Completion Equipment

Completion equipment for most of wells consist of below

equipment depend on the design and method of well completion.
1. Production tubing

2. Wellhead systems

3. Xmas tree

4. Packers

5. Wireline nipple and mandrel systems

6. Subsurface safety systems

7. Tubing-annulus circulation equipment

 1. Production Tubing
The bulk of the completion string comprises threaded joints of
tubing which are coupled together.

The integrity of the tubing is vital to the safe operation of a

production or injection well.

The tubing must be specified to provide the following capabilities:

1. The inside diameter of the tubing must provide a produced fluid
velocity to minimize the total pressure loss as defined by the tubing
performance relationship. e.g. 41/2" O.D. x 13.5 lbs/ft

2. The tensile strength of the string of made up tubing must be high

enough to allow suspension of all the joints to the production zone
without tensile failure occurring of any of the joints above. e.g. H-40,
J-55, C-75, L-80, N-80 and P-105.
 3. The completion string must be able to withstand high internal
pressures as a result of fluid flow entry into the tubing. e.g.
burst pressure.
4. The completion string must be able to withstand high external
differential pressures between the annulus and the tubing. e.g.
collapse pressure.
5. The tubing must be resistant to chemical corrosion which may
arise because of fluid contact in the wellbore, and might
ultimately accelerate string failure by one of the loads and
stresses mentioned above (2)-(4). e.g. acidic corrosion and
sulfide stress cracking.
Coupling Types: Standard API Coupling Connections-Two standard
API coupling tubing connections are available:
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.
 1.1 Specification of Tubing
The string is defined initially by the well productivity analysis which
suggests the optimum tubing ID based upon a range of available sizes.

Frequently the completion string will comprise lengths of several different

diameter tubing, with the diameter decreasing towards the bottom of the
well.

The use of larger diameter tubing higher up the well may be useful to
counter the increasing flow velocities as the fluid expands and gas is
liberated from solution as pressure declines up the tubing.

The reduction in tubing size in the lower sections of the well may be
necessary because of limited equipment availability and mechanical
limitation, e.g. production liner inside diameter.

Once the size is specified, the design based upon the 3 mechanical
conditions of tension, burst and collapse is undertaken.
 Ultimately the design will yield a specification for a string
comprising one or more types of tubing defined as follows:
 2. Wellhead Systems
The wellhead is the basis on which the well is constructed and tubulars
suspended during the drilling and completion operation. The wellhead
serves three important functions:
1. Each of the casing strings which are run, cemented and have an
extension to surface or the seabed, as well as the production tubing
string(s), are physically suspended within the wellhead.
2. The wellhead provides the capability of flanging up a device to control
the flow of fluid from or into the well. In the drilling phase, this flow
control device is known as a blowout preventer stack (B.O.P.) and this
remains in place until the production tubing string has been suspended in
the well. Once the completion string is in place, the B.O.P. is removed and
the production flow control system, known as the Xmas Tree, is installed
on top of the wellhead.
3. Each wellhead spool or landing area offers a flanged outlet allowing
hydraulic communication into that annulus.
 3. Xmas Tree
The Xmas Tree is the production flow control system and it is a system of
valves which control physical or hydraulic access into the tubing string or
the annulus between the production casing and tubing string.

The access capabilities required are as follows:

1. A capability to inject into or produce from the production tubing -

access is provided through the flow wing valve or kill line valve.

2. A capability to lower into the production tubing a wireline service

tool string - the vertical access is provided through the swab value.

3. A capability to completely close off the well.

The simplest type of Xmas Tree utilizes a series of valves connected to

each leg of a cross piece as shown in Figure.
Simple Wellhead Assembly including Casing Spools and Xmas Tree
 4. Production Packers
A packer provides physical isolation of the casing/tubing(s) annulus above
the production zone.

Packers are an essential piece of completion equipment in a large number

of wells. The reasons for their use varies from well safety considerations to
production flow stability.

Some of the more common reasons for using packers are outlined below:
1. Well protection
2. Production stability
3. Zonal isolation
4. Annulus to tubing isolation
5. Injection operation
6. Temporary isolation
4. Production Packers

Production Packer
 4.1 Packer Applications
1. Well Protection: Since the packer isolates the casing/tubing annulus
above the production zone, it is designed to prevent the formation fluids
communicating up the annulus and provides:

Corrosion Protection - contact of well fluids containing H2S, CO2 or

organic acids with the casing and outside wall of the tubing is
prevented.

Abrasion Protection - since no flow occurs up the annulus, abrasion

due to solids such as sand entrained within the produced fluids is
prevented.

Casing/Wellhead Burst Protection - the elimination of reservoir

pressure communication prevents the generation of high annular
casing pressures at surface. e.g. In a gas well where the liquid in the
annulus unloads and gas then fills the annulus and exerts a casing
head pressure.
 4.1 Packer Applications
2. Production Stability: In oil wells producing from a reservoir with a
solution gas drive reservoir or where the bubble point is reached close to the
perforation, the flow of a two phase mixture into the tubing string can lead
to gas segregation and its accumulation in the annulus where its volume will
gradually increase until it offloads by U-tubing up the production tubing. This
phenomenon is known as an "annulus heading cycle.

3. Zonal Isolation: In wells designed to produce either up a single tubing

string completed selectively over several zones or where a tubing string is
provided for each zone, a packer is required to isolate between each zone to
prevent comingling of production or inter-zone fluid flow.

4. Annulus to Tubing Injection: In a variety of completions, fluids are

injected into the annulus and the completion string is designed to allow
these fluids to enter the tubing string at specific depths and at a certain
flowrate. In such cases, the use of a packer prevents the fluid merely U-
tubing at an uncontrolled rate via the bottom of the tubing which would lead
to ineffective production of hydrocarbon. e.g. gas lift wells.
 4.1 Packer Applications
5. Injection Operations: In injection operations such as water or gas
reinjection, or stimulation operations such as fracturing, the use of high
surface pressures is necessary either to generate an economic injection
rate or to exceed the fracture initiation pressure. Without the use of a
packer, these pressures would be communicated up the annulus and
might cause concern regarding the burst criteria for the casing/wellhead.

6. Temporary Isolation: In some cases it is necessary to provide some

degree of protection across the production zone to prevent the loss of
fluid into the reservoir from a higher density fluid in the wellbore during
workover operations and well closures. In such cases running a bridge
plug - a type of full bore packer capable of being run down through the
tubing, and setting it just above the perforations would provide zonal
isolation and protection.
 4.2 Basic Packer Components and Mechanics

A typical packer comprises the

following components:
a) Sealing element

b) Slip system

c) Setting and release mechanism

d) Hold down button

 4.2 Basic Packer Components and Mechanics
a) Sealing Element(s):
The isolation of the annulus is normally provided by the extrusion of
the sealing element by some form of axial compression, such that it
fills the annulus at the packer between the completion string and the
casing.

The sealing element consists of one or more rings of elastomer or

combination of elastomers.

Obviously the material of construction of the sealing element must be

able to withstand the anticipated conditions in the wellbore with
regard to pressure, temperature and chemical composition of the
fluids likely to exist in the wellbore. For example, in H2S or CO2
conditions.
 4.2 Basic Packer Components and Mechanics
b) Slip System:
The system of slips comprise a set of mechanical latch keys which are
located either above or below, or both above and below the sealing
element.
The purpose of the slips is to support the packer during the setting
operation and subsequently.
The slips act by being forced into contact with the inside wall of the
casing.

c) Setting and Release Mechanism:

The packer can either be set independent to the completion string or
as an integral part of the string.
Since it will be desired to set the packer at a specified depth, it is
necessary to be able to control the actuation of the setting mechanism
only when required.
 4.2 Basic Packer Components and Mechanics
d) Hold Down Buttons:
During production operations variation in bottomhole pressure
beneath the packer can lead to significant changes in the differential
pressure exerted across the packer i.e. the differential between the
pressure beneath the packer and pressure in the annulus above the
packer.

Some designs of packer incorporate a feature known as hydraulic hold

down buttons whereby the pressure in the packer bore is used to force
a set of additional slips outwards onto the inside wall of the casing,
thus preventing any vertical upwards movement of the packer i.e.
particularly where high bottomhole pressures may exist such as in
injection wells.
 4.3 Classification of Packers
The primary method of classifying packers
is with regard to their permanency in the
hole,i.e. whether the packer is retrievable
or permanent.

The retrievable packer, as the name

suggests, can be unset and pulled from
inside the casing normally by manipulation
which allows the reversal of the setting
process to take place.

A permanent packer , is designed to

remain in the hole and although it can be
pulled from the hole, the retrieval process
is not simply the reverse of the setting
procedure.
 5. Wireline Serviced Nipple and Mandrel
Systems
A nipple is a tubing sub which has a box and pin threaded connection, and
a precisely machined and configured, internal bore.

This internal bore will accept a suitably sized mandrel having a matching
external profile which can be run down the inside of the tubing string
using wireline.

The nipple normally provides two facilities:

1. a facility to allow latching of the mandrel within the nipple profile.

2. a sealing capability for the mandrel within the bore of the nipple.

The nipple therefore has to offer a landing/locking profile and a seal bore.
To avoid mechanical damage, the seal bore is generally located beneath
the locking profile.
 5. Wireline Serviced Nipple and Mandrel
Systems
A variety of nipple/mandrel systems are available to offer the following
capabilities:

1. Isolation or plugging of the tubing string for well shut in, or for
hydraulically setting packers.

2. A ported device which allows communication between the tubing

and the annulus.

3. Emergency closure of the tubing or annular flow conduit by remote

or direct control.

4. The installation of downhole pressure and temperature recording

gauges.

Two basic types of landing nipple are available: the selective and the non
selective (no-go nipple).
 5.2 Selective Nipple
Selective nipples incorporate internal
profiles that enable the associated slickline
tools and equipment to be run through, or
set in the nipple profile, under the control
of the slickline unit operator.

It is important that the selective nipples are

run sequentially and that a note of the
depth of each nipple is made to assist
mandrel placement during subsequent
work.

Representation of type R (selective)

and type RN (nogo) locking mandrels
 5.3 No-go Nipple
A nipple that incorporates a reduced
diameter internal profile that provides
a positive indication of seating by
preventing the tool or device to be set
from passing through the nipple.

In many completions, a no-go landing

nipple is preferred for the deepest
nipple location, providing a no-go
barrier to protect against a tool
string being run or dropped below the
tubing string.

No-go nipple profile

 6. Subsurface Safety Systems
For well isolation or closure under normal operating conditions, the
production wing valve and master gate valve will be used.

The advantage of these valves is that if the valve malfunctions, then it can
be repaired or replaced with little difficulty. These valves are therefore
defined as being the primary closure system for the well.

However, in the absence of an effective surface closure system, well

security is endangered. This could occur in a variety of situations:

1. Xmas tree removal during workover preparations to pull tubing.

2. Removal of valves or valve components for servicing.

3. Accidental damage to Xmas tree.

4. Leakage on wellhead - Xmas tree flange seals.

 6. Subsurface Safety Systems
To provide some degree of security in the event of any of the above
situations occurring, it would be ideal to have a safety valve system
located beneath the wellhead within the tubing system. This component is
termed a Sub-Surface Safety Valve or SSSV.
These valves are available based upon two different control philosophies,
namely:
1. Direct Controlled SSSV (D.C.SSSV) which are designed to close when
downhole well conditions of pressure/flowrate vary from preset
design values. These valves are often referred to as "storm chokes".
2. Remotely or Surface Controlled SSSV (S.C.SSSV) whereby closure and
opening of the valve is actuated and accomplished using a surface
control system which feeds hydraulic pressure directly to the
downhole valve assembly.
Both valve systems are designed to provide protection in the event of a
catastrophic loss of well control.
 7. Tubing-Annulus Circulation Equipment
One vital operation which frequently has to be performed on a well is to
circulate between tubing and annulus. This is required during the
following situations:
1. To displace out the tubing contents during completion to provide a
fluid cushion which will initiate production. This is normally done by
displacing down the tubing and taking returns up the annulus, i.e.
forward or normal circulation.
2. To displace out the tubing contents to a heavier kill fluid to provide
hydrostatic over balance of reservoir pressure prior to pulling tubing
or other workover activities.
3. To allow continuous or intermittent injection from the annulus into
the tubing of fluids, e.g., gas for a gas lift process.
There are four principal items of down hole equipment designed to
provide selective communication capability: Sliding side door or sliding
sleeve, Side pocket mandrel with shear valve, perforated joint and Ported
nipple
 7.1 Sliding Side Door
Function
Provide communication between tubing &
annulus reservoir.
Application
Fluids Circulation
Fluids Displacement
Well Killing
Production Access.
Placement
As close as possible above top production
packer.
Above each reservoirs perforation.
7.1 Sliding Side Door
 7.2 Side Pocket Mandrel
SPM originally designed for gas lift system but it also used
for communication device.
The side pocket tubing mandrel consists of a tubing
mandrel with ports located on its outside wall.
Side pocket mandrels can be of round or asymmetrical
oval cross section but at one side of the mandrel, an inner
sleeve or pocket is located.
This side pocket has ports in the outer wall of the mandrel
through which communication between the annulus and
tubing can be accomplished.
Using wireline tools a variety of valve devices can be
installed and retrieved.
7.2 Side Pocket Mandrel
 7.3 Perforated Joint
Function
Eliminate flow restrictions.
Provide true downhole readings.
Prevent instrument vibration.

Application
True production data acquisition.
Construction Perforated Holes

Tubing pup joint perforated with

greater flow areas than tubing
Placement
Installed above gauge hanger
landing nipple.
7.3 Perforated Joint
 7.4 Ported Nipple
Function
Provide communication between tubing &
reservoir.

Application
Production access in sand accumulation
zones.

Construction
Short Tubular
Nipple Profile
Seal Bores
Flow Ports

Placement
Installed above sand accumulation zones
reservoirs perforation.