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WELL COMPLETION EQUIPMENTS

By: Dr. Syahrir Ridha

Thanks to: Prof. Bahman Tohidi (Heriot-Watt University)

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Well design and completion

Lesson Outcomes
Having worked through this chapter the Student will be able to:

Discuss and review the main equipment options:

Production tubing Wellheads Xmas trees Packers Subsurface safety valves Nipple profiles Tubing-annulus circulation devices

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Completion Equipments
1. 2. 3. 4. 5. 6. 7. Production Tubing Wellhead Systems X-mas Tree Packers Nipple and Mandrel Systems Sub-Surface Safety Systems Tubing-Annulus Communication Equipment

1. Production Tubing

Design of production tubing should satisfy the following criteria: Minimising pressure drop High strength for suspension of tubing joints High internal pressures for fluids flow High external pressures (between annulus & tubing) Resistant to chemical corrosion
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Production Tubing
Tubing Diameter OD + lbs/ft (4 OD, 9.5 lbs/ft) Tensile Strength H-40, C-75, L-80, et al Number is an indication of minimum yield strength multiply 1000 in psi. Letter grades indicate the manufacturing process Internal Pressure Internal vs differential pressure Burst pressure is calculated for gas filled tubing Maximum generally occurs at surface
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Production Tubing
External Pressure Collapse is most likely at the bottom of the well Corrosion Acid corrosion; i.e. CO2 Sulphide stress cracking/hydrogen embitterment; i.e. H2S Some treatment use of inhibitor Coupling Types Connections that require internal pressure Metal to metal

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2. Wellhead Systems

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Wellhead Systems
It has the following functions: Suspension of casings and tubings Flanging up fluid flow devices X-mas tree and/or BOPs Hydraulix communication with annulus Application in an offshore platforms or land based, wellhead can be devided into: Conventional Spool System Compact Spool Systems Mud Line Suspension System
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Conventional Spool System

a. Run the 30 conductor, 20 casing is run and cemented. Sometimes the top of 20 casing is welded, so it can transfer some weigh to the 30 conductor. b. The 17 hole is drilled,13 3/8 casing is run with the hanger landing in the 20 housing. The casing is cemented in place. c. A new 12 hole is drilledwith a new spool being installed for each casing string.
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Conventional Spool System

The disadvantages of this type of wellhead are: A lot of time is spent flanging up the spools; The large number of seals, increases the chance of pressure leak; BOPs must be removed to install the next casing spool; A lot of headroom is require, which may not be available in the wellhead area of an offshore platform.

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Compact Spool System

This compact type was developed as an alternative to the conventional spool discussed above. A compact spool enables several casing strings or tubing to be suspended from a single spool. The BOPs can be connected to the top of housing and the next hole section drilled.

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Compact Spool System

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Mud Line Suspension System

Wellhead is built up on the seabed, but production well be completed back to the platform. A wellhead built up on the seabed will be used to suspend casing strings Each casing will have an extension string from subsea wellhead to a subsidiary wellhead at the platform where the BOP and X-mas tree will be attached.

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3. X-mas Tree
It is a system of valves which controls physical or hydraulic access into the tubing string or the annulus. The access capabilities required are: Capability to inject fluids Capability to produce fluids Capability to lower wireline service tool Capability to completely close the well Manually controlled valve and remotely controlled valve (hydraulically)

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X-mas Tree

One major disadvantage of cross piece Xmas Tree is the large number of flanges significantly increased possibility of leakage.

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X-mas Tree

A solid block construction uses of a yoke piece configuration Normally the Xmas Three is connected by a flange or clamp to the top of the wellhead.
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4. Packers
It provides physical isolation of the casing/tubing annulus above the production zone. Provide well protection Corrosion protection Abrasion protection Casing/wellhead burst protection Production stability Production annulus heading

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Packers
Zonal Isolation Selective or segregate production Annulus to Tubing Injection Gas lift or chemical Injection Operations Economic injection rate or fracturing Temporary Isolation Bridge plug

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Well design and completion

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Packers
Packers have four key features:
1. 2. 3. 4. Slip Cone Packing-element system Body or mandrel.

The slip device penetrate and grip the casing wall when the packer is set. The cone drives the slip outward and into the casing wall when setting force is applied to the packer. Once the slips have anchored into the casing wall, additional applied setting force energizes the packing-element system and creates a seal between the packer body and the inside diameter of the casing.
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Packer Classifications
Permanent Packer
Permanent packers difficult to remove and it can be removed from the wellbore only by milling. Retrieval is usually accomplished by some form of tubing manipulation The permanent packer is fairly simple and generally offers higher performance in both temperature and pressure.

Retrievable Packer
The retrievable packer may or may not be resettable, but removal from the wellbore normally does not require milling. The retrievable packer can be very basic for low pressure/low temperature (LP/LT) applications or very complex in high pressure/high temperature (HP/HT) applications. This packer will invariably cost more with the same quality of permanent packer
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Packers Selection

Casing and tubing size Depth of the well and bottom-hole pressure Annular fluid type and differential pressure Extent of thermal stress and potential forces Need for tubing retrieval without the packer Bore size offered by the packer Completion string equipment compatibility The deviation angle, effect on setting mechanism

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5. Nipple and Mandrel Systems Applications

Isolation and plugging of the tubing string for well shut in, workover, or hydraulically setting packers. A ported device for communication between the tubing and the annulus. Emergency closure of the tubing or annular flow Installation of downhole pressure and temperature recording gauges.

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6. Sub Surface Safety System

They are required for X-mas tree removal for workover Removal of surface valves Damage to X-mas tree Leakage on X-mas tree SSSV are available besed on Direct control (D.C. SSSV) Remotely of Surface contro (S.C. SSSV)

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Directly Controlled (D.C. SSSV)

Differential pressure operated safely valves Ambient or pre-charged type safety valves Advantages
Simple construction and operating principle Easy installation and retrieval Cheaper installation cost

Disadvantages
Not 100% reliable Performance could be affected due to solid deposition Testing of valve operation is not easy

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Surface Controlled (S.C. SSSV)

Held open by hydraulic pressure Either ball or flapper type Tubing or wireline retrievable Tubing retrievable must be reliable Tubing retrievable offer larger flow area

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7. Tubing-Annulus Communication Equipment

The communication (circulation) is required for: To displace out the tubing contents to initiate production To displace tubing contents with a kill fluid To allow continuous or intermittent injection:
Corrosion or scale inhibitor Gas for gas lift

Available options are:

Sliding side door or sliding sleeve Side pocket mandrel

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Sliding side door

Is it this?

A completion device that can be operated to provide a flow path between the production conduit and the annulus. Sliding sleeves incorporate a system of ports that can be opened or closed by a sliding component.

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Side Pocket Mandrel

A completion component that is used to house gas-lift valves and similar devices that require communication with the annulus. The design of a side-pocket mandrel is such that: the installed components do not obstruct the production flow path enabling access to the wellbore and completion components below. Consists of a tubing mandrels with ports located on its outside wall

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Running Procedures

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THANK YOU

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