Evolution of Well Completion from

Traditional to Smart Technology Course

01st – 02nd October 2023

Mahmoud Farag Radwan

Subsurface & Integrity Operation Dept. Head
https:\\www.linkedin.com/in/mahmoud-farag-radwan-a9266626
 Mahmoud Farag Radwan

Mahmoud Radwan is a Subsurface & Integrity Operations Dept. Head at AMAL

Petroleum Company (AMAPETCO) with more than 15 years of experience in oil
& gas industry. Mahmoud worked in Well Engineering, Intervention, Integrity &
Short Work-over at several companies, including CUDD Well Control, KDT Global
Solutions, Badr El-Din Pet. Co. (BAPETCO), Qarun Pet. Co. (QPC) and Wadi El-
Biography Sahel Petroleum Co. (WASPETCO).
Also, a freelance instructor at Upstream Oil & Gas in Egypt & GCC since 2008.
Mahmoud received a BSc degree in Petroleum Engineering from Al-Azhar
University in 2007.
o Evaluating Sustainable Annulus Pressure (SAP) in Sour Wells and the Possible
Causes to Avoid Recurrence to the Well Integrity Annual Middle East
Conference in Abu Dhabi; UAE in Apr 2015
o Implementing NDT methods for maintenance and inspection to the Asset
Integrity Management North Africa Conference in Cairo; Egypt in Nov 2015
o Feasibility Evaluation of Using Downhole Gas-water Separation Technology in
gas Reservoirs with Bottom Water; paper number: SPE-183739-MS to the 20th
Middle East Oil & Gas Show and Conference in Mar 2017
Publications http://dx.doi.org/10.2118/183739-MS
o Managing the Operational Challenges in Corroded Wells through Well Integrity
Management System to the Improving Brownfield Performance Technical
Convention, in Cairo; Egypt in Dec 2019
o Safe and Economic Attractive Rigless Operations Using a Digital Slickline in
Unmanned Platform with Low Structure Loads and Spacing; paper number:
SPE-202857-MS to the Abu Dhabi International Petroleum Exhibition &
Conference (ADIPEC) in Nov 2020 https://doi.org/10.2118/202857-MS
 To provide a knowledge of Traditional
and Smart Well Completions; its
components and different design
options to meet.

Mahmoud Farag Radwan

 Agenda
 Introduction to Well Completion

 Types of Well Completion Configurations

 Traditional / Conventional Completion Equipment

 What is A Smart Completion?

 Case History

 Smart Completion Business Value

 Smart Completion Equipment

 Smart Completion Combined with Artificial Lift

 Case Study

 References / Credits
Mahmoud Farag Radwan
 Casing Design : Basic Construction

1 1. 30” conductor
2 2. Conductor setting depth
3 3. 20” surface casing
4
4. 20” shoe
5 5. Cement
6 6. Formation open to C annulus
7
7. 13 3/8” casing
8
8. Formation open to B annulus
9
10 9. 9 5/8” production casing
10. Liner hanger
11
11. 7” Liner
12. TD – Total Depth
12 Mahmoud Farag Radwan
Introduction to Well Completion

Mahmoud Farag Radwan

 What is a Completion?
The design, selection and installation of
tubular, tools and equipment, in the wellbore,
for the purpose of conveying, pumping or
controlling production (or injection) fluids
Three Basic Functions of a completion
•Let reservoir fluids into the well, from where it can then
flow or be pumped to the surface.

•Keep over or underlying water out of the well.

•Keep the formation out of the well.

Mahmoud Farag Radwan
Top Level Completion Design Objectives
 Optimize Production

 Adequate Monitoring & Servicing

 Suitable Components for Well Environment and Changes

 Consistent with Reservoir Strategy

 Ensure ROI via:

Cost efficient Installation

Reliability

Risk Management

 Safe: Well security, environment

Mahmoud Farag Radwan
 Well Completion Define & Justify
Key Well Objectives
Res. Exploitation Strategy
Surface Constraints Well
Design Process Well Proposal
Lifetime Requirements
Monitoring Requirements
 The Design Philosophy of
Define Completion Workover & de-completion
Well Completion is to Objectives
“Maximize Profitability” by: Cost Model
No
 Maximizing well hydrocarbon Confirm Feasibility Analogues and Field Data
recovery. Well Geometry Reservoir
 Considering the full Inflow Model Communication Reservoir
hydrocarbon resource life cycle. Rock Data
Outflow Model Fluid Data
Yes
Feasible
Detailed Design Stimulation
Drill & Complete Sand Control
Tubing Size
Operate & Maintain
Artificial Lift
No Requirements Well Design Model
Met?
Facilities Model
No
Optimized
Solution Cost VS Benefit Analysis

Mahmoud Farag Radwan

WELL COMPLETION
WC is the “hardware” of the outflow system & final stage of a
drilled well.

Quality concepts for WC is;

“A Quality Well is a well which contributes, over its life cycle,

maximum monetary value, without compromising safety &
environmental standards”

Mahmoud Farag Radwan

 WELL COMPLETION TYPE
1. PRODUCER
2. INJECTOR
3. KILL

The well is either Vertically & Horizontally completed.

• Open Hole Completion

• Uncemented Liner Completion

• Gravel Pack / WWS Completion

• Tubingless Completion

• Cemented & Perforated Completion

• Single String or Multiple String Completion

• Convectional or Monobore Completion
Mahmoud Farag Radwan
WELL COMPLETION

1. Conventional Completion
2. Mono-bore Completion
“Completion with fullbore access across the payzone without diameter
restrictions”.

CONVENTIONAL Same tubing ID CONVENTIONAL

WRSV Use full bore slimline tubing run SSSV

TRSV
SSD Omit, use CT well servicing
Minimize annular “waste” (swedge ▼or run Liner)
SPM Omit or use slimline SPM

Bottle Neck ▪▪
◦◦◦◦
No Restriction

Use TCP or CT run guns

Mahmoud Farag Radwan
 Int Segregation
3 PRODUCING ZONES

Concentric String
Multiple String
MULTIPLE
Single String
Co-Mingling Int
SINGLE
Standard
DESIGN CONSIDERATIONS

Sub-Pump

Mahmoud Farag Radwan

Plunger Rod
2 OUTFLOW

Gas Lift
SEC RECOVERY
WELL COMPLETION

Rod
High Rate Liner
PRI RECOVERY High Pressure
Simple, Low Cost
Tubing-less
HORIZONTAL
Internal GP
PERFORATED CASING
Standard
1 INFLOW
PERFORATED LINER
Ext GP
P//Pack Screen
UNCEMENTED LINER
WWS

VERTICAL
Slotted Pipe
OPENHOLE
 1 INFLOW 2 OUTLOW 3 PRODUCING ZONE

ZONE 1 ZONE 1

ZONE 2 ZONE 2

PRODUCING PRODUCING
WELLBORE
ZONE ZONE ZONE 3
ZONE 3

Interface between Producing Interface between Wellbore No of Zones

Zones & Wellbore & Surface Facility
Mahmoud Farag Radwan
VERTICAL VERTICAL
HORIZONTAL

HORIZONTAL Gas Cap

GOC
Hits multiple
fractures
Oil Rim

Coning WOC Limited Drawdown

Hits few
fractures

Mahmoud Farag Radwan

 1. Inflow system - VERTICAL
Technological advances allow boosting of the well inflow to a considerable extent –
albeit at a cost.

WWS or
SLOTTED PREPACK
OPEN HOLE LINER GRAVEL PACK
Mahmoud FaragSCREEN
Radwan
1. Inflow system - VERTICAL

STD CEMENTED & INTERNAL GRAVEL

PERF PROD CASING PACK
Mahmoud Farag Radwan
1. Inflow system - horizontal
OPEN HOLE SLOTTED LINER PRE-PACK SCREEN
Production
Casing

Cement Sheath Slotted Liner Pre-Pack Screen

Open Hole Section

◦◦ ◦◦◦ ◦◦ ◦◦◦ ◦◦ ◦◦◦ ◦◦

GRAVEL PACK CMT & PERF LINER

Graded Gravel

Gravel Pack Screen Perforations

• •••••••••••••••••••
•
••• •••• •••• ••••
Mahmoud Farag Radwan
2. OUTFLOW – PRI RECOVERY
It’s essentially a conduit with flow controls & where necessary artificial lift or pressure
boosting facilities.

TUBINGLESS HIGH PRESSURE MONOBORE

With out tubing. Cemented, perforated & With high rate liner
completed with tubing &
accessories.

Low pressure gas reservoir Restriction Free

Susceptible for WI
2. OUTFLOW – SEC RECOVERY
ROD PUMPING
Pumping Unit

HYDRAULIC PUMPING

Production Casing

Tubing

Sucker Rod String

Gas

Operating Fluid Level

Oil

Tubing Anchor

Plunger
Pump Barrel

Travelling Valve
Stationary Valve

Gas Anchor

Perforations
Sump
2. OUTFLOW – SEC RECOVERY
GAS LIFT

Compression

Manifold Gas

Surge
Tank
Water Oil

Motorised
Flowline Valve
Continuous Intermittent
Gas Lift Gas Lift

Gas Supply
Unloading Unloading
Control And
Valves Valves
Metering System

Operating
Gas Lift
Valve (OGLV)

Standing Valve
Mahmoud Farag Radwan
3. PRODUCING ZONES – SINGLE
Single Single Single
Single
Selective Selective Commingle
Completion
Interval Interval

Mahmoud Farag Radwan

3. PRODUCING ZONES – MULTIPLE
Concentric Multiple Multiple
Multiple
Completion Commingle Selective
Completion
Completion Completion

Mahmoud Farag Radwan

 WELL COMPLETION

Well Completion design is dictated by the type of well to be completed.

1. Producer

2. Injector

3. Kill

The 3 considerations of designing well completions are;

1. Inflow system

2. Outflow system

3. Number of zones to be produced

Mahmoud Farag Radwan

Well COMPLETION
It is the hardware of the outflow system.

There many different types & functions of downhole accessories installed in a

the outflow system depending on the type of a well.

It is essentially important to understand these accessories prior doing Well

Intervention operations.

Mahmoud Farag Radwan

 Tubing Hanger

Well COMPLETION Control Line

Flow Coupling
COMPLETION ACCESSORY: SCSSV Landing Nipple
1 Anchoring Device
 Landing Nipples Top No-Go Nipple

2 Circulation Device
 SSD SPM
 SPM
Top No-Go Nipple
3 Isolation Device
 Packer SSD
Top Packer
 Tubing Seal Assembly, PBR
4 Anti-Erosion Device SSD

 Blast Joint
Producing Zone 2 Blast Joint
 Flow Coupling
5 Others Btm Packer
 WLEG Bottom No-Go Nipple
 Perforated Joint Perforated Joint
WL Entry Guide
 Control Line
 Tubing Hanger Producing Zone 1

Mahmoud Farag Radwan PRODUCER COMPLETION SCHEMATIC

 WELLHEAD
& XMAS TREE

Mahmoud Farag Radwan

Wellhead

Provides the following functions:

 Anchor & connections for each individual casing

 Pressure isolation of individual casing
 Connection for Xmas tree
 Connections for completion string
 Isolation of production annulus
 Access to annulus for pressure monitoring and/or pumping.

Types of Wellheads:
 Compact Wellhead (sub-sea)
 Conventional Wellhead

Mahmoud Farag Radwan

WELLHEAD & XMAS TREE
COMPACT WELLHEAD

It’s positioned on the seabed. During drilling sub-sea BOP is installed above it.

Mahmoud Farag Radwan

WELLHEAD & XMAS TREE
CONVENTIONAL WELLHEAD

It’s a built up of modules. During drilling BOP is installed

above it & it must be removed each time a new module
to be installed & replaced the BOP on top of it before
commence drilling.

Features:

1 Starter Spool (Conductor Pipe)

2 Surface Casing Head
3 Surface Casing Hanger
4 Production Casing Head
5 Production Casing Hanger
6 Tubing Head
7 Tubing Hanger

Mahmoud Farag Radwan

WELLHEAD & XMAS TREE
XMAS TREE
Surface valves manifold to control flow of well fluids & access for well
intervention activities.
Features:
1 LMV
Manual, NOT working valve optimum conditions.
2 UMV
Emergency valve (Hyd/Pneu) & cut wire.
3 FWV
Permits passage of well fluids to CV.
4 CHOKE VALVE (CV)
Restrict, control or regulate flow of well fluids.
5 KWV
Permits entry of kill fluids into tubing or equalize.
6 SV/CV
Permits entry of well interventions.
Mahmoud Farag Radwan
 Xmas Tree Type
Xmas Tree type:
 Solid Block (Mono Block) Xmas Tree
- Contains fewer components (for
high pressure wells)
 Composite Block Xmas Tree
- Valves are located on separate
block & joined by API flange.
 Horizontal Xmas Tree
- New concept used for sub-sea
completion.

Mahmoud Farag Radwan

WELLHEAD & XMAS TREE

Wellhead Connection Types;

 Screwed type (low press <1 000psi).
 API Flanged type (high press <5 000psi).
 API Flanged type are mostly used by OPCO –
because it’s less susceptible & easier oriented.

Example of API Flange specification:

9⅛” – 5000 psi API Flange.

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

working pressure.

Mahmoud Farag Radwan

Dual Solid Block Xmas Tree

Mahmoud Farag Radwan

 What is A Smart Completion?
“A Smart Completion is defined as one that
provides the ability to both monitor and control at
least one zone of a reservoir”
i.e.
 Completion with permanent down hole monitoring
- Pressure and Temperature
- Flow rate
- Water cut
 And surface operated down hole flow control
-Hydraulic operated flow control valves
-Electric operated flow control valves
Mahmoud Farag Radwan
 What is a Smart Completion?
What is a smart completion?
 Surface operated down hole flow control
 Permanent down hole monitoring
 Minimal intervention

Mahmoud Farag Radwan

 Case History
• The first Smart-well Completion was installed in
August 1997 Saga’s Snorre Platform in the North Sea

• Initial Smart-wells use permanently downhole

electronic gauge and sensors

• In 1998 WellDynamics use Direct Hydraulic and Mini

Hydraulic system

• Development of new monitoring systems like Fiber-

optic with high level of reliability, accuracy,
resolution and stability.
Mahmoud Farag Radwan
 Smart Completions: Business Value

Reduced well intervention costs

Accelerated production

Reduced well costs

Reduced surface facilities

Increased ultimate recovery

Real Business Value

Mahmoud Farag Radwan

Mahmoud Farag Radwan
Mahmoud Farag Radwan
 Elements of Smart Well Completions

Power and Architecture and

Communications Infrastructure

Flow Flow
Control Monitoring

Flow
Field Solutions Optimization Data Management
Closing the Loop Interpretation
Valuation

Mahmoud Farag Radwan

 Components of Smart Completion
 Permanent down hole sensors

 Surface operated down hole flow control valves

 Control lines and electric cables

 Cross coupling cable protectors

 Multiport Production and isolation packers

 Tubing hanger and X-mass tree

 Surface control and data acquisition system

 Data visualization and interpretation software

Mahmoud Farag Radwan
Elements of Smart Well Completion Technology

Communications / power cable

Surface data acquisition and control

Mahmoud Farag Radwan
 Permanent Down Hole Sensors
 Single point Pressure

 Single point temperature

 Fiber optic (Distributed temperature survey(

 Flow meter

 Water cut

 Temperature arrays
 Monitoring Devices / Flow Watchers
Pressure Sensors Flow Measurement Electric Water cut Meter

Pressure - Flow Stations

Densitometer Formation Arrays

Mahmoud Farag Radwan

Mahmoud Farag Radwan
 Down Hole Flow Control Valves
 Hydraulically actuated are most common

 Direct hydraulic valves require minimum of one

control line per valve

 Multi-drop systems share control lines but add

complexity to the system

 Valves can be On/Off, Discrete position or infinitely

variable

 Electric valve

Mahmoud Farag Radwan

Mahmoud Farag Radwan
Mahmoud Farag Radwan
Mahmoud Farag Radwan
 Passive Inflow Control Device
 Reservoir Pressure
 Fluid Mobility = K/µ

Mahmoud Farag Radwan

Comparison of Commercial ICD Types

Mahmoud Farag Radwan

 Types of ICDs

Plug 1.6mm 2.5mm 4mm

Mahmoud Farag Radwan

Active / Autonomous Inflow Control Devices (AICD)

Mahmoud Farag Radwan

Autonomous Inflow Control Valve

Mahmoud Farag Radwan

AICV Applications
Swellable Packer Technology

Mahmoud Farag Radwan

 Swell Packer, A Simple Tool

A swell packer is a piece of rubber that swells in oil

Engineering a compound that has the right

properties for use as an isolation tool is extremely
challenging

Mahmoud Farag Radwan

Oil & Rubber – Natural Enemies
– All rubber absorbs oil and swells
– Industry has spent millions attempting to stop
this process
– Standard rubbers swell and degrade in
contact with oil
– Rubber degrades to the point of becoming
more liquid than solid

Mahmoud Farag Radwan

 The Mechanics
– The swelling process is one of thermodynamic absorption
– Hydrocarbons are absorbed into the packer element on a
molecular level
– The hydrocarbon molecules enter the cross linked rubber
forcing these links to stretch thus increasing volume and
swelling the element
– Mechanical properties of rubber engineered to suit
isolation usage

Mahmoud Farag Radwan

Swell Packer– Rising To The Challenge

– No moving parts
– Slip on design avoids complexity with metallurgy&
couplings
– Improved sealing capabilities over mechanical packers
– Inbuilt swell delay mechanism - safe deployment in OBM
– Highly erosion resistant
– Reduced risk simple installation

Mahmoud Farag Radwan

Added Flexibility from Modular Design

Single element for ICD type applications

Stacked elements for increased differential pressure

Spaced elements for increased differential pressure and well bore contact

Mahmoud Farag Radwan

Stability Testing

Mahmoud Farag Radwan

Swell Packer performance is Predictor
Swell
calculator

Q)

1
10

Densit 4. lb/in3 5 5days 15

y hours

8 8. 8.4 8.6 8. 9 9. 9.
2 8 2 4

Max differential 400o+p ~

pressure si
c
Q)
L 2
Graph Min
:!,
Limits Max 0
8 9.5 in
Diameter "
0 30days :: 1
Time ::

Mahmoud Farag Radwan

Stability Verification with differential pressure

I p• -
•Q

Mahmoud Farag Radwan

 Water Swellable Packer
What is a water swelling packer

• A Swellpacker that will swell in water!

• Osmosis is the swelling process
• Same design as hydrocarbon Swellpacker
design

Mahmoud Farag Radwan

 The Swelling Process

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,· Mahmoud Farag Radwan
 Cable Protectors
 Control lines & cables are run outside the
tubing
 Cross coupling protectors are the most
commonly used protectors
 Mid-Joint and other special application
protectors are also available
 Cast Iron or Molded metal

Mahmoud Farag Radwan

 Multi-Port Packers
 Allow passing of control lines

 Production packers

• Provide isolation and anchoring

 Isolation packers

• Provide isolation only

 Open Hole packers

• Swell or Mechanical

Mahmoud Farag Radwan

 Wellhead and Tubing Hanger
 Wellhead and Tubing Hanger

 Control line and cable penetrations

Mahmoud Farag Radwan

 How does it all come together
Control Lines and cables

SCSSSV

P/T Gauges

SSD & Seating Nipple

P/T
GauF
gleosw control
Multi-port Multi-port valve Flow control
Packer Packer valve

Multi-port Bull nose

Flow control P/T
P/T Packer
valve Gauges
Gauges

Mahmoud Farag Radwan

 Surface Control System
 Electro Hydraulic controls for downhole valves

 Monitoring of downhole sensors

 SCADA Compatible

3
2
1
0
Mahmoud Farag Radwan
 Data Communications
Well Site Acquisition
Answer Products And Control

Connecting to Your
Reservoir
Reservoir Management
Production Optimization
Subsea Interfaces

Formation Sensors

Production Sensors

Smart Completion
+
ESP
Mahmoud Farag Radwan
 Benefits of Combining SC with ESP
 Dedicate ESP energy to lifting oil rather than water

 Apply higher drawdown to lower productivity zones

 Reduce the size of down hole ESP gas separator and gas
handling equipment

 Reduce ESP size to better match oil lifting requirements

 Reduce wear-and-tear due to gas slugging

 Reservoir protection during ESP work over

Mahmoud Farag Radwan

Hydraulic Wet Mate Connect SCSSSV

 Provides connections for hydraulic control lines in

two-stage Smart Well Completions
POD ESP

 SC Packers, sensors, and flow control valves

Expansion
remain in place joint
Down hole
Disconnect
Production Packer
 Allows retrieval of control lines and clamps above
Flow
control
the top SC packer with ESP valve
Open
hole

 Consists of Packer
Flow
control
valve
• Receptacle that is run with the lower completion
Open
hole
• Stinger that is run with the upper completion PaFclkoer
control
w
Mahmoud Farag Radwan Bull vnaolsve
 Parts of a completions
•Lower “Sandface” Completion: Productivity
• Vertical or Horizontal
• Open hole (Bare foot(
• Cased & Perforated
• Screens Packers
– Cased hole packers
• ICDs – Open hole packers
• Active Down Hole Flow Control – Swell Packers
– Multiport packers
• Monitoring
•Upper Completion: Safety & Connectivity
• ESP
• Safety Valve
• Nipples
• Sliding sleeves
• Injection Mandrels
Mahmoud Farag Radwan
• Monitoring
Example of an Smart Injector completion

Conventional
 No real time measurements
 Periodic logs to measure injection Packer

rate & profile

Mahmoud Farag Radwan

Example of an Smart Injector completion

 FlowWatcher
 Real time measurements
•Injection rate Multi-port Packer

Flow Control valve

•Volume FlowWatcher

•Pressure Packer

•Temperature

Mahmoud Farag Radwan

 Example of an Smart Injector completion

 FlowWatcher
 Fiber Optic DTS
 Real time measurements
Multi-port Packer
•Injection rate
Flow Control valve
•Injection profile FlowWatcher
Multi-port Packer
•Volume
•Pressure Slotted Tail Pipe

Fiber optic
•Temperature

Mahmoud Farag Radwan

 Smart Injector with passive control

 FlowWatcher
 Fiber Optic DTS
 Real time measurements
Multi-port Packer
•Injection rate
Flow Control valve
•Injection profile
Multi-port Packer
•Volume
•Pressure Slotted Tail Pipe

Fiber optic
•Temperature
 Balanced injection Profile, ICD

Mahmoud Farag Radwan

Case Study

Mahmoud Farag Radwan

Conventional Completion vs. Smart Completion

o Conventional o Smart

Pros Pros
• Low CAPEX Cost • Surface operated down hole flow
• Flexible in design, Selection control & monitoring
& running • Applied in complicated reservoir

• Technology Available with a great prod. & ROI

worldwide • Minimal intervention

Cons Cons
• No real-time down-hole • Need a detailed feasibility study
measurement or control • Need a skilled people & qualified
• Need more Well Intervention & service providers
High (OPEX) • Full technology not available in all
• No great production gain & ROI countries
Mahmoud Farag Radwan
 References / Credits
 Halliburton, Schlumberger, Baker
Hughes, Weatherford, Reslink and
InflowControl

 Saudi Aramco Great Achievements

 SPE Papers and JPT Articles

Mahmoud Farag Radwan

Thank You
Q&A

Mahmoud Farag Radwan