempt at solving the multiphase well flow problem. It was developed using
measured field data from 334 flowing wells and 15 continuous flow gas lift wells. The wells
producing through tubing sizes ranging from 23/8 to 3. The production rate were less than 500
STB/day at GLRs less than 1500 scf/STB.
This method, although easy to apply, will give erroneous results when applied to wells that are
not producing under condition very similar to those from which the developing data were
obtained.
Hagedorn and Brown
The method was developed by experimental pressure drop and flow rate data from a 1500 ft
deep instrument well. Pressure were measured for flow in tubing size ranging from 11/4 to 27/8.
A wide range of liquid rates and gas/liquid ratios was included, and the effects of liquid viscosity
were studied by using water and oil as the liquid phase. The oil used had viscosity at stock tank
condition of 10, 35 and 110 cp.
The method has been found to give good results over a wide range of well conditions.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 13 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Duns and Ros
The authors performed an experimental study of vertical two-phase flow in laboratory. The
experiment, which consists of 4000 run and 20,000 data points, was conducted at low pressure
using air, oil and water as the fluids components.
The test section was 10 m long and the pipe diameters ranged from 3.2 cm to 8.2 cm. Some annular
flow tests were also conducted.
Three flow patterns were defined, and a flow patterns map was constructed from which the flow
pattern can be determined based on the superficial velocities of the liquid and gas phases. The
flow patterns are described as follows:
1. Bubble flow pattern: the liquid phase continuous, the gas phase moves as discontinuous
bubble or plugs.
2. Slug flow pattern: both liquid and gas are discontinuous.
3. Mist flow pattern: the gas phase is continuous and the liquid moves as droplets dispersed
in the gas or in the annular ring around the inside the pipe.
The method is considered to be applicable over a wide range of well conditions.
Orkiszewski
The author performed a comparison study on some 148 measured well conditions and found that
none of the correlations existing at that time (1967) adeguately predicted the measured results.
He than used the data of Hagedorn and Brown and the field data from 148 well conditions to
develop a new correlation to be used in the Bubble and Slug flow patterns. He recommended
using the Duns and Ros method for Mist flow.
The flow patterns considered are:
Bubble flow, Slug flow, Transition flow, Mist flow.
The method is applicable over a wide range of well conditions, but in some cases, a mixture
density less than no-slip density will be calculated. Also, discontinuities in the calculated pressure
traverse (gradient) can occur as the mixture velocity exceeds 10 ft/s. This results from changing
equations for mixture density at this velocity.
Beggs and Brill
This correlation was developed from experimental data obtained in a small scale test facility:
0 and 1.5 sections of acrylic pipe 90 ft long. The pipe could be inclined at any angle.
The parameters studied and their range of variation were:
1.- gas flow rate 0-300 Mscf/d
2.- liquid flow rate 0-30 gal/minute
3.- average system pressure 35-90 psi
4.- pipe diameter 1-1.5
5.- liquid hold-up 0-0.870
6.- pressure gradient 0-0.8 psi/ft
7.- inclination angle -90 to +90
8.- horizontal flow pattern
The method can be applied to a flow in a pipe at any angle of inclination, including downward flow.
Although the method has been found to predict the pressure gradient in vertical wells, in some
cases, it gives good results for pipeline calculation.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 14 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
At the next page, Table 2.3, resumes the most known correlations with some notes and the
applicability field.
TABLE 2.3: APPLICABILITY OF PRESSURE LOSS PREDICTION
METHODS
Method Years Type Accuracy Data Type Fluids Applicability
and Comments
Duns and
Ros
1963 Flow
Pattern
Dependent
Good Laboratory,
experimental
plus field data
Oil, Water,
Gas
Conservative.
Tends to
overpredict
pressure drop.
Good predictive
method where
several flow
patterns are
present
Hagedorn
and Brown
1965 Slip Flow Good ( in
some flow
patterns )
Field
experimental
Oil, Water,
Air
Does not predict
a correct TPC
minimum. Poor in
bubble flow.
Liquid hold-up
prediction can be
less than for no-
slip flow. Should
be used with
caution.
Hagedorn
and Brown
Flow
Pattern
Dependent
Good Field
experimental
Oil, Water,
Air
Optimistic. Tends
to underpredict
pressure drop.
This is the
preferred
correlation in the
absence of other
data.
Orkiszewski 1967 Flow
Pattern
Dependent
Fair Some
Hagedorn and
Brown Data,
Field
Oil, Water,
Gas
Conservative,
Tends to
overpredict
pressure drop.
Can cause
convergence
problems in
computing
algorithm
Aziz et al 1972 Flow
Pattern
Dependent
Variable -
depends on
version
Laboratory and
Field
Oil, Water,
Gas
Optimistic. Tends
to underpredict
pressure drop.
Beggs and
Brill
1973 Flow
Pattern
Poor Laboratory Air, Water Developed for
deviated wells but
tends to
significantly
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 15 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
TABLE 2.3: APPLICABILITY OF PRESSURE LOSS PREDICTION
METHODS
overpredict
pressure drop.
Should be
avoided unless
well is highly
deviated (>45)
Beggs and
Brill with
Palmer
Flow
Pattern
Dependent
Fair Laboratory Air, Water Developed for
deviated wells but
tends to
overpredict
pressure drop.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 16 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
3.5.6 DEFINITION OF THE COMPLETION STRATEGY
From the calculation of the pressure gradient the well could result naturally flowing, i.e. FTHP > 0, or
not flowing. If the calculated FTHP is lower than required by design constraints or the well is not
naturally flowing, different operative conditions and/or the artificial lift options should be taken into
account.
3.5.7 MATERIAL SELECTION
Suitable materials should be selected to avoid corrosion related problems.
Three options are available within Agip:
1. refer to the Corrosion Dept. (CORM), if the conditions are severe or not-standard
2. refer to tables in the literature
3. refer to Welcome Expert System criteria already mentioned in previous paragraph of this volume.
3.5.8 DOWNHOLE EQUIPMENT SELECTION
The following considerations should be taken into account.
1. Downhole technological and/or market availability
2. Operability of Wireline tools, Coiled tubing or other workover tools
3. Restrictions to be verified for possible erosion
For erosion, the reference is the following API formula that provides the maximum safe fluid velocity
[ft/sec]:
vmax = C / ()
where is the mixture density [lbm/ft
3
] and C is an experimental constant.
Based on AGIP operating experience and test data from manufacturers, currently recommended C
factors for various materials are as follows:
Carbon steel : 100
13%Cr stainless steel : 200
Duplex stainless steel and over: 250
The erosion is critical for water injection wells and for gas wells with possible presence of sand or
fines.
3.5.9 CHECK OF TUBING RESISTANCE.
The tubing should be checked against the stresses expected throughout the expected well life (Ref.
Tubing Stress Analysis chapter 3). If the check fails, the sizing should be changed to an heavier
tubing or to a stronger material, or the design load should be reduced.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 17 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
3.5.10 CHECK OF PARTICULAR CONDITIONS:
1.- Gas slippage in case of high GOR and low pressure inside tubing for oil wells
2.- Gas slippage in case of gas well in presence of liquid (water or condensate); in this case a
minimum velocity of the gas is required to remove the liquid.
Compare the range of producible rates in table at point 3) with the minimum rate function of tubing
size and tubing pressure, see Figure 2.3.
Figure 2.3: Prediction of minimum gas flow rate required for liquid removal (not to scale)
100
1000
10000
0,1
1
10
100
1
10
1
1000
100
2000
3000
5000
2
3
4
5
W
a
t
e
r
s
c
a
l
e
C
o
n
d
e
n
s
a
t
e
s
c
a
l
e
PREDICTION OF MINIMUN GAS FLOW RATE REQUIRED
FOR LIQUID REMOVAL FROM GAS WELLS
TUBING I. D. in. MINIMUM FLOW RATE MM cu. ft / day TUBING PRESSURE psi
The nomogram (ref.: ASME TRANS. (1969) vol. 246 page 1475) should be used as follows.
Starting from the tubing pressure value on the left-hand axis draw a line to the tubing diameter on
the right-hand axis. The central axis then displays the minimum gas flow rate required to remove
the liquid fraction.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 18 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
3.- Hydrate formation in gas condensate wells can occur in restrictions of the tubing string or/and
across the surface choke. An approximated evaluation can be made by using diagrams like one in
figure 2.4.
(In the diagram in figure 2.4 the starting point is the initial pressure (on Y-axis); moving horizontal
when crossing the curve related to the temperature of the fluid in that point allows to evaluate the
minimum pressure downstream of the restriction to avoid hydrates formation).
Note that the available diagrams are referred in general to natural gas (methane) but the presence
of H2S and/or CO2 increase the hydrates temperature and reduce the pressure above which
hydrates form.
Figure 2.4: Permissible expansion of a 1.0 gravity natural gas without hydrate
formation
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 19 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
4. A possible failure damage must be considered in terms of economic cost, workover complexity,
environmental impact, workers and people injuries.
The final result of tubing sizing is the pressure (and sometimes also temperature) gradient
throughout the expected well life. An example is shown in figure 2.5, where every curve is related to
an operative condition in a given year of the well life.
Figure 2.5: Pressure (fig. 2.5A) & temperature (fig. 2.5B) gradient for production well
Figure 2.5A
BALTIM South: FLUID PRESSURE GRADIENT
VERTICAL WELL - FLUID GAS - TUBING 3.5"
CASE COMPARISON
180 200 220 240 260 280 300 320 340
-4.000
-3.000
-2.000
-1.000
0
PRESSURE [kg/cm2]
D
E
P
T
H
[
m
]
Prod.200km3d
Water340m3d
Prod.50km3d
Water300m3d
Prod.500km3d
Water=0
Prod.300km3d
Water=0
Prod.250km3d
Water=0
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 20 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 2.5B
BALTIM South: FLUID TEMPERATURE GRADIENT
VERTICAL WELL - FLUID GAS - TUBING 3.5"
CASE COMPARISONS
0 20 40 60 80 100 120
-4.000
-3.000
-2.000
-1.000
0
TEMPERATURE [C]
D
E
P
T
H
[
m
]
Undisturbed
Prod.250 km3d
Wc = 0
Prod.300 km3d
Wc = 0
Prod. 500 km3d
Wc = 0
Prod. 50km3d
W300m3d
Prod. 200 km3d
W340m3d
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 21 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
3.6 EFFECTS OF VARIABLES CHANGE ON THE PRESSURE GRADIENT CURVES
The next figures show the effect of single parameter change.
Figure 2.6 shows the tubing sizing effect on the pressure gradient curves, figure 2.7 shows the
GLR effect, figure 2.8 shows the flow rate increasing effect, figure 2.9 shows the oil gravity
increasing effect and figure 2.10 shows the viscosity effect on pressure gradient.
Figure 2.6: Tubing size effect on the pressure gradient curves
10
9
8
7
6
5
4
3
2
1
0
D
e
p
t
h
,
1
,
0
0
0
f
t
0 5 10 15 20 25 30 35
Pressure, 100 psi
T
u
b
i
n
g
s
i
z
e
1
i
n
.
1
1
/
4
i
n
.
2
i
n
.
3
i
n
.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 22 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 2.7: GLR effect on the pressure gradient curves
0 4 8 1 2 1 6 2 0 2 4 2 8
1 0
9
8
7
6
5
4
3
2
1
0
D
e
p
t
h
,
1
,
0
0
0
f
t
P r e s s u r e , 1 0 0 p s i
G
L
R
(
s
c
f
/
s
t
b
)
0
2
0
0
5
0
0
1
,
5
0
0
Figure 2.8: Flow rate increasing effect on pressure gradient
1 0
9
8
7
6
5
4
3
2
1
0
D
e
p
t
h
,
1
,
0
0
0
f
t
0 5 1 0 1 5 2 0 2 5 3 0 3 5
P r e s s u r e , 1 0 0 p s i
q
(
s
t
b
/
d
)
2
,
0
0
0
1
,
0
0
0
2
0
0
5
0
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 23 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 2.9: Gravity increasing effect on pressure gradient
0 5 1 0 1 5 2 0 2 5 3 0 3 5
1 0
9
8
7
6
5
4
3
2
1
0
D
e
p
t
h
,
1
,
0
0
0
f
t
P r e s s u r e , 1 0 0 p s i
B r i n e wa t e r w = 1 . 0 7
F r e s h wa t e r w = 1 . 0 7
AP I g r a v i t y = 1 0
AP I g r a v i t y = 5 0
Figure 2.10: Oil viscosity effect on pressure gradient
0 4 8 12 16 20 24 28
10
9
8
7
6
5
4
3
2
1
0
D
e
p
t
h
,
1
,
0
0
0
f
t
Pressure, 100 psi
D
e
a
d
o
i
l
v
i
s
c
o
s
i
t
y
5
0
0
c
p
-
1
6
.
2
A
P
I
5
0
-
2
3
.
0
c
o
n
s
t
a
n
t
v
i
s
c
o
s
i
t
y
1
.
0
c
p
-
3
5
A
P
I
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 24 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
3.7 TUBING FEATURES
3.7.1 TUBING CHARACTERISATION
Tubing consists of non-welded pipes which are run into the well, and made up one on top of the
other until the desired depth. The parameters characterising the tubing are listed below.
Nominal diameter, Outside Diameter (OD)
All well tubulars follow the API specifications in standardising on outside diameter. Hence, 4
tubulars have an OD of 4. In addition, API defines tubing as having an OD from 11/20 to 4 .
Tubulars with OD of 4 or greater are classified as casing.
Length Range (R)
Tubulars are manufactured in lengths termed 'joints'. The API specification only allows tubing joints
to be manufactured in two length ranges. However, some mills can produce Range 3, and, where
practicable and possible, this range is preferred.
Range 1: 20 to 24 feet
Range 2: 28 to 32 feet
Range 3: 32 to 48 feet
The API casing standard allows three ranges, namely:
Range 1: 16 to 25 feet
Range 2: 25 to 34 feet
Range 3: 34 to 48 feet
Permissible maximum variation is 2 ft either for range 1 or range 2.
Weight per Foot (Ib/ft)
The ability of a tubular to withstand stress is governed by its mechanical strength (grade) and wall
thickness. Since API standardises tubulars on OD, an increase in wall thickness decreases the
inside diameter (ID) and obviously increases the weight. Tubulars are therefore specified in terms of
OD and weight of pipe per linear foot. However, some suppliers do exceed API tolerances on OD in
order to minimise the reduction in ID. The API specifies a limited number of standard weights for any
particular tubular size. However, non-API heavy walled tubing is also available for high strength
applications. These tubulars have proprietary grades, and the stress analysis should be discussed
in detail with the individual manufacturer.
Drift ID
It is important that all production/completion tubulars are drifted in accordance with AGIP
recommendation. This should allow the safe passage of any equipment and will ensure injection
and production rates are not impeded.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 25 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
3.7.2 TUBING STEEL GRADES
The oilfield technicians do not use very often the international recommended nomenclature for steel.
Standard API steel grades are designed by a capital single letter and a number (two figure). The
letter indicate general characteristic of steel, but generally these letters have very little relevance in
determining the physical properties of the tubular. The number indicate the minimum yield strength
expressed in thousand pound per square inch.
Sometimes the manufacturers indicate by themselves with meaningful letters (two) the steel grades
and generally with the number indicating the minimum yield strength in thousand p.s.i.
Hence there are effectively the same pipe, but with a different designation: in any case the API
reference, whiles for CRA tubulars, is the reference one.
The figure of a steel is important since it provides information as to the minimum tensile properties
of the pipe and is also a function of most of the pipe's other physical properties, i.e. burst and
collapse. It should not be confused with the ultimate tensile strength (UTS), which is not used in pipe
identification. The minimum yield stress value is used in all tubular stress analysis.
API standard grades are listed below and the designations indicate minimum yield strength in 1000
psi and the grade of new pipe can be identified by colour bands as follows:
J-55 green band K-55 two green bands
C-75 blue band L-80 red with brown band
N-80 red band C-95 brown band
P-105 white band
The standard API steel grades and the tensile requirements for tubing are :
Yield strength (psi) Tensile strength (psi)
minimum maximum minimum
H-40 40,000 80,000 60,000
J-55 55,000 80,000 75,000
K-55 55,000 80,000 75,000
L-80 80,000 95,000 95,000
N-80 80,000 110,000 100,000
C-90 90,000 105,000 100,000
C-95 95,000 110,000 105,000
T-95 95,000 110,000 105,000
P-110 110,000 140,000 125,000
Q-125 125,000 150,000 135,000
Standard API steel grades for tubing type L and T are intended for hydrogen sulphide (H2S) service,
they are heat treated to remove martensitic crystal structure; with L grade hardness must not exceed
23 Rockwell C.
CRA materials are at the not covered by API standardisation. They are identified by suppliers name
and same definition of yield in 1000 psi.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 26 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
CRA materials are less homogeneous than carbon steel and suffer of higher tensile characteristics
versus temperature.
In the next two figures there are shown the temperature variations of the Yield strength, the Tensile
strength and of the Elongation for Sumitomo C.R.A. 25%Cr, 75,000 psi and Sumitomo 13% Cr
Super Martensitic, 95,000 psi.
Figure 2.11: Tensile properties of Sumitomo 25%Cr 75 ksi steel
Y
S
,
T
S
(
k
s
i
)
900
700
500
0 100 200
Temperature C
RT 100
60
80
100
120
200 300 400
40
20
Y
S
,
T
S
(
M
P
a
)
Temperature (F)
E
I
.
(
%
)
500
YS
TS
Tensile properties at elevated
temperature of SM 25CR-75
Figure 2.12: Tensile properties of Sumitomo 13%Cr 95 ksi supermartensitic steel
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 27 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Y
S
,
T
S
(
k
s
i
)
900
700
500
0 100 200
Temperature C
100
70
90
110
130
200 300 400
40
20
Y
S
,
T
S
(
M
P
a
)
Temperature (F)
E
I
.
(
%
)
Tensile properties at elevated
temperature of SM 13CRS-95
TS
YS
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 28 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
3.7.3 TUBING CHECKS
Before using tubing for completion it is advisable to carry out various checks, to make sure they are
in good condition. There are electromagnetic methods to spot transverse and longitudinal defects
due to construction, such as rolling scales, cracks etc. However, these are applied only to the pipe
body. To note cracks in the threaded parts, in the couplings or in the upsetting, magnetic-optic
system are used. We use iron powder sprinkled on the parts concerned which are then immersed in
a magnetic field and helped by a Wood lamp. Ultrasonic systems are also used especially when
internal defects or exact thickness are to be checked.
Generally above inspections are made in the mill as part of the Quality Plan associated with each
order.
3.8 TUBING CONNECTION
There are two API standard connection available:
Non Upset
External Upset
The API Non Upset tubing connection (NU) is a 10-round thread form, wherein the joint has less
strength than the pipe body.
The API External Upset tubing connection (EUE) is an 8-round thread form wherein the joint has
greater strength than the pipe body. API EUE connections are available also for very high pressure
service having a long thread form (50% longer than standard)
API couplings extra clearance can be turned down without loss of joint strength. Special clearance
collars are usually marked with a black ring in the centre of the colour band indicating the steel
grade.
For small diameter tubing it has been developed an Integral connections, 10-round thread form.
Generally speaking, AGIP never use API connections, unless for ESP (Electrical Submersible
Pump) or Sucker Rod Pump applications, where the wells are not normally flowing to surface.
Same connections, in a very precise moulding, are used to connect Fiberglass tubing which for
installation in limited load conditions can be conveniently used as economic alternative to CRA pipe.
3.8.1 TUBULAR CONNECTIONS
Machined threads at the end of the tubulars allow joints to be assembled into strings. These
threaded connections must provide pressure integrity and have sufficient strength to withstand the
tubing body stresses.
The API specifications only apply to API tubing and casing connections and do not apply to the non-
API proprietary connections like VAM. Non-API contentions sometimes termed premium
connections, have been designed to overcome some of the limitations in the API equipment,
including:
Providing greater axial strength.
Smaller connection OD.
Improved pressure integrity (gas tight sealing).
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 29 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
3.8.2 CONNECTIONS DESCRIPTION
Tubular connections are like complex pressure vessel closures in that they are required to maintain
structural integrity and gas/fluid saleability. The structural integrity of these connections is
accomplished by the:
Threads.
Seals.
Shoulders.
There are three main types of connections listed in order of structural performance. They are:
Integral upset.
Threaded and coupled.
Flush joint.
Integral upset tubulars, e.g. Hydril (CS, PH6), are manufactured from one piece of pipe. They are
similar in appearance to drillpipe, but are far superior in terms of structural performance. The
connections in threaded and coupled tubulars are manufactured from the same materials as the
pipe body.
Flush joint connections are also manufactured from one piece of pipe. However, due to the design
of the connection (internally and externally flush), it does not possess the same strength as either
the integral upset or the threaded and coupled connection.
Each connection type has its applications, depending on the conditions.
The design of a tubular connection is similar to other machine design processes. Design of tubular
connections is based on the following simplifying assumptions:
The material is ductile.
Service loads are applied statically. In other words, service loads are neither dynamic or applied
by impact.
Service temperature neither exceeds the creep range (about 600F (316C)) nor falls below the
null ductility transition temperature (below about 4F (-20C)) under load conditions.
Typical loading conditions that affect structural integrity of connections are tension or compression,
internal or external differential pressure, surface and production temperature and corrosion. For
helical buckled tubing and in high angle directional drilling, bending must also be considered. The
same loading conditions also affect sealing integrity of connections, but in different ways. For
example, axial tension can break, pull-out or jump-out a connection by exceeding its structural
strength. It can also cause leakage of some connections by plastically deforming threads or
reducing the contact bearing pressure of the sealing surfaces. Therefore, tubing designers more
often desire tensile strength greater than pipe body in order to avoid distortion of seals.
3.8.3 THREADS
Any thread form has basic features that include height (depth), stab flank angle, load flank angle,
root radii, crest radii and surface finish. All threads follow a helix, whether cylindrical or tapered, and
so possess pitch and lead. Threads are then matched to opposing threads with either precise
interference, clearance or a combination of both. There are many different types of connections and
thread variations that have been marketed. However, the basic thread forms in use today may be
classified as:
8-round thread forms
Buttress thread form
Shortened (stub) ACME thread form
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 30 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Reversed flank thread form
Tubular connections in the past have utilised sharp V thread forms. Line pipe and bolts and nuts still
use this thread form. The thread form offers adequate performance on non-upset pipe for oil wells
ranging in depths up to 5000 ft.
3.8.4 SEALS
3.8.4.1THREAD SEALS
API 8-round and Buttress are typical of connections that depend on thread seals. The connection is
designed in such a manner that when threads are assembled, the annular clearance between
mating crest and root is a crescent-shaped space having a nominal 0.003 in clearance. With proper
thread compounds which must plug this annulus, the joint is capable of performing an adequate
control for leak resistance, provided appropriate torque is applied to the connection.
Thread compound sealability is a function of application procedure, temperature and time. The
grease base of API modified thread compound (75% content by volume) is the greatest limitation of
8-round threads. It can react with cleaning solvents, condensates, carbonic acid, hydrogen sulphide
and ethane. It dries out with temperature and time, decreasing its resistance to the flow of gases or
condensate. A suggested upper limit of temperature is approximately 210F for long term
applications. API modified compound is 67% metal filler by weight. It is possible to increase leak
resistance by minimising clearance between mating thread elements. This may, however, cause
thread wear or galling where service requirements include repeated make-up.
3.8.4.2 PLASTIC (ELASTOMERIC) SEALS
This type of connection relies on a Teflon seal ring in the groove between mating surfaces. The ring
is free to expand or contract with temperature in the direction of fluid flow, so that the metal
connector walls are not significantly stressed by thermal effects. The seal materials have, in general.
thermal coefficients of expansion that are several times that of steel. High flowing temperatures can
create enough expansion pressure from the Teflon to separate pin and box threads and extrude the
edges of the ring from its groove. Upon cooling, the seal ring contracts, but its shape has changed,
and it is no longer tight in its groove. A loose seal ring can result in leakage. Experience to date
(mainly in the USA) has shown that plastic seals are satisfactory up to 7500 psi. Above this, metal-
to-metal seals should be utilised. However, in the North Sea and in the rest of the world, metal-to-
metal seals are predominantly used above 5000 psi.
Plastic seals (Corrosion Barrier, CB ring) have been used by Agip and qualified in Special Premium
Joint connections to be applied to Internally Plastic Coated Tubing.
3.8.4.3METAL-TO-METAL SEALS
Metal-to-metal seals are of either shouldering type, sliding (flank) type or a combination of the two.
The two types of metal-to-metal seals depend on a designed interference for the initiation of the
sealing interface during assembly. The sliding sealing elements may consist of a curved surface pin
seal mating to a conical female seal surface. The purpose of the curved seal is to concentrate the
radial interference force to ensure an intimate contact with the female (box) member of the
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 31 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
connection. Shouldering metal seals, like VAM, utilise mostly compressive axial strain to maintain
the sealing interface.
Metal-to-metal seals have proved to be not only reliable, but also durable. These independent
sealing elements have been used on various products and subjected to practically every
conceivable type of service in oil and gas completions. As long as the metal-to-metal seal coupled
or integral joint casing or tubing is not pulled onto yield, not over torque, and handled with care, they
offer high temperature, high pressure and gas tight performance. Depending on the joint material
used, they may be almost indestructible as far as wear or galling after repeated use is concerned.
However, they are least capable of field repair and cost the most to make and gauge.
3.8.4.4 PRESSURE ENERGISED METAL-TO-METAL SEALS
Pressure energization refers to an increase in contact pressure at the sealing interface that is
caused by an increase of pressure of the fluid being sealed. A pressure energised seal can utilise
relatively low contact stress to initiate the sealing interface because the contact pressure increases
at a greater rate than the fluid pressure.
3.8.4.5SURFACE FINISH TOPOGRAPHY
Surface finish topography is an important factor controlling fluid sealability. Smooth surfaces tend to
permit 'channelling' through the lubricating film between the surfaces. Surfaces having roughness
greater than 32 microinch, appear to trap lubricant in the surface discontinuities which act somewhat
like a gasket with a multitude of tiny high points breaking up continuity of lubricating film, thus
preventing channelling. A good surface roughness range for seal finishes was found to be from 32
to 125 microinch
3.8.4.6 SHOULDERS
The principal function of the shoulder in the sealing mechanism is to absorb and retain the load
generated by the torque. This is commonly referred to as a pre-load and is extremely important
when energising the metal-to-metal seal in premium connections.
Other types of shoulder are referred to in various proprietary connections, and these are commonly
used as 'land-off' shoulders and assist the seal shoulder. These shoulders do provide some
interference and some assistance in sealing. However, despite manufacturers' claims, this should
not be considered as a reliable seal.
3.8.5 CONNECTIONS REQUIREMENTS
Depending on application, a connection may have to satisfy all or some of the following
requirements:
Sufficient joint strength.
Adequate sealing force.
Resistance to damage when re-run.
Resistance to galling.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 32 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Quick and easy make-up.
Smooth ID transition.
A connection has to maintain sufficient structural integrity and resistance to leakage over all the
applied service loads, including fracking, workovers, drilling bridge plugs etc. Most premium
connections have better structural properties than the pipe body, although this should be confirmed
with either a tubing specialist or the manufacturer.
3.8.6 GENERAL CONNECTION SELECTION
3.8.6.1 INTRODUCTION
Selection of the appropriate connection should be based on the following factors:
The intended application for which the connection will be used.
The performance capabilities of the connection in its intended application.
Availability to location. Refurbishment and re-threading facilities for used pipe.
Cost.
Local Government requirements/constraints.
The drilling or production engineer should procure connections from reputable manufacturers,
ensure protection for connectors through all stages of inspection, storage and shipment and verify
final integrity of assembled connections during field handling, running and testing.
Unfortunately, the user faces a difficult task in selecting a connection for the particular size, weight
and grade suitable for the intended application for the following reasons:
A large number of candidate connections that at first sight would appear to meet the downhole
requirements.
The connection industry often rates its connections nominally, rather than on minimum
dimensions and minimum strength values.
Often, little or no data is available to support the manufacturer's performance claims.
3.8.6.2 CONNECTION TYPES
Production casing traditionally consists of production liners, production and tie-back casing. The
primary attribute of production casing connections is their ability to withstand all well conditions
without leaking or parting. Production casing and tubing connections must contain production fluids,
and therefore require high sealing capability.
Sealing requirements differ for liquids, steam and gas/ condensates. Long-term gas or condensate
sealing at high temperature can only be accomplished with metal-to-metal or plastic seals. With the
progress of technology and scientific improvements in material and product design, a variety of
connections are now available for critical service applications.
The thread compound in connections that rely on thread seals, is susceptible to deterioration with
temperature and time and to corrosive degradation. Plastic seals can extend the sealing range up to
375F. Metal-to-metal seals extend the sealing range further up to 650F.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 33 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
For production casing, five generic connections are normally used:
API 8-round (STC or LTC).
API Buttress (BTC).
Metal-to-metal seal, formed and integral (flush) (IFJ).
Metal-to-metal seal, threaded and coupled (MTC).
Metal-to-metal seal, upset and integral (or coupled) (MIJ).
STC and LTC are acronyms for short and long thread coupled, respectively.
The API connections for production casing may or may not have plastic seals.
Three generic tubing connections are normally used on production tubing:
API 8-round (EUE).
Metal-to-metal seal, threaded and coupled (MTC).
Metal-to-metal seal, upset and integral (or coupled) (MIJ).
EUE is an abbreviation for externally upset end tubes.
The API connections on production tubing may or may not incorporate plastic seals.
API EUE is the basic tubing connection. The premium/non-API connections usually incorporate a
metal-to-metal sealing. Premium connections provide extensive improvements in comparison to the
above standard connections in:
Pressure ratings.
Tensile capacity.
OD clearance.
Gas and fluid sealability.
The other improvements that are less frequently required include:
Controlled assembly stress.
Smooth ID transition.
Use of internal plastic coatings.
API BTC that run out on the pipe OD, provide the greatest possible tensile resistance for
connections on plain (non-upset) end pipe, with some loss of sealability. Upsets provide additional
metal from which greater tensile capacity can be achieved, in excess of the pipe body capacity. This
is important when pulling casing beyond its tensile overpull rating or pulling tubing beyond its yield
point. It ensures that seals and threads are not distorted plastically and subsequently leak.
Providing the metal-to-metal seal coupled connection is not pulled to yield, over-torqued and is
handled with care, it will provide a reliable seal.
Flush type connections are designed to maximise clearance downhole, requiring that tensile
efficiency be sacrificed. However, such connections are usually run as shorter strings that do not
require full pipe body tensile efficiency. Flush connections without cold-formed ends can only meet
full pipe body internal pressure ratings when the thread is designed for the specific weight of pipe,
and the thread and pipe OD are not eccentric. Therefore, fully internal pressure rated flush
connections are normally cold-formed. Boxes are expanded to ensure adequate wall thickness over
the primary seal. Pins are swaged (nosed down) and bored to ensure uniform deformation of the pin
during assembly.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 34 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
3.8.7 AGIP STANDARD JOINTS SELECTION CRITERIA
The connections indicated by Welcome Expert System are all Premium type, for Agip standard the
API connections are not considered.
In the Welcome Expert System the available connections are collected in a data base where they
are grouped in Coupling connections and Integral connections.
Agip Standard Dpt. qualified the connections (see doc. STAP M1M-5006) and they are:
Coupling : AMS 28 (manufacturer Dalmine)
VAM ACE (manufacturer Vallourec and Sumitomo)
Integral : Agip A-DMS (Agip Dual metal seals)
The Hydril PH-6 and the PJD Dalmine connections are also considered by Welcome. They have not
been subject to complete qualification programme per API 5CT, but their reliability is proven by
years of application.
The connection selection depend on the material selection performed by corrosion analysis results.
The selection criteria are showed here below grouped by material type.
The listing order indicate the priority also.
Material: Incoloy 825, Duplex 1(25%, 22% Cr, Cold Worked), 28% Cr
Connection: AMS 28 and VAM Ace
Material: Martensitic 13% Cr.
Connection: Hydril CS (o equivalent PJD8)
AMS 28
VAM Ace
Material: Low Alloy Steel
Connection:
for offshore well Hydril PH-6 (or equiv. PJD 6)
Hydril CS (or equiv. PJD8)
AMS 28
VAM Ace
for onshore well
oil well, depth <5000 m: AMS 28
Hydril CS (or equiv. PJD8)
Hydril PH-6 (or equiv. PJD 6)
VAM Ace
other cases: Hydril PH-6 (or equiv. PJD 6)
Hydril CS (or equiv. PJD8)
AMS 28
VAM Ace
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 35 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Material: 22% e 25% Cr S.A.
Connection:
oil well: AMS 28
VAM Ace
Hydril CS (or equiv. PJD8)
Hydril PH-6 (or equiv. PJD 6)
else: Hydril CS (or equiv. PJD8)
Hydril PH-6 (or equiv. PJD 6)
AMS 28
VAM Ace
Material: Carbon Steel
Connection:
for offshore well
oil well, depth <5000 m: PJD
else: Hydril PH-6 (or equiv. PJD 6)
for onshore well
injection well (storage) : AMS
production well:
depth <2500 m and SBHP <350 kg/cm: AMS
depth <2500 m and SBHP >350 kg/cm: PJD
Hydril CS (or equiv. PJD8)
depth >2500 m and <5000 m: PJD
Hydril CS (or equiv. PJD8)
Hydril PH-6 (o equiv. PJD6)
other cases: Hydril PH-6 (o equiv. PJD 6)
3.9 3.9 WELL MONITORING
Injection rates, pressures and temperatures can be monitored continuously downhole using
Downhole P & T instruments permanently installed in specific mandrels installed and connected
permanently to the surface via an instrument wire (1/4 OD).
This is done in a regular basis subsea injectors not being available any other means of having
bottom hole measures or in installation where there is the need to continuously monitor Bottom Hole
Flowing Pressure (e.g. ESP application).
For land or platform applications common wireline techniques can be adopted; in particular in these
wells it is sound to select downhole nipple profiles such to allow for the possibility of running PLTs.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 36 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
3.10 WELL COMPLETION DESIGN EXAMPLE: WAKAR FIELD
3.10.1 INTRODUCTION AND TUBING STRESS ANALYSIS
Due to the location of the platform close to the shipping lines, to the well gas production and the
rating required (7500 psi min), a special completion configuration has been designed, to guarantee
for the well safety in case of accidental damage to the platform and/or to the wellheads.
Besides the installation of a conventional Tubing Retrievable Safety Valve, infact, it has been
foreseen the installation of a Sub Surface Tubing Hanger (Anchor). This, in case of accidental
controlled rupture of the tubing above the Safety Valve, will hold the rest of the string intact and shut
in the well at the Safety Valve.
To allow for the controlled rupture of tubing above the Safety Valve, a pup joint manufactured with a
controlled section (machined for 80% of tubing yield for the two trips system) is installed below the
mud line (almost 100 m from cellar deck). In case of an accident to the platform where this is taken
off location, any bending of casings and pull on tubing will shear the controlled section at the mud
line living it undisturbed, ready for an overshot to catch it; the reaction point for the tubing while
pulled is the tubing hanger positioned below the safety valve which for this purpose needs bi-
directional slips. Two different configurations have been evaluated with different manufacturers:
- One trip system; all downhole equipment run in a single stage.
- Two trip system; two separate runs for lower and upper completions.
Table 2.5: Tubing Stress Analysis Result Summary: safety factor
Tubing size section Max Prod.
1st year
Shut In
1st year
Injection
5000 psi
3 bpm
Pull
50,000 lb
3.5, 9.2#
13 Cr
head
SS Anchor
bottom
2.82
3.04
4.4
1.67
1.68
1.92
1.93
1.76
4.2
1.54
1.57
4.8
Safety Joint
3.5
2.33 1.33 1.57 1.35
4.5, 12.6#
13 Cr
head
SS Anchor
bottom
2.38
2.63
3.96
1.48
1.49
1.62
1.76
1.64
3.83
1.55 (*)
1.63(*)
4.77(*)
Safety Joint
4.5
1.97 1.18 1.42 1.25(*)
(*) 70000 lbs pull for 4
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 37 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Table 2.6: Anchor and Packer Loads Summary (1000 lbs - with direction up and
down)
Tubing
size
section
Max Prod.
1st year
Shut In
1st year
Injection
5000 psi
3 bpm
Max Prod.
4th year
Min Prod.
10th year
3.5, 9.2#
13%Cr
Anchor
820 ft
Packer
11909 ft
17.2
36.9
0.1
54.2
28.0
63.7
15.6
59.3
4.7
51.9
4.5, 12.6#
13%Cr
Anchor
820 ft
Packer
11909 ft
18.2
47.1
0.7
88.7
35.7
96.6
15.8
82.7
0.5
73.0
Recommended configuration is for the two trips system, reasons for which are given in the integral
study text.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 38 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
3.10.2 TUBING SIZE AND MATERIAL
The production profile requested will require to cope with a variety of rates and water cuts during the
well life and bottom hole static pressure depleting quite rapidly.
Moreover the high initial rate will require to maintain the ID as big as possible to accomplish for the
erosional velocity of produced fluids. On this respect calculations have been done using a C factor
of 200 not considering any sand/silt production.
Conversely possible lifting of condensate drop out later in the field life would need to be
accommodated through a velocity string whose provision has been asked for.
As a result, to comply with the initial rates and to guarantee for a safe production velocity through
the Sub Surface Safety Valve and lowermost restrictions, a tubing 4 12.6 pounds per foot has
been selected, considering all possible loads applicable during the well life (running, packer setting,
production, killing).
Material selected is Martensitic 13% Cr s.s., which will take care of possible corrosion resulting from
condensation of connate water throughout the outflow and of possible produced water, due to the
high content of CO
2 .
To accomplish for the installation of the 4 it has been required the revisitation of the casing
profile.
The two wells have been suspended with the 9 5/8 as production casing, but, due to casing wear
during drilling it has been required to tie back the 7 production liner at surface. This configuration
does not accommodate for the installation of the 4 10K WP Sub Surface Safety Valve.
For this reason the production casing profile has been reviewed; as a result the new profile
foresees:
1. to cut and recover the present 9 5/8 @ 350 m below the mudline,
2. to tie back a mixed production casing (7 29# at bottom swaged to 9 5/8 47# at - 350 m anchored
inside the drilling wellhead on the platform (cellar deck).
This, besides guaranteeing the possibility to install the Safety Valve, will allow to install an integer
production casing; moreover it will give a load shoulder for the system to suspend the string in
accordance with proposals. Figure 2.13 shows one of the proposed completion sketch.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 39 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 2.13: Wakar field: one of the proposed completion sketch
Sub Surface TBG HGR bi directional:
allow annulus circulationand retrieval - rerunning
SCSSV 4.5" PJ
Packer Permanent - Retrivable
Perforated Joint
sea bed level
sea level
well bay leve
safety joint
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 40 OF 40
REVISION
TEAP-P-1-R-8792 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
3.11 FIGURES AND TABLES LIST
Figure 2.1: Inflow and outflow performance diagram
Figure 2.2: Pressure gradient plot (production and injection)
Figure 2.3: Prediction of minimum gas flow rate required for liquid removal (not to scale)
Figure 2.4: Permissible expansion of a 1.0 gravity natural gas without hydrate formation
Figure 2.5: Pressure (fig. 2.5A) & temperature (fig. 2.5B) gradient for production well
Figure 2.6: Tubing size effect on the pressure gradient curves
Figure 2.7: GLR effect on the pressure gradient curves
Figure 2.8: Flow rate increasing effect on pressure gradient
Figure 2.9: Gravity increasing effect on pressure gradient
Figure 2.10: Oil viscosity effect on pressure gradient
Figure 2.11: Tensile properties of Sumitomo 25%Cr 75 ksi steel
Figure 2.12: Tensile properties of Sumitomo 13%Cr 95 ksi steel
Figure 2.13: Wakar field: one of the proposed completion sketch.
Table 2.1: Producible oil and gas rate range Vs tubing size
Table 2.2: Pressure drop terms contribution
Table 2.3: Applicability of pressure loss prediction methods
Table 2.5: Tubing Stress Analysis Result Summary: safety factor
Table 2.6: Anchor and Packer Loads Summary
ARPO
ENI S.p.A.
Divisione Agip
ORGANIZING
DEPARTMENT
TYPE OF
ACTIVITY'
ISSUING
DEPT.
DOC.
TYPE
REF. N. PAG.
1
OF
33
TEAP P 1 R 8793
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
TITLE
Well Completion & Workover Course Volume 1
CHAPTER 4
- TUBING STRESS ANALYSIS -
DISTRIBUTION LIST
TEAP
STAP Archive
LIST of CONTENTS (authors)
Cap. 01 - Well Completion Design - M. Marangoni
Cap. 02 - Material Selection - M. Marangoni
Cap. 03 - Tubing Design - B. Maggioni
Cap. 04 - Tubing Stress Analysis - B. Maggioni
Cap. 05 - Packers - M. Marangoni
Cap. 06 - Surface Wellhead - M. Marangoni
Cap. 07 - Safety Valves and Miscellaneous - M. Marangoni
Cap. 08 - Perforating - M. Marangoni
Cap. 09 - Formation Damage - M. Viti
Cap. 10 - Sand Control - M. Viti
Cap. 11 - Workover - G. Treglia
Date of issue:
(eq. 3.1)
where:
F is the force active at the string bottom
L is the string total length
E is the elastic modulus of the steel grade used for tubing
As is the bottom string section (Seal bore Packer area minus tubing internal area)
see Figure 3.1
Figure 3.1: Hookes law
F
L1
4.3.2 BUCKLING EFFECT
To define the string buckling the Neutral point concept should be introduced.
Consider a string freely suspended in the absence of any fluid inside casing and an upward
force F applied at the lower end of the string.
The force compress the string and if it is large enough, the lower section of the string buckle
into a helix.
The compression is maximum on the lower section of the string and decreases the distance
becoming zero at the Neutral point . The string above the Neutral point is in tension, starting
from zero at the Neutral point and increasing upwards.
The Neutral point is the place where the total primary axial stress is equal to the average of
the radial and tangential stresses.
Below the neutral point the pipe is buckled, whereas above this point the pipe is straight.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 10 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
n
F
w
(eq. 3.2)
n is the distance between the neutral point and the bottom of the string
(measured length)
w is the weight per unit length of the string considering the inside and outside fluids
weight
w = w
s
+ w
fi
-w
fo
(eq. 3.3)
w
fi
= A
i
fi
(eq. 3.4)
w
fo
= A
o
fo
(eq. 3.5)
A
i
and A
o
are the internal tbg area and the external tubing area
fi
and
fo
are the inside and outside fluids density
To calculate the length variation due to buckling effect it is necessary to determine the
Neutral point position. If the neutral point is located inside the string, in this case the string is
partially compressed and partially tensioned and the tubing shortening can be evaluated be
means of the following formula:
L
F r
E I w
2
2 2
8
(eq. 3.6)
if n < L
where:
r is the tubing-casing clearance
I is the moment of inertia of tubing cross section with respect to its diameter, that is:
( )
I
D d
4 4
64
(eq. 3.7)
where:
D is tubing OD
d is tubing ID.
w is the weight per unit length calculated the same way than in Hookes law formula
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 11 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 3.2: Buckling effect
F
L2
If the compression force applied to the string bottom is so high to buckle all the string, the
Neutral point is located out of the string and the length variation can be evaluated by:
L
F r
E I w
L w
F
L w
F
2
2 2
8
2
_
,
1
]
1
(eq. 3.8) if n L >
4.3.2.1 FORCE ACTING AT THE PACKER LEVEL: PISTON FORCE
The force to consider applied on the string to calculate the buckling effect is named Piston
force and is calculated by the formula:
( ) ( )
F P A A P A A
a i p i o p o
(eq. 3.9)
The areas indicated in the formula can be found by figure 3.3.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 12 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 3.3: Areas for piston force calculation
Ao
Ai
r
Ap
Pi
Po
In the next three figures there are the possible tubing-packer connection in terms of areas.
Figure 3.4: Areas for different tubing connection types
Ao
Ai
r
Ap
Pi
Ai
r
Ap
Pi
Ai
r
Ap
Pi
Ao Ao
Po Po Po
Note that if the tubing outside pressure is greater than tubing inside pressure the buckling
effect does not occur.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 13 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
To summarise, the piston force Fa acts as per Hookes law if negative (tension) and both
Hookes law and Buckling effect if positive (compression)
4.3.2.2 FORCE ACTING ALONG THE STRING: FICTITIOUS FORCE
The pressure acting along the tubing string is represented by the resultant applied at the
bottom section. The actual forces are distributed along the whole string wall but for
calculation purposes it is easy to apply the resultant: for this reason the force is called
fictitious, not because it does not exist but only because it is the resultant of a distributed
force.
To understand the effects of the external and internal pressure on the string see the figure
below:
Figure 3.5: Internal and External pressure effects
R
R
Pi Pi
Po Po
Internal Pressure Effect External Pressure Effect
The pressure effects can be calculated by
F A P
f
I
i i
(eq. 3.10)
F A P
f
II
o o
(eq. 3.11)
where the first indicate the effects of the internal pressure along the lateral wall of the string
equivalent to a force acting on the bottom section of the string as compression force.
The second force indicate the effects of the external pressure on the external lateral wall of
the string applied, as resultant, at the bottom of the string and acting as tension.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 14 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Note that the areas the forces are acting on, are different due to the both two forces, hence:
F F F F
f f
I
f
II
a
+ + (eq. 3.12)
The Fictitious force is defined, substituting the relations defined in the previous section, by:
( ) F A P P
f p i o
(eq. 3.13)
The pressure to consider in the formulas of the fictitious force is the change in pressure
inside the tubing at the packer level and the change in pressure outside the tubing at the
packer level.
The difference is intended from reference condition pressure and load condition pressure.
The formula that defines the Fictitious force used to calculate the buckling effect becomes:
Ff = Ap (Pi - Po) (eq. 3.14)
4.3.3 BALLOONING EFFECT
The fluids flowing in the tubing give two effects: the pressure drop that modifies the radial
pressure force, and a force on the tubing wall due to the drag force of the fluids.
The Ballooning effect encompass both effects by the two terms of the formula:
L
E
P R P
R
L
im
3
2
2
2
1
om
- /L . [i - R o - . (1 + 2)/2].L / (R-1) (eq. 3.15)
where:
Poissons ratio of the tubing material
Pim Change in surface tubing pressure
Pom Change in surface casing pressure
i Change of the density of liquid in the tubing
o Change of the density of liquid in the annulus
Drop of pressure in the tubing due to flow per unit length
R Ratio OD/ID of the tubing
L Tubing length
is drop of pressure in the tubing due to flow per unit length as said and it is assumed to be
constant. is positive when the flow is downward and conversely equal to zero in case of no
flow.
In figure 3.6 is showed the inside and outside pressure effect on the tubing.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 15 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 3.6: Ballooning effect
REVERSE BALLOONING BALLOONING
4.3.4 TEMPERATURE EFFECT
Often the temperature effect is the most important fraction of the total length variation. The
effect is linked to the temperature variation and to the thermal expansion coefficient proper
of the tubing material. The simple equation is:
L T L
M 4
(eq. 3.16)
where:
coefficient of thermal expansion of the tubing material
(for steel = 6.9 10
-6
in/in/F)
The average temperature variation can be calculated by:
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 16 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
( ) ( )
T
T T T T
M
final initial
Head
final initial
bott
+
om
2
(eq. 3.17)
Typical values of thermal expansion coefficient are listed in the table below:
Table 3.2: Thermal expansion coefficient ( )
Carbon steel 6.9 10
-6
in/in/F
Low alloy steel 6.9 10
-6
in/in/F
13%Cr (80-95 ksi) 6.1 10
-6
in/in/F
22%Cr (65-110-120-140 ksi) 7.9 10
-6
in/in/F
25%Cr (75-110-120-140 ksi) 6.89 10
-6
in/in/F
28%Cr (110-125 ksi) 8.5 10
-6
in/in/F
Incoloy 825 (110-120 ksi) 7.92 10
-6
in/in/F
4.4 TUBING-PACKER CONNECTION TYPES
Tubing packer connection types considered for the stress analysis are showed herebelow:
Figure 3.7: Tubing-packer connections
FREE FREE DOWN LOCKED ANCHORED
The first, tubing free, allows all tubing movement, both downwards and upwards; this is the
case of Polished Bore Receptacle (PBR) or Seal Bore Extension.
The second allows only upwards movement and it is the same as above but with shoulder
on the locator.
The third, fixed tubing, does not allow any movement, it is the case of latched, anchored
tubing, or tubing directly made up on the packer (modular setting).
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 17 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
4.4.1 SLACK-OFF OR PICK-UP EFFECT
If the tubing packer connections are fixed type or Nogo down type it is possible to slack-off
weight on the tubing string after packer setting. In this case the string is compressed.
With fixed type connection it is possible to tension the string either pulling the tubing string
or pressurizing it for setting an hydraulic packer.
Figures below show the tubing packer connections: both allow to slack-off weight on the
string, the second allow also to pick-up/tension the string.
The weight slack-off is described by the formulas below, there are two terms: the first
consider the elastic length variation (Hookes law) and the second the buckling effect.
L
F L
E A
F r
E I w
so
so
s
so
2 2
8
(eq. 3.18)
where Fso is the slack off force on the packer.
Figure 3.8: Tubing-packer connections for slack-off and pick-up
4.4.2 PACKER SETTING
To set an hydraulic packer, generally, the tubing pressure should be increased, at packer
level, of a certain amount (generally in a range from 1500 to 4500 psi) after tubing has been
plugged.
Two effects act on the tubing string: the elastic reaction due to the pressure acting on the
plug section and the ballooning effect.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 18 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
L
F L
E A
a
s
1
L
E
P
R
L
im
3
2
2
1
F L
E A
L
P
s
4
(eq. 3.24)
It is the same to stretch the tubing of a lengthening L4.
Figure herebelow shows the situation and the diagram below shows the force-tubing length
variation plot and the Fp and L4 meaning.
Generally the tubing packer reaction is a non linear problem due to the buckle of the string.
In these cases the first step is to plot the system variation length/force diagram.
That curve is plotted in figure 3.11, and length variation can be calculated by the following
formulas:
L
F L
E A
s
2 2
8
(for F > 0) (eq. 3.26)
Then by the Fictitious force, previously calculated, the tubing situation load case can be
located on the diagram. This point is (Ff, Lf) on plot. Then an axis translation should be
done to re-locate the origin in (Ff, Lf); in fact a force as Ff applied to the string bottom,
stretches the string and causes the buckling deformation.
In the new axiss diagram through the total length variation Lp = - Ltot it is possible to
evaluate the string lengthening. That Lp determines on the plot the tubing-packer force.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 20 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 3.10: Tubing-packer force
Fp
L4
L
F
F
p
L4
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 21 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 3.11: Non-linear Tubing-packer force
Fp
Lp
L
F
Ff
Lf
Fp
Lp
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 22 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
4.6.2 PACKER-TO-CASING FORCE
The packer-to-casing force is simply the tubing-to-packer force plus the plug forces acting
on the packer. It can be calculated as follow
FP-C = FT-P + (AC - AP) po (eq. 3.27)
where:
Ac = area defined by the casing ID, in
2
po = pressure differential across the packer, psi
In some cases, eg fracture stimulation. although the tubing may have satisfactory design
factors, problems may occur with the load rating of the packer. In these instances, the
equipment manufacturer should be contacted and the anticipated packer loading discussed.
4.7 MORE ABOUT HELICAL BUCKLLNG
When a tube is loaded in axial compression, it will shorten in accordance with Hooke's law.
However, if the tube is sufficiently long, which is almost always the case for well tubing, as
the compressive force increases, a critical force will be reached that corresponds to an
unstable condition. At this critical and higher compressive load, any amount of crookedness
of the tube or slight movement of the load will cause the tube helically buckle.
In presence of internal and external pressures, tubing behaves as if it was subjected to a
force called the Fictitious or the effective buckling force. This force is given by:
Ff = FTOTAL - (
t
+
r
) (Ao - Ai) = FTOTAL + (poAo - piAi)
2 (eq. 3.28)
The effective buckling force is sometimes also referred to as the excess axial force
The criteria used for buckling is as follows:
1. - If Ff is negative, the tubing behaves as though it is in compression, and helical buckling,
will occur. This concept can be difficult to understand since it is hard to visualise how the
radial and tangential stresses affect buckling.
2. If the tubing is free to move and only subjected to pressure / area forces, the effective
buckling force at packer depth reduced to
Ff = Ao (po - pi) (eq. 3.29)
Hence, in this situation buckling can only occur if the internal pressure is greater than the
external pressure.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 23 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Note, to maintain the correct sign for length changes (shortening is negative), use the
absolute value of Ff in the buckling equations.
4.7.1 THE SIGNIFICANCE OF BUCKLING
Bending moments due to buckling or instantaneous dogleg generate axial stresses in the
tubing. Bending induces axial compressive stresses in one side of the pipe and axial tension
stresses in the other side of the pipe. The equation for the axial stress due to bending is as
follows:
bend = + E x ID/2 /L (eq. 3.30)
5730 x 12
where:
ID/2 = pipe radius where the stress is calculated, in
/L = dogleg severity, deg/100 ft
In order to calculate the bending stresses due to buckling, the pitch, radius of curvature and
dogleg severity should first be determined.
The pitch is the distance in feet between spirals on the helix and is calculated with the
following formula:
P = ( 8 E I )
1/2
(eq. 3.31)
Ff
The radius of curvature of the helix in feet is given by:
r
c
= P
2
+ 4
2
r
2
(eq. 3.32)
4
2
r
2
and equivalent dogleg in degrees per 100 ft:
/L = 5730 (eq. 3.33)
rc / 12
The dogleg calculated with the previous equation is plugged into the equation to determine
the bending stresses due to buckling,
HB
.
These stresses are confined to the bends only, and hence they do not affect the axial force
profile in the string. However, bending stresses may contribute to tubing failure
by yielding the material, and they are therefore taken account of in the von Mises equivalent
(VME) stress and, hence, in the triaxial design factor.
Triaxial stress, or VME stress, will be discussed in a later section.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 24 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Buckling of production tubing strings can be tolerated in many cases provided that the stress
intensity in the pipe is at acceptable levels. Buckling is generally acceptable provided that
the peak VME stress in the pipe, including the axial bending stresses due to buckling and
deviation, are less than the specified minimum yield stress of the material with an
appropriate design factor.
Basically, there are two instances when buckling of production tubing is unacceptable even
if the VME stress intensity is acceptably low:
1. When tools have to be run through the tubing, e.g. before and after perforating with a
through-tubing perforating gun.
2. When the equivalent dogleg severity from buckling compromises the structural integrity or
sealing capability of the tubing connections.
Obviously, if the tubing is severely buckled, the running of tools in the tubing is complicated.
Preferably, during conditions where it is necessary to run tools in the tubing, the tubing
should not be buckled. However, it is generally possible to run tools in pipe which is only
mildly buckled.
The maximum free passage length for a tool in a helix shaped tube is calculated with the
following formula:
Ltool = P cos
-1
[ (ID - ODtool) ] (eq. 3.33)
( r + ID / 2 )
where:
Ltool = rigid length of a tool that can pass through the buckled tubing, ft
ODtool = tool diameter, in
ID = tubing ID or drift diameter, in
cos
-1
[...] cosine, in radians.
The free passage length value can be used as a guide to determine if the amount of
buckling will prevent the running of tools. Keep in mind that tools are not completely rigid
and therefore the free passage length calculated is conservative.
Remember, if buckling is a problem, it is possible to decrease the buckling intensity or
eliminate buckling by applying external surface pressure which tends to straighten the pipe.
Also, buckling can be lessened by using a lower initial slack-off weight if this is feasible.
4.8 STRESS, STRAIN AND DESIGN FACTORS DEFINITIONS
4.8.1 STRESS & STRAIN DEFINITION
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 25 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Stress is generated in a material when a force is applied; it is a distributed force inside the
material.
In the stress-strain diagram of steel are defined yield stress and tensile stress:
the yield stress is the stress (in force per area unit) where beginning the plastic deformation
of the steel out of the elastic region; The tensile stress is the maximum of the stress-strain
curve, after that there is the rupture stress. When a tube is loaded in axial tension by a
force, the axial stress can be evaluated by the following formula:
F
= _______
Ao -Ai
where:
is the stress in pound per square inches (psi)
F is the axial force in pound
Ao - Ai is cross sectional area in square inches
The elongation or the deformation induced is the Strain:
= L / L
where
is the strain in pound per square inches
L is the change length in inches
L is the tubing length in inches
Elasticity of the ductile material is resumed by the modulus of elasticity or Young modulus,
E, it is defined by Hookes law:
= E .
(E = 3.0 x 10^6 psi for carbon steel)
The radial strain and the axial strain is linked, in the elastic region, by means of the
Poissons ratio, that is:
radial strain
= ------------------
axial strain
( typical values is 0.3 for carbon steel)
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 26 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
tensile
yield
ropture
Figure 3.11bis : Carbon steel stress-strain diagram
4.8.2 AXIAL TENSION DESIGN FACTOR
Assuming that tubing connection which is equivalent to or stronger than pipe body is used,
the axial tension design factor is calculated as follow:
DFTENSION = Yp (Ao - Aj) / FTOTAL (eq. 3.34)
Yp = Yield Pint
4.8.3 BURST DESIGN FACTOR
Barlow's equation for thin-walled pressure vessels is used to calculate the internal pressure
resistance of the pipe body. The equation yields the pressure which generates a tangential
stress in the pipe or coupling wall equal to the minimum specified yield stress of the
material. Note, Barlow's formula is generally used for pressure vessels with a wall thickness
that is approximately one-tenth or less of the vessel's radius. Barlow's formula assumes that
the stress resulting from internal pressure is uniformly distributed across the wall thickness.
If the wall thickness is greater than one-tenth the radius. Barlow's formula is conservative.
The following formula is used to calculate the internal yield pressure for the pipe body:
pb = 0.875 . 2 .Yp . t (eq. 3.35)
OD
where:
t = wall thickness. in
OD = external diameter of the tubing, in
The 0.875 factor allows for the API minimum wall thickness tolerance.
The burst design factor is given by:
DFBURST= pb / (Pi -Po) (eq. 3.36)
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 27 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
pb = Minimum Internal Yield Pressure
(Pi - Po) = Differential Burst Pressure
4.8.4 COLLAPSE DESIGN FACTOR
4.8.4.1 COLLAPSE MODE
There are four possible API collapse failure modes:
Yield strength collapse
Plastic collapse
Transition collapse
Elastic collapse
The appropriate collapse mode is determined by comparing the ratio of the tubing's OD/t
with the calculated values of OD/t which indicate the transition between the modes.
Unfortunately, the values of OD/t vary with axial stress, and so have to be calculated at each
point in the tubing where there is a change in loading. The step by step procedure below
based on API Bulletin 5C3 details the process and is repeated at each section of the string
where there is a change in loading.
1. Determine reduced Yield strength Ypr
2. Determine OD/thickness ratio at the transition between collapse mode
3. Compare actual OD/ thickness with the transition ratio (previous step)
4. Determine appropriate collapse pressure
5. Determine collapse design factor
4.8.4.2 COLLAPSE DESIGN FACTOR DETERMINATION
The collapse design factor is given by:
DFCOLLAPSE = pc = CollapsePressureResistance (eq. 3.37)
(po - pi) Differential Collapse Pressure
4.8.5 RADIAL AND TANGENTIAL STRESSES
The inner and outer radial and tangential stresses are calculated from Lames equations for
thick walled cylinders. The radial stress is given by:
r
= pi Ai - po Ao _ (p i - p o) Ai Ao (eq. 3.38)
(Ao - Ai) (Ao - Ai) A
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 28 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
where:
A =area corresponding to either inner or outer radius, in
2
For the inner radius (A = A i ) this reduces to:
r,j
= -P
i
and for the outer radius (A = A
o
):
r,o
= -p
o
The tangential stress is given by:
t
= pi Ai - po Ao _ (p i - p o) Ai Ao (eq. 3.39)
(Ao - Ai) (Ao - Ai) A
For the inner radius this reduces to:
t,j
= pi (Ai + Ao) -2 po Ao (eq. 3.40)
(Ao - Ai)
and for the outer radius:
t,o
= 2pi Ai - po (Ai + Ao)
(Ao - Ai) (eq. 3.41)
4.9 TRIAXAL STRESS DESIGN FACTOR
Axial force and pressure loads generate triaxial stresses in tubing rather than biaxial or
uniaxial stresses as inferred by the API load capacity equations. The three principal
stresses for a cylinder or tube are axial, radial and tangential.
4.9.1 VON MISES EQUIVALENT STRESS INTENSLTY
An accurate and widely accepted criterion for predicting the onset of yielding of ductile,
isotropic materials is the distortion-energy theory. This theory is also called the shear-
energy theory or the Hencky-von Mises theory. The Hencky-von Mises theory is based on
energy concepts. The total elastic energy is divided in two parts: one associate with the
volumetric changes of the material and the other causing shearing distortions. A yield
criterion for combined stress is established by equating the shearing distortion energy at the
yield point in pure tension to that under combined stress. Well documented experiments
have shown that the Henckv-von Mises theory predicts yielding of ductile isotropic materials
with a high degree of accuracy.
The mathematical statement of this theory for a cylinder is given below. The VME stress, is
calculated as follows:
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 29 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
VME
={0.5 (
a
-
t
)
2
+(
t
-
r
)
2
+(
r
-
a
)
2
}^0.5 (eq. 3.42)
The triaxial stress intensity design factor is given by:
DFVME = YP = Minimum Specified Yield Stress (eq. 3.43)
VME VME Stress
In the absence of bending, the peak VME stress always occurs at the pipe inside surface. If
bending due to buckling or instantaneous doglegs occurs, the peak VME stress can occur
on the pipe inside or outside surface. As stated previously, bending generates axial
compressive stresses in one side of the pipe and axial tensile stresses in the other side of
the pipe.
The procedure to calculate the peak VME stress in tubing subjected to bending moments is
as follows:
1) Calculate the radial and tangential stresses on the pipe ID and OD using Lame's
equations
2) Calculate the bending stresses due to helical buckling and hole deviation on the pipe ID
and OD
3) Calculate the maximum axial stresses on the pipe ID and OD
4) Calculate the VME stress at the four locations
The peak VME stress is the maximum of the four calculated above.
Direct comparison of the peak VME stress to the yield stress of the material provides a
single equivalent design factor for all the simultaneous loads imposed on the string.
4.9.2 EFFECT OF DIMENSIONAL TOLERANCES ON VME STRESS
Since tubing is manufactured with dimensional tolerances on the pipe OD and wall thickness
these tolerances should be considered when calculating the VME stress intensity. The API
tolerances for tubing are shown below. The higher VME stresses are calculated for pipe with
minimum allowable wall thickness and maximum allowable OD. Hence, to calculate the
maximum possible VME stress, use the maximum OD, minimum wall thickness and
corresponding radii to calculate the axial, bending and tangential stresses.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 30 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Table 3.3: API dimensional tolerances for tubing
_______________________________________________________________
Tolerance
Outside diameter, OD:
4.0 and smaller +/-0.03
4.5 and larger +1.00%
-0.50%
Wall thickness, t -12.50%
Weight:
Single lengths Car-load lots +6.50%
-3.50%
Car-load lots -1.75%
_______________________________________________________________
A car-load is considered to be a minimum of 40,000 LB (18,144 kg). Inside diameter. ID is
governed by the outside diameter and wall thickness.
4.9.3 TRIAXIAL LOAD CAPACITY DIAGRAM
A method has been developed to represent the triaxial load capacity of the pipe on a two-
dimensional graph. The triaxial load capacity diagram is a representation of the VME triaxial
stress intensity in relation to axial force and either internal or external pressure. Since the
triaxial stress is defined by these three independent variables, a normalization procedure is
used to create a two-dimensional representation. The normalization operation used to
create the diagram shows the planes where external pressure equals O psi as the top half or
burst region of the figure. The plane where internal pressure is O psi corresponds to the
lower half or collapse region of the diagram.
The anticipated service loads along the length of the string can be plotted on the triaxial
load capacity diagrams. For different burst pressure loads, the normalized internal pressure
generating the same triaxial stress with the same axial force as the combined load, but at O
psi external pressure, is calculated and plotted on the diagram.
An analogous procedure is used to obtain a normalized external pressure under differential
collapse pressure loading. Additionally, the specified API load capacity design factors for
pressure (burst and collapse) and axial tension can be graphically represented. A direct
visual comparison can be made between the anticipated service loads and the API load
capacity and VME stress intensity design factors.
An example of a triaxial load capacity diagram is shown as Figure 3.12.
The following parameters are useful in understanding the diagram:
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 31 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
1. The API operating window is the area enclosed by the API pressure and tension capacity
of the pipe, adjusted by suitable design factors. The biaxial effect of tension on collapse
resistance is included.
2. The Von Mises stress curve defines the stress level in the pipe in terms of internal or
external pressure and axial force. The inner dashed curve shows the application of a
design factor to the peak VME stress.
3. A service load line shows the variation in the stress intensity in a tubing string over the
length of the string.
4.10 RECOMMENDED MINIMUM DESIGN FACTOR
The term safety factor is often misused for design factor. A design factor is the rated load
capacity of the member divided by the maximum anticipated load on the member. A safety
factor on the other hand is the failure load of the member divided by the actual load on the
member. Obviously, prudent engineering practices require that the actual safety factor be
larger than the design factor.
The following minimum acceptable design factors are recommended to ensure a safe tubing
string design:
API load capacity burst pressure 1.3
API load capacity collapse pressure 1.1
API load capacity axial tension 1.6
Load capacity axial compression 1.2
VME stress intensity 1.25 (Carbon steel)
VME stress intensity 1.33 (C.R.A.)
The minimum acceptable design factors listed above should be viewed as guidelines rather
than absolute cut-offs. Of course, use of a tubing string design with lower than
recommended design factors should be approved by management. In these instances, the
consequences of running a tubing string with lower than recommended design factors have
to be thoroughly evaluated. Note, the added cost to upgrade a tubing string to a stronger
design is inconsequential as compared to the cost of a workover or catastrophic failure.
As stated previously, design factors for tubular products are based largely on past
experience. Nevertheless, some justification for the minimum recommended design factors
listed above can be offered. Since it is essential that it is possible to recover the tubing from
a well, a relatively high axial tension design factor is justified. A minimum axial tension
design factor of 1.6 based on yield stress should be maintained for all anticipated service
conditions. Use of a minimum axial tension design factor of 1.6 also provides additional
overpull capability in case the tubing becomes stuck and subsequently have to be pulled
from the well. When this happens, it is common practice to apply overpull forces up to the
pipe or connection yield strength, ie an axial tension design factor of 1.0.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 32 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Many operators use a minimum acceptable burst pressure design factor as low as 1.0. Note
that a burst design factor of 1.0 results in an automatic 10% under-design. Even if the pipe
were hydrostatically tested to the API maximum alternate test pressure, at a l.0 burst design
factor the pipe could be subject to an in-service pressure higher than the test pressure.
Prudent engineering practices dictate that the pipe should never be exposed to an in-service
pressure higher than the test pressure.
Since the minimum internal yield pressure is based on 87.5% of normal wall thickness and
the hydrostatic test pressure is equivalent to 80% of nominal pipe, a 1.094 internal pressure
design factor is required to prevent working the pipe to a pressure higher than the test
pressure.
For some sizes, weights and grades where the coupling partially controls performance
properties, the maximum alternative API hydrostatic test pressure is 80% of the internal
pressure resistance rating. Consequently, as a practical minimum, a burst design factor of
1.25 is required. Moreover, 1.30 is preferable and is used by many operators.
A relatively low API load capacity collapse pressure design factor is conventionally used for
two reasons:
1. The probability of the well being completely evacuated is lower than the probability of the
axial tension and differential burst pressure loads that are normally considered.
2. Although collapse failures are unacceptable they generally do not result in an extremely
dangerous situation. A burst failure or rupture can lead to a blow out and lives can be lost
if such a failure occurs.
Since the VME design factor which considers all the significant variables affecting the pipe
is a very accurate indicator of the relative safety of the string design, a relatively low VME
design factor is acceptable.
The primary justification for all of the recommended minimum design factors is experience.
Experience with all types of oil and gas wells has shown that use of the recommended
design factors combined with a realistic analysis method and good engineering practices
result in safe tubing string designs. Furthermore, none of the recommended minimum design
factors can be considered excessive. Consequently, use of these design factors should not
lead to excessively costly or over-designed tubing string designs.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 33 OF 33
REVISION
TEAP-P-1-R-8793 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
4.11 FIGURES AND TABLES LIST
Figure 3.1: Hookes law
Figure 3.2: Buckling effect
Figure 3.3: Areas for piston force calculation
Figure 3.4: Areas for different tubing connection types
Figure 3.5: Internal and External pressure effects
Figure 3.6: Ballooning effect
Figure 3.7: Tubing-packer connections
Figure 3.8: Tubing-packer connections for slack-off and pick-up
Figure 3.9: Packer setting
Figure 3.10: Tubing-packer force
Figure 3.11: Non-linear Tubing-packer force
Figure 3.11bis : Carbon steel stress-strian diagram
Figure 3.12: Triaxial load capacity diagram example
Table 3.1: Required and acceptable safety factors
Table 3.2: Thermal expansion coefficient
Table 3.3: API dimensional tolerances for tubing
ARPO
ENI S.p.A.
Divisione Agip
ORGANIZING
DEPARTMENT
TYPE OF
ACTIVITY'
ISSUING
DEPT.
DOC.
TYPE
REF. N. PAG.
1
OF
23
TEAP P 1 R 8794
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
TITLE
Well Completion & Workover Course Volume 1
CHAPTER 5
- PACKERS -
DISTRIBUTION LIST
TEAP
STAP Archive
LIST of CONTENTS (authors)
Cap. 01 - Well Completion Design - M. Marangoni
Cap. 02 - Material Selection - M. Marangoni
Cap. 03 - Tubing Design - B. Maggioni
Cap. 04 - Tubing Stress Analysis - B. Maggioni
Cap. 05 - Packers - M. Marangoni
Cap. 06 - Surface Wellhead - M. Marangoni
Cap. 07 - Safety Valves and Miscellaneous - M. Marangoni
Cap. 08 - Perforating - M. Marangoni
Cap. 09 - Formation Damage - M. Viti
Cap. 10 - Sand Control - M. Viti
Cap. 11 - Workover - G. Treglia
Date of issue:
3 . 5 3 1
002700006304
002574300004
002531830557
002700008043
AISI 4130
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 21 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 7
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 22 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 8a
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 23 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 8b
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 24 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 8c
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 25 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 8d
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 26 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 9
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 27 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 10
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 28 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 11
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 29 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 12
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 30 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 13
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 31 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 14a
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 32 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 14b
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 33 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 15
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 34 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure. 16
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 35 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 17
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 36 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 18
6
2
3
4
5
18
17
16
15
14
27
12
11
10
ITEM
1
DETAIL C
DETAIL A
DETAIL D
DETAIL B
9
8
7
21
22
23
24
25
27
28
19
20
DETAI L B DETAIL A DETAIL D DETAIL C
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 37 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 19
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 38 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 20
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 39 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 21a
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 40 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
DETAIL B DETAIL D DETAIL A DETAIL C
DETAIL A
DETAIL B
DETAIL C
DETAIL D
21
74
75
18
16
17
15
20
22
23
24
25
28
LIMIT SWI TCHES - type "GO SWITCH"
SEE DRAWING BHW
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 41 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure21b
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 42 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 21c
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 43 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure22a
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 44 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 22b
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 45 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure22c
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 46 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 22d
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 47 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 23a
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 48 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 23b
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 49 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure23c
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 50 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 23d
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 51 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 24a
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 52 OF 52
REVISION
TEAP-P-1-R-8795 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 24b
ARPO
ENI S.p.A.
Divisione Agip
ORGANIZING
DEPARTMENT
TYPE OF
ACTIVITY'
ISSUING
DEPT.
DOC.
TYPE
REF. N. PAG.
1
OF
24
TEAP P 1 R 8796
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
TITLE
Well Completion & Workover Course Volume 1
CHAPTER 7
- SAFETY VALVES & MISCELLANEOUS -
DISTRIBUTION LIST
TEAP
STAP Archive
LIST of CONTENTS (authors)
Cap. 01 - Well Completion Design - M. Marangoni
Cap. 02 - Material Selection - M. Marangoni
Cap. 03 - Tubing Design - B. Maggioni
Cap. 04 - Tubing Stress Analysis - B. Maggioni
Cap. 05 - Packers - M. Marangoni
Cap. 06 - Surface Wellhead - M. Marangoni
Cap. 07 - Safety Valves and Miscellaneous - M. Marangoni
Cap. 08 - Perforating - M. Marangoni
Cap. 09 - Formation Damage - M. Viti
Cap. 10 - Sand Control - M. Viti
Cap. 11 - Workover - G. Treglia
Date of issue:
he
)hg
where
P
c
= capillary pressure
p
w
= water density
p
he
= fluid density
h = height above fracture
g = gravity
The underbalance should be approximately twice the capillary pressure since it has to act at a
distance in the reservoir. This approach addresses the cleanup of the formation damage by drilling/
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 22 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
completion fluids, but it does not consider the cleanup of a perforation through flushing of loose
debris and removal of the crushed zone around the perforations.
A series of recently conducted experiments and calculations done by Service Companies gives new
insight into the phenomenon of perforation cleanup. The cleanup after underbalanced perforating
occurs in two stages: first through high transient fluid pressure gradients and, second, by steady-
state pressure gradients across the zone of reduced permeability. The former lasts only a short
period of time and involves limited flow volumes, while the latter occurs over an extended period of
flow.
The concept of transient cleanup may be viewed as requiring a minimum Reynolds number that
results in sufficient drag force to remove the permeability-reducing fines from the formation pores.
For sufficiently high underbalance (800 to 1000 psi), the initial surge is enough to effectively clean
the damage, and little, if any, cleanup occurs during post-shot flow. At lower values of underbalance
(200 to 600 psi) for 200 md-sandstone, the postshot flow does remove some damage, yet a
significant amount of damage remains in place and cannot be cleaned even at subsequent high
differential pressures.
From the standpoint of productivity, the goal is to achieve the highest value of underbalance.
However, for a number of reasons, the drawdown imposed on the formation should be limited. The
drawdown should not cause mechanical failure of the formation.
Excessive drawdown may lead to mechanical deformation of the casing and may cause permeability
damage in the near wellbore region because of movement of fines. Initial spurt rates under high
drawdown may be so high as to reach critical velocity through the completion; that is, the drawdown
is limited by the area open to flow. Imposing higher values of drawdown than those needed to reach
critical flow accomplishes little beyond endangering the completion mechanically.
The critical flow rate can be calculated easily if the smallest area open to flow is known. The formula
is given by,
Q
liquid
= P
R
A / (471 . R
0.5
)
where:
Q = critical flow rate (B/D),
R = gas/liquid ratio (mcf/bbl),
P
R
= reservoir pressure (psig), and
A = area open to flow (in
2
)
The initial spurt rate can be calculated with a constant drawdown approach using an apposite graph.
Service Companies have a number of tools to aid in the prediction, modelling and evaluation of
completions and well tests. They usually calculate perforation performance and analyse productivity
results taking in account log data, production logging and well test data. Information are available
from Service Companies engineering departments.
8.4 8.4
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 23 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Perforating techniques
Two basic perforating techniques are available to the completion design engineer.
- Through-tubing perforating-the guns are lowered into the well through the production string.
These guns may be conveyed with wireline or coiled tubing.
- Casing gun or high shot density perforating-large diameter guns are lowered into a cased well
before the production string is run. The guns may be conveyed with wireline or the tubing string.
8.4.1 THROUGH-TUBING PERFORATING
-The wellhead and completion string are in place and tested before the casing is perforated.
-The underbalance differential from the reservoir into the wellbore provides perforation cleanup.
-Perforations may be made as required over the life of the well, with or without a rig on site.
-Operating times are low, providing good job efficiency and use of rig time. Maximum perforated
interval per run is limited by the surface set-up lubricator and is typically 30 feet.
8.4.2 CASING AND HIGH SHOT DENSITY GUN PERFORATING
-Gun size is limited only by the casing inside diameter allowing the highest performance deep
penetrating or big hole charges to be used at optimal shot density and perforating pattern.
-When guns are conveyed on wireline, the overbalanced differential from the wellbore into the
formation allows the use of longer guns than with through-tubing perforating. Typically 60 feet [
18 m] can be readily achieved. Only simple wellhead control equipment is needed.
-Compared to expendable through-tubing guns, carrier-type guns significantly reduce the
amount of perforating debris introduced into the wellbore during the perforating process.
8.4.3 WIRELINE- AND TUBING-CONVEYED PERFORATING
Perforating guns are conveyed into the well on either electric line (wireline) or tubing (production
tubing or drillpipe). The choice between wireline and tubing-conveyed perforating should be made
based on the completion objectives and operational considerations. From the operational viewpoint,
wireline perforating operations are usually faster when there are a few short intervals to perforate.
TCP operations are more efficient for long, multiple zone perforation intervals. Because of the
higher operating speeds of wireline perforating, explosives are exposed to high downhole
temperatures for a shorter time than with TCP. This is an important consideration in high-
temperature wells. Tubing-conveyed perforating has a number of benefits:
-TCP combines the advantages of the through-tubing gun systems with those of casing gun and
HSD systems.
-Large guns may be fired in an underbalanced condition with the full well-control equipment and
production string in place.
-Long intervals may be efficiently perforated in one run with a kill string in place if required.
-The programmed underbalance is applied to all intervals perforated, evenly and in a controlled
fashion.
-A variety of firing systems and accessories accommodates a wide range of well conditions and
completion techniques.
-After firing, expended guns may be dropped to the bottom of the well allowing future through-
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 24 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
tubing operations
8.5 Safety and operating environment
8.5.1 SAFETY
Safe operating practices are critical to the long-term success of any activity, especially when the
results may be as devastating as the surface detonation of a perforating gun. Service Companies
safety commitment should include strict operating rules, properly designed and built equipment and
well-trained, highly qualified personnel. While this commitment extends to all activities, only the
aspects dealing with the transportation and use of explosives at the wellsite are considered in the
following sections.
8.5.2 TRANSPORTATION
The transportation of explosives to and from the wellsite is an integral part of the design and use of
a perforating system. In most cases, loaded guns may be transported to the wellsite, but they must
never be transported armed (with a detonator attached). All guns should have a positive pressure
release in the event of fire. Failure to provide this release could result in an explosion of the
perforating gun because of pressure build-up in the gun as it heats.
Detonators and detonating cord remnants are always transported separately in approved containers
with key-controlled security locks.
8.5.3 WELLSITE
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 25 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 7.8 shows Schlumberger example of their Explosive Safety Handling Procedure.
EXPLOSIVES
Field Safety Procedures Schlumberger
1. Hold consultation with client if
possible.
2. Check well area for hazards and
correct when necessary
3. Hold spot safety meeting.
4. No smoking except in designated
areas. Smoking materials must be
stored when
leaving these areas.
5. Rig up cable. Remove rig wiring
that might contact cable.
6. Outside preparations before
attaching an explosive device:
a. Check voltage between the rig,
casing and cable armour. Eliminate
at source if present.
b. Install safety grounding traps and
connect to unit.
c. Install Casing-to-Rig Voltage
monitor.
d. DO NOT PROCEED WITH
OPERATIONS IF RESIDUAL
VOLTAGE IS IN EXCESS OF 0.25V.
e. Put out sign reading "Danger-
Explosives - Turn Off - 2-Way Radios
- Radio Phones."
f. Turn off all radio transmitters within
1000 ft of the well. Radios must be
disabled such that an incoming call
does not activate the transmitter.
g. If the well is within 2
1/2
miles of a
large transmitter (radio or TV
station), or if all wellsite transmitters
cannot be turned off, contact your
Division Engineer or Division
Technical Manager.
h. On water operations, install the
positive grounding cable from truck
to barge or OSU to generator skid.
7. Instrument cab preparations for
explosive operations:
a. Disconnect the survey AK piug.
b. Turn off all USP and PSP switches and
power down CSU.
c. Turn off main circuit breakers.
d. Turn off AC generators. (On units with
generator driven by main engine, pull
"Main Disconnecf' switch on the Power
Distribution Panel to "OFF." Also turn off
exciter field switch.)
e. Turn off safety switch and remove key.
8. Procedure for attaching any explosive
device (such as CST, FIT, FT, BST,
perforating Guns, etc.) to the cable.
Refer to step 9 for arming procedures.
a. Verify that Casing-to-Rig Voltage
monitor is reading less than 0.25V.
b. Clear line of fire of all personnel.
c. Attach explosive device to the head or
collar locator. The individual performing
this operation must have the safety switch
key in his possession at this time and
retain it until the tool is 100 ft below
ground level.
9. Arming perforating guns (ONLY THE
ENGINEER MAY ARM A GUN):
a. If a thunderstorm threatens to arrive on
location within 30 minutes, do not arm the
gun.
b. The cable must be attached to the gun
string before the bottom gun is armed.
Guns that are not electrically connected
to the cable when the head is attached
(multicarrier selective switching systems)
may be armed immediately prior to their
use and then attached to the cable.
c. Confirm that line of fire is still clear.
d. Check gun wires for sparking.
e. Trim gun wires and trim the
Primacord.
f. Insert biasting cap in Blasting Cap
Safety Tube.
g. Connect biasting cap wires to gun
lead wires.
h. Remove biasting cap from Safety
Tube and crimp to Primacord, using
Blasting Cap Crimping Pliers, or insert
biasting cap in booster holder.
i. Prepare gun for watertight seal.
10. Proceed into well.
11. Operational procedure in hole:
a. At or below 100 R below ground
level, turn on safety switch, restore AC
power, etc. Proceed in hole.
b. Tie in, position gun, and shoot.
c. Come out of hole. At or below 100 ft
below ground level, prepare the
instrument cab as for explosives
operations (7a-e and 9a).
12. All guns must be safely relieved of
any trapped pressure immediately
upon removal from well according to
instructions in Perforating Manual.
13. If the gun(s) did not fire,
immediately disarm the lowermost
gun (using the procedure prescribed in
the Perforating Manual) before the
gun is disconnected from the cable.
14. After the job, check to see that all
equipment brought to the well is
loaded on the truck.
15. Police the area for Primacord
remnants, charges, trash, etc.
Figure 7.8
8.5.4 STRAY VOLTAGE SAFETY
Electrical detonators used in perforating operations are susceptible to detonation caused by induced
currents from stray voltage sources. Stray voltage may originate from many sources such as faulty
electrical power distribution on the rig, electrical welding, cathodic protection and nearby radio
frequency (RF) transmission.
Stray voltage induced by faulty rig wiring is the easiest to locate and remedy; the other sources are
often much more difficult to diagnose and eliminate.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 26 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Voltages induced in electrical detonation circuits by RF emissions are the most difficult to detect.
This hazard is best eliminated by disabling the transmitter during the surface portions of the
operation. When vital navigation or communication links make this impossible, a survey of the
transmitter fields is necessary to determine the conditions under which the perforating operation
may be attempted.
As an alternative, Schlumberger offers a perforating system, S.A.F.E.* Slapper-Actuated Firing
Equipment, for protection against both RF-induced stray voltages and those voltages induced by
cathodic protection and welding. The S.A.F.E. system uses Exploding Foil Initiator (EFI) technology,
which has proven resistant to stray voltage because of the high currents required for detonation.
The following procedures are recommended for perforating with electrical, heat-type detonators:
- Always use detonators with safety resistors.
- Consider each perforating site independently.
- Eliminate all sources of stray voltage to provide
maximum safety.
Safety procedures are described in more detail in the Wireline and TCP Operating Procedures
sections.
Equipment is also available to operate at temperatures and pressures beyond these levels. The
choice of equipment depends on the situation in a particular completion . To provide appropriate
equipment for hostile operations, advanced planning is recommended. In this section, the effects of
temperature, pressure and fluid properties are briefly presented, along with information about the
use of perforating guns in deviated wells.
8.5.5 HIGH TEMPERATURE AND PRESSURE
High temperature and pressure are factors in the choice of explosive type, carrier design and the
wellsite operation itself. Wellsite operations are affected because the temperature rating for
explosives is time dependent.
The Schlumberger time and temperature ratings are established so that there is no degradation in
perforator performance (penetration and entrance hole) up to the maximum rating, but for safety
reasons, the one-hour or one-hundred hour ratings should never be exceeded. The chart in Fig. 7.9
shows the time-temperature ratings for the explosives used in Schlumberger-manufactured
perforating guns. Refer to the Gun Systems chapter for ratings of individual guns.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 27 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
10 100
1000
1
200
300
400
500
600
700
200
HNS
HMX
RDX
Exposure time (hr)
T
e
m
p
e
r
a
t
u
r
e
(
F
)
Figure 7.9
Explosive type 1-hour Rating 100-hour Rating
RDX 330F [166C] 200F [ 93C]
HMX 400F [204C] 300F [149C]
HNS 500F [260C] 460F [238C]
Exceeding the time-temperature ratings may have serious results. Shaped charges and detonating
cord in a sealed carrier or capsule may autodetonate low-order when exposed to temperatures
above their ratings. This will result in a bomb-like effect with severe deformation or destruction of the
carrier (or capsule) and possible well damage and sticking of the gun. Autodetonation of the
detonator, on the other hand, will result in high-order initiation of the ballistic chain (detonating cord
and charges) resulting in perforation of the well.
Hydrostatic pressure and the type of fluid that surround the perforating gun are also important
considerations. Exceeding a carrier's pressure rating may result in flooding the guns or crushing the
carrier. This, in turn, may cause a low-order detonation and a bomb-like effect possibly damaging
the well and sticking the gun. Also, minimum pressure ratings should be observed to prevent
excessive swell and/or splitting of the carrier, resulting in possible sticking of the gun in casing,
tubing or small restrictions. The ability of a carrier to withstand the forces that occur during
perforating is related to whether its fluid environment is liquid or gas.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 28 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
The ratings given for Schlumberger's guns in the Gun Systems section include both minimum and
maximum pressures. In most cases they include the capability for the carrier to survive shots in air
with no hydrostatic pressure. Also, the gun dimensions shown take into account worst-case effects;
i.e., shooting at minimum pressure in air or liquid, de
pending on the rating of the gun.
In the case of exposed guns with pressure-sealed detonators, overpressuring may cause a high-
order initiation of the ballistic chain. Guns equipped with these detonators should not be subjected
to high pressures on the surface, such as during wellhead equipment pressure tests.
High temperatures and pressures also affect the elastomers of the pressure seals. In high
temperature/ high pressure operations, the seals should be changed between runs into the well to
avoid failures. To meet the requirements for high temperature/pressure operations, Schlumberger
offers perforation equipment certified according to the procedures of the joint industry Program to
Evaluate Gun Systems (PEGS) to operate up to 25,000 psi [ 1700 bar] and at one-hour ratings of up
to 500F [260C]. This equipment has been built according to quality-control specifications that
ensure operations up to the rated conditions.
8.5.6 FLUID CHEMICAL PROPERTIES
Fluid chemical properties, such as concentrations of hydrogen sulphide [H2S] and acid, that will
exist in the well during and immediately after perforating need to be considered in planning
completion operations. In sufficient concentrations, hydrogen sulphide and acids will attack
perforating guns, causing general corrosion and possibly hydrogen embrittlement that may lead to
material failure. Factors affecting the degree to which hydrogen attack occurs include the
aggressiveness of the environment, type of material, amount of stress the material is under, length
of time it is exposed, and the pressure. Operations in the presence of H2S or acid require special
precautions for perforating guns and their associated hardware. Perforating guns themselves are
not hydrogen sulphide-proof as per the National Association of Corrosion Engineers, but the
associated equipment (accessories, TCP firing heads, wireline cable) may be made so either
routinely or by special arrangements. Perforating guns are more or less resistant to the effects of
hydrogen attack depending on the factors discussed above. The following points should also be
considered:
- If inhibitors are used, care must be taken to use those that do not affect elastomers in the
pressure seals.
- Hollow-carrier perforating guns are generally preferred to exposed guns for operations in
environments with high H2S concentrations (more than 2%) and when acids are used at high
bottomhole temperatures (above 280F [138C]).
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 29 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
8.5.7 MUD WEIGHT
In addition to the effects of hydrostatic pressure on the perforating guns, mud weight may affect the
operation of TCP firing systems. High-density muds tend to segregate with time, and this affects
both pressure-actuated firing systems and drop-bar and electrical firing systems. However,
pressure-actuated firing heads are preferred to other firing systems when higher-density muds are
used because the mud's ability to transmit pressure levels is generally less impaired than the ability
of a drop bar to reach the firing head in this condition. To ensure that mud solids do not affect the
operation of a firing head, a fluid isolation sub should be used.
8.5.8 WELL DEVIATION
Wells that are deviated beyond 45 may be a problem for wireline-conveyed perforating guns
because of increased frictional forces on the cable, reduced gravitational force along the wellbore,
and smaller clearance between the maximum rigid length of the gun and the casing ID at doglegs.
The recommended maximum rigid tool length for various clearances and dogleg angles is shown in
Table 7.3.
Maximum rigid tool length versus clearance
Dogleg severity (degree//100 ft)
(D-d) 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
0.25 21.9 15.5 12.6 10.9 9.8 8.9 8.3 7.7 7.3 6.9 6.6 6.3 6.1 5.8 5.6
0.5 30.9 21.9 17.8 15.5 13.8 12.6 11.7 10.9 10.3 9.8 9.3 8.9 8.6 8.3 8.0
0.75 37.8 26.8 21.9 18.9 16.9 15.5 14.3 13.4 12.6 12.0 11.4 10.9 10.5 10.1 9.8
1 43.7 30.9 25.2 21.9 19.5 17.8 16.5 15.5 14.6 13.8 13.2 12.6 12.1 11.7 11..3
1.25 48.9 34.5 28.2 24.4 21.9 19.9 18.5 17.3 16.3 15.5 14.7 14.1 13.6 13.1 12.6
1.5 53.5 37.8 30.9 26.8 23.9 21.9 20.2 18.9 17.8 16.9 16.1 15.5 14.8 14.3 13.8
1.75 57.8 40.9 33.4 28.9 25.9 23.6 21.9 20.4 19.3 18.3 17.4 16.7 16.0 15.5 14.9
2 61.8 43.7 35.7 30.9 27.6 25.2 23.4 21.9 20.6 19.5 18.6 17.8 17.1 16.5 16.0
2.25 65.6 46.4 37.8 32.8 29.3 26.8 24.8 23.2 21.9 20.7 19.8 18.9 18.2 17.5 16.9
2.5 69.1 48.9 39.9 34.5 30.9 28.2 26.1 24.4 23.0 21.9 20.8 19.9 19.2 18.5 17.8
2.75 72.5 51.2 41.8 36.2 32.4 29.6 27.4 25.6 24.2 22.9 21.9 20.9 20.1 19.4 18.7
3 75.7 53.5 43.7 37.8 33.9 30.9 28.6 26.8 25.2 23.9 22.8 21.9 21.0 20.2 19.5
3.25 78.8 55.7 45.5 39.4 35.2 32.2 29.8 27.9 26.3 24.9 23.8 22.7 21.9 21.1 20..3
3.5 81.8 57.8 47.2 40.9 36.6 33.4 30.9 28.9 27.3 25.9 24.7 23.6 22.7 21.9 21.1
3.75 84.6 59.8 48.9 42.3 37.8 34.5 32.0 29.9 28.2 26.8 25.5 24.4 23.5 22.6 21.9
4 87.4 61.8 50.5 43.7 39.1 35.7 33.0 30.9 29.1 27.6 26.4 25.2 24.2 23.4 22.6
4.25 90.1 63.7 52.0 45.0 40.3 36.8 34.1 31.9 30.0 28.5 27.2 26.0 25.0 24.1 23.3
4.5 92.7 65.6 53.5 46.4 41.5 37.8 35.0 32.8 30.9 29.3 28 26.8 25.7 24.8 23.9
4.75 95.2 67.3 55.0 47.6 42.6 38.9 36.0 33.7 31.7 30.1 28.7 27.5 26.4 25.5 24.6
D= Hole ID (in.)
d= Gun OD (in.) Table 7.3
Between 45 and 65 deviation, wireline perforating operations can often be successfully completed
with the aid of weights. The Table 7.4 lists the common available weights for wireline perforating.
Beyond 65, tubing-conveyed perforating (either on drillpipe/production tubing or on coiled tubing) is
the preferred technique. Roller adapters and orienting equipment are available for TCP operations
in highly deviated or horizontal wells.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 30 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
OD (in.) Type Service Length
(in.)
Weight
(lb)
Pressure Rating
(psi)
Temperature
Rating (F)
3
3/8
Steel Standard 60 150 20,000 450
1
11/16
Steel Standard 48.4 30.4 20,000 450
2 Steel Standard 48.4 42.7 20,000 450
1
3/8
Steel Standard 45.8 19 20,000 450
1
11/16
Tung. Standard 72 74 20,000 450
2
1/8
Tung. Standard 72 104 25,000 450
1
3/8
Tung. H2S 72 48.5 20,000 450
1
11/16
Hi-dens H2S 72 61 25,000 500
2
1/8
Hi-dens H2S 72 105 25,000 500
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 31 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
8.6 WIRELINE THROUGH-TUBING GUNS
Through-tubing guns are used primary for under-balance initial or subsequent conditions that have
the tubing and bottomhole assembly already in place. Optimal underbalance can be applied to
achieve clean, productive perforations while maintaining absolute well control.
This kind of guns are designed specifically for use on an electric wireline cable.
They include retrievable hollow carrier guns (Domed Scallop and Scallop guns) and exposed
guns(Enerjet e HyperCap).
A variety of charges is available for through-tubing guns, depending on the application.
The hollow carrier and strip gun system offer selectivity to shoot more than one zone per run.
Because load through-tubing guns contain only secondary high explosives, they are safe to
transport and handle when all the procedures are observed. In Figure 7.10 is represented the shots
geometry.
Damaged zone
diameter
Open hole
diameter
Crushed zone diameter
Perforation length
Phase angle
P
e
r
f
o
r
a
t
i
o
n
s
p
a
c
i
n
g
(
d
e
p
e
n
d
i
n
g
o
n
s
h
o
t
d
e
n
s
i
t
y
)
Figure 7.10
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 32 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
8.6.1 GUN SELECTION
Selecting the most appropriate gun depends on several factors, including:
- internal diameter of nipples and valves in downhole assembly
- bottomhole temperature and pressure
- perforator performance and value
- sensitivity to perforating debris
- borehole fluid
- required shot phasing and density
- deviation and doglegs
The minimum restriction in the downhole assembly is usually the primary limiting factor. In general,
one should use the largest gun that can be accommodated by restrictions in the well. Penetration
depth and entrance hole size usually increase with gun size since bigger charges are possible.
They also increase using arm exposed gun rather then a hallow carrier gun.
The hallow carrier guns, in confront of the exposed guns, are fully retrievable and are capable of
withstanding high pressure and temperature. This guns can be run at very high speeds.
Phasing and shot density are parameters that affect productivity. Increasing this parameters will
increase productivity, according with various studies and field practice.
The correct choice of this parameters has to be done consulting the guns constructors handbook.
Figure 7.11 shows the flowing pressure distribution around wellbore in two cases of different
phasing (0 and 180).
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 33 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Perforation
Wellbore
204
181
158
135
112
Perforation
Wellbore
204
181
158
135
112
Figure 7.11
Doglegs in the well should be considered when planning for the maximum length (and diameter) of
gun to be run.
For deviations beyond 60 to 70, electrical coiled tubing should be used to convey wireline through
tubings-guns.
The following gun size selection chart shows the guns available for selection parameters of tubing
size, temperature and pressure.
Through Tubing Guns Selection
Casing/Tubing (in.) Gun Type Max. Temperature (F) Max. Pressure (psi)
2
3/8
1
3/8
in. Domed Scallop 500 25,000
2
3/8
1
11/16
in. Pivot Gun 330 12,000
2
3/8
1
11/16
in. Enerjet 365 20,000
2
3/8
1
11/16
in. HyperCap 300 10,000
2
3/8
1
11/16
in. Domed Scallop 500 25,000
2
7/8
2
1/8
in. HyperCap 250 5,000
2
7/8
2
1/8
in. Enerjet 415 20,000
2
7/8
2
1/8
in. Domed Scallop 500 25,000
2
7/8
,3
1/2
2
1/8
in. 60, 80 Scallop 500 25,000
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 34 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
8.6.2 SPECIAL PRECAUTIONS
This kind of guns are often run with wellhead pressure control equipment. The lubricator should
never be pressure tested with an armed perforating gun inside. A pressure leak in the gun or
detonator could result in gun detonation. The use of a Wireline Safety Valve is recommended to
avoid this hazard.
8.7 Wireline Casing Guns
Casing guns are used to perforate wells before the completion string has been run (or, in some
cases, after it has been pulled) and are usually shot in overbalanced conditions to maintain well
control. This kind of guns are designed specifically for use on an electric wireline cable.
8.7.1 GUNS SELECTION
Selecting the most appropriate gun depends on several factors, including:
- casing internal diameter
- bottomhole temperature and pressure
- perforator performance and value
- deep penetration or big hole application
- required shot phasing and density
The casing internal diameter must be considered so that the best perforator performance compatible
with casing size can be achieved. Penetration depth and entrance hole size usually increase with
gun size since bigger charges are possible. In general, one should use the largest gun that can be
accommodated by the casing.
The following table shows the recommended casing guns for different casing size.
Casing Guns Selection
Casing/Tubing (in.) Gun Type Max. Temperature (F) Max. Pressure (psi)
41/2 31/8 in. HEG 210 4,000
41/2 33/8 in. PPG 400 25,000
5 33/8 in. PPG 400 25,000
51/2 4 in. PPG 400 25,000
51/2 4 in. PPG 210 4,000
7 5 in. PPG 330 25,000
The type of completion will dictate the choice of perforator charge type, either deep penetration or
big hole charges. Deep penetrating charges are the usual choice for natural and stimulated
completion. DP charges that penetrate beyond the damaged zone next to the borehole give the best
well productivity. Big hole charges are normally used in gravel-packed completions.
Phasing and shot density are parameters that affect productivity. Increasing this parameters will
increase productivity, according with various studies and field practice.
The correct choice of this parameters has to be done consulting the guns constructors handbook.
8.8 Operative Perforating Techniques
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 35 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
8.8.1 WIRELINE PERFORATING TECHNIQUES
The basic wireline perforating string is made up of a cable head, a correlation device, a positioning
device for through-tubing application and one or more guns.
The cable head serves three functions: to connect the gun string to the electric wireline, to provide a
controlled weak point to free the cable if the guns become stuck and to provide a fishing profile.
Before perforating operations begin, a copy of the reference log on which the perforation intervals
were selected should be obtained and the perforation intervals recorded on the perforation
worksheet. The reference log may be an openhole or cased hole evaluation or perforating depth
control log.
A correlation nuclear/casing collar log should be run across the perforation interval to be perforated
and should be on depth with the reference log (Fig. 7.12). If there is a depth difference between the
reference log and the correlation log, the correlation log must to be corrected to the reference log
depths.
The correlation device is normally a casing collar locator (CCL) or a gun gamma ray (GR) with a
CCL (GR/CCL).
In order to help the correlation work, is recommended to use a pup joint, which is easily
recognisable by the CCL, somewhere near (above) the perforation interval.
C
GR GR
Reference log Correlation log
C
o
r
r
e
l
a
t
i
o
n
l
o
g
i
s
t
o
o
d
e
e
p
CCL
CCL
Nuclear
misure point
Figure 7.12
On through tubing gun system, a positioning device is used to orient the shots toward the casing
and minimise the gun-to-casing clearance. Two types of positioning devices are spring and
magnetic positioning devices.
The gun is composed of a head to provide electrical and mechanical connection to the CCL or
positioning device, the gun body and lower head or bottom nose.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 36 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
In hollow carriers, the lower head provides pressure confinement and access to the detonating cord
and electrical connections.
If the guns are to be shot selectively, a selective switch adapter is also used.
8.8.2 TCP (TUBING-CONVEYED PERFORATING) TECHNIQUES
8.8.2.1 PREJOB PLANNING
Completion objectives must be considered carefully when planning the perforating operation.
Non-standard or unusual conditions, such a high bottomhole temperatures and pressures, long
exposure times, high well deviations, small restrictions or an H
2
S environment may call for special
equipment and techniques.
The reservoir and the type of completion form a unique set of conditions that determine the
selection of various options:
-the casing size and formation characteristics usually dictate the gun size and charge type
-computer-generated simulations like help in selecting the best gun/charge option
-selection of a suitable explosive package is based on the anticipated maximum exposure time of
the gun string at or near bottomhole temperature
-the requirements for well testing operations will affect the choice of TCP firing heads and
accessories, and the size of perforating guns in some cases
-formation characteristics together with safety and economic considerations determine the
amount of underbalance and how it is established
-the amount of underbalance, completion type and installation influence the selection of a firing
system and accessories
-accurate knowledge of the ID of all string restrictions is essential to choose the firing system
and to plan for possible fishing tool, positioning tool or cutter runs.
A detailed completion sketch including ID, OD, depth or length of all components and the exact
location of the restrictions together with an intended job prognosis are used as a basis for review
and discussion by all concerned parties.
A typical TCP job prognosis includes:
-rig floor assembly procedures for guns and firing systems
-running-in procedure
-depth control and packer setting
-pressure testing sequence for tubulars
-establishing underbalance
-firing procedure
-flow and cleanup periods
-testing sequence
-reversing and pulling out (temporary completion)
-realising the guns (permanent completion)
-contingency plans (misfire, fishing)
Proper job planning requires that basic but important decisions be made in advance of the actual
job:
-insertion of radioactive pip tags in the casing (if necessary)
-additional drilling to provide enough rathole (if guns are to be dropped)
-equipment to handle the guns and any optional equipment:(pup-joint, crossover, fishing tools,
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 37 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
elevators, etc.)
8.8.2.2 TESTING REQUIREMENTS
Many TCP operations are conducted in conjunction with a well test utilising a downhole test valve for
flow control. Combining perforating and testing operations provides a powerful means to evaluate
the effectiveness of the completion itself as well as to gain valuable information about the reservoir.
Impulse testing provides an evaluation of production potential and near-wellbore skin that allows for
the planning of stimulation operations.
Drillstem testing brings information about reservoir-wide parameters, including pressure,
permeability, fluid properties, and the detection of reservoir features, such as faults and boundaries.
Testing plants are an important consideration when planning TCP operations. The key factors
include:
-number, type and duration of tests to be run
-packer type, operation, specifications, setting method
-test tool operating pressures
-string dimensions
-tbg/csg/pckr tests
-stimulation plans.
8.8.2.3 DOWNHOLE OPEN STRING SYSTEM
The downhole open string system (Fig. 7.13) is one of the simplest and most commonly used
systems for temporary and permanent completions. It is suitable for moderately deviated oil wells in
which the reservoir is not depleted and the desired underbalance is 500 to 1000 psi.
The underbalance is achieved in several ways:
-the tbg may be displaced with as lighter fluid, such as brine or diesel, or with nitrogen before
the packer is set (if there isnt a by-pass valve above the packer)
-the tbg may be swabbed out after the packer is set
-the tbg fluid may be lifted with nitrogen or gas through coiled tbg or gas-lift valves.
The first one is the most often used technique. The use of nitrogen or coiled tbg is frequently
excluded because of cost or availability.
When a firing system is either a drop bar, a trigger charge or a wet connector firing system, a debris
circulating sub is recommended. The sub is positioned 30 ft above the firing head, and the volume
between the debris sub and the firing head is filled with a clean fluid.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 38 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 7.13
8.8.2.4 DOWNHOLE CLOSED STRING SYSTEM
The Downhole Open String System is used on temporary, permanent and workover completions in
oil and gas wells with moderate deviation. It is especially well adapted to situation requiring a large
underbalance or with existing perforations below the packer.
The underbalance is achieved by filling the tubing to the required cushion height as it is run in the
hole. The production valve below the packer remains closed until the packer is set. The valve is
opened by the passage of a drop bar, the trigger charge firing head or the wet connector tool.
Large underbalances are achievable with a closed system because the tbg may be run dry.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 39 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
In the case of the drop bar and trigger charge firing heads, a minimum hydrostatic cushion pressure
of 300 psi with clean fluid is required. Also, the downhole temperature at the top of the cushion
should be lower of the boiling point of the cushion fluid used.
High underbalance can also be achieved using a surge-disc sub. The surge disc shatters as the
drop bar or slickline tool passes through it. Precautions are needed to avoid excessive debris
accumulation on top of the surge disc sub that would make it impossible to break the disc.
A drop bar is commonly used in reperforating applications. The production valve, which is fast-
acting, one-shot sliding sleeve, is opened by rathole pressure as the bar passes through it This
creates an instantaneous underbalaced condition below the packer just before the guns fire,
allowing simultaneous backsurging of all perforations.
A wet connector firing system may also be used to activate downhole accessories. This firing
system may be run in conjunction with a Measurement While Perforating Tool (MWPT) to monitor
the TCP operation and to estimate the reservoir characteristics.
A gun release sub may be run with the string either as a safety joint (if the guns become stuck) or to
drop off the guns after perforating. The gun release sub is usually positioned one joint above the
production valve to keep the release sub clean or allow hydraulic actuation.
After the guns are dropped, at least 60 ft of open casing should be left above the top shot on
permanent completions to allow safe production logging.
8.8.2.5 TESTING/TCP SYSTEM (FIG. 7.14)
The annulus pressure firing system is ideally suited for Impulse and drillstem tests in which guns are
run below a downhole test valve. The system operate at any deviation, is practical immune to debris,
and does not require a fullbore string. The firing system is usually A Differential Pressure Firing
(DPF) system.
With the DPF, differential pressure between the annulus above the packer and rathole actuates the
firing head. Therefore, guns cannot be fired before the packer is set. Annulus pressure from above
the packer is ported to the firing head through the packer and slotted pipe via a packer conversion
kit.
As annulus pump pressure is increased at surface, the downhole test valve opens. At this time a
pressure difference will be created across the packer with the cushion pressure below it and the
annulus plus pump pressure above it. The firing head is set to fire at this pressure. Opening the test
valve while simultaneously firing the guns is a possible option for applications in which open
perforation exist in the well.
Annulus pressure-operated reversing valves are set to operate at pressures well above those
required to fire the guns to avoid the possibility of prematurely aborting the test.
Underbalance may be established as a closed system with the downhole test valve.
Alternatively, underbalance may be established as an open system, by circulating light fluid through
the packer bypass or by displacing the tubing fluid with nitrogen.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 40 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Figure 7.14
A gun release may be combined with the Fullbore Packer Conversion kit and may be operated
eithermechanically or hydraulically. Alternatively, an automatic gun release may be used.
8.8.2.6 FIRING HEADS
Many TCP firing heads are available to fit a variety of completion needs.
The main difference between firing heads is the method of actuation.
The Differential Pressure Firing head (Fig. 7.15) is actuated by the differential pressure between the
annulus above the packer and the rathole pressure below.
The DPF includes these features:
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 41 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
-a safety spring disables the firing pin when the hydrostatic pressure is below 600 psi (250 psi
optional), making the gun string safe on and near the surface
-the packer must be sealed and the test valve must be open before the guns can be fired
-the system is specifically designed to be combined with test tools
-pressure equalisation prevents firing flooded guns.
The Hydraulic Delay Firing head (Fig. 7.16) is an absolute firing head. It is actuated by tubing
pressure shearing calibrated pins when a preset pressure level is reached, initiating a time delay
period during which underbalance pressure is established before the guns are fired. Once the delay
has expired, pressure at the firing head drives the firing pin into the detonator.
The HDF includes these features:
-a minimum of 150 - to 300- psi hydrostatic pressure is required to activate the firing pin, making
the gun string safe on and near the surface
-the adjustable firing delay makes the head suitable for operations with nitrogen
-precision shear pins ensure accuracy in the firing pressure
-pressure equalisation prevents firing flooded guns.
The Bar Hydrostatic Firing (BHF) head (Fig. 7.17) is a drop bar actuated device. Once it is actuated,
hydrostatic pressure drives the driving pin into the detonator.
The BHF includes these features:
-a minimum of 150 - to 300- psi hydrostatic pressure is required to activate the firing pin, making
the gun string safe on and near the surface
-the device has both uncomplicated design and operation
-pressure equalisation prevents firing flooded guns.
The Wet Connector Firing (WCF) head is actuated by electric current passed from the surface via
wireline through a wet connector to a resistirised electric detonator.
The WCF includes these features:
-gun firing is under total control of the engineer at the surface
-before perforating takes place, the wireline is mechanically latched to the firing head to
prevent cable movement after firing
-it may be combined with a Measurements While Perforating Tool with GR, CCL, pressure and
temperature measurements to provide same-trip correlation, real-time pressure data and
perforating.
The Trigger Charge Firing system (Fig. 7.18) adapts either the absolute pressure, drop bar or
jardown firing mechanism to a transfer assembly that is run into the well on slickline (or electric line)
after the tubing string and guns have been run, tested and positioned. The absolute pressure and
drop-bar versions have the same mechanism used in the HDF and BHF, respectively.
The TCF includes these features:
-heads containing primary explosives are run into the well latched and retrieved independently
of the gun string
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 42 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
-the firing head is disconnected before gun retrieval
-the choice of firing head may be made after guns have been run
-drop bar, jar-down and HDF versions require a minimum of 150 - to 300 - psi hydrostatic
pressure to be activated.
Redundant firing system are available that allow the primary firing heads to be combined with one
another as required. Both firing heads are located at the top of the gun string allowing the guns and
heads to be made up safely, and both heads retain their full safety features.
8.8.2.7 FIRING HEAD ASSEMBLY
Each firing head assembly includes, from top to bottom:
-any equipment attached to the firing head
-the firing head including the detonator (or two firing heads if side-by-side redundant heads are
used)
-a fill sub, which provides the tensile support for the string and allows space for debris
accumulation below the head
-a firing head adapter to mechanically and balistically connect the firing head to the safety
spacer and guns below.
The firing head is made up vertically to the safety spacer positioned in the rotary table. The safety
spacer provides a minimum 10 - ft [3 - m] blank section between the firing head assembly and the
top shot of the upper gun in the string.
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 43 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Fig 7.15
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 44 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Fig 7.16
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 45 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Fig 7.17
ARPO
ENI S.p.A.
Divisione Agip
IDENTIFICATION CODE PAG 46 OF 46
REVISION
TEAP-P-1-R-8797 0 1
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
Fig 7.18
ARPO
ENI S.p.A.
Divisione Agip
ORGANIZING
DEPARTMENT
TYPE OF
ACTIVITY'
ISSUING
DEPT.
DOC.
TYPE
REF. N. PAG.
1
OF
34
TEAP P 1 R 8798
The present document is CONFIDENTIAL and it is the property of ENI
It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given.
TITLE
Well Completion & Workover Course Volume 1
CHAPTER 9
- FORMATION DEMAGE -
DISTRIBUTION LIST
TEAP
STAP Archive
LIST of CONTENTS (authors)
Cap. 01 - Well Completion Design - M. Marangoni
Cap. 02 - Material Selection - M. Marangoni
Cap. 03 - Tubing Design - B. Maggioni
Cap. 04 - Tubing Stress Analysis - B. Maggioni
Cap. 05 - Packers - M. Marangoni
Cap. 06 - Surface Wellhead - M. Marangoni
Cap. 07 - Safety Valves and Miscellaneous - M. Marangoni
Cap. 08 - Perforating - M. Marangoni
Cap. 09 - Formation Damage - M. Viti
Cap. 10 - Sand Control - M. Viti
Cap. 11 - Workover - G. Treglia
Date of issue: