CHAPTER 5:

WELLBORE COMPLETION CONCEPTS AND

DESIGN

CGE578: DRILLING ENGINEERING II

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CONTENTS
• Definition of Well Completion
• Types of Well Completion
• Factors affecting well completion
design
• Completion String Components
and Functions

Example of WCP Schematic Diagram

(Source: Internet)
 E-BOOKS

1. Petroleum Engineering Handbook - Howard B.

Bradley
2. Petroleum Production Systems – Prentice Hall
3. Production Operations – Volume 1 & 2 (Well
Completion, Workover & Stimulation)
 Well completion is a series of activities
DEFINITION OF
to prepare a newly drilled well for
WELL COMPLETION
production of oil and gas or other
purpose such as injection. It cannot be
Well completion being describe as designed/ operated alone. Must joint
the assembly of downhole tubular effort with other sub-disciplines such as
and equipment required to enable production engineering and reservoir
safe and efficient production from engineering
an oil or gas well so that the well
can be flowed in a controlled
manner.
 COMPLETION PROCESS

Reservoir Well Completion

Reserves Completion Fluid
Pressure Perforations
Artificial Lift
Fluids Completion Accessories
Saturations Sand Control
Characteristics Stimulation

Rock
Zones
Properties Well Construction
Well Type
+ FDP
Mud
Drilling particulars
Economy No of Wells Casings
Revenues Architecture Tubing Size
Expenses Prod Rates Cementing
 DESIGN AND COMPLETION
OBJECTIVES

1. Provide communication between the reservoir & the well

2. Optimize production/injection performance
3. Ensure safety – safe for production oil e.g. to control sand
production. Unconsolidated? Consolidated?
4. Maximize the integrity and reliability of the completion over
the completed well life
5. Minimize the total costs per unit volume of fluid produces or
injected (e.g. cost of maintaining production)
6. Facilitate future workovers and abandonment options
 WCP: DESIGN PROCESS
But, well completion is
The well is designed BOTTOM to
drilled TOP to TOP
BOTTOM

Production packer ID
Tubing

ID
Prod Casing
 WCP : DESIGN
CRITERIA
• Profitability: provides production
optimization and minimize operating
cost over its life.
• Flexibility: for handling the current
and future problems.
• Simplicity: to allow the most efficient
installations and maintenance
activities.
 • Production casing to be set above the zone
TYPES OF WCP: OPEN of interest and prior to drilling.
HOLE • Simplest & cheapest completion (no
equipment requires to be installed)
• Drawback – all zones open to flow, no
control, open hole only applied in
consolidated formation in a range of
environment;
• Low cost
• Deep wells, consolidated with depletion
drive
• Naturally fractured reservoir
• Some horizontal and multi lateral wells
• Borehole may become unstable – collapse
or formation at production of sand may
occur
 Advantages Disadvantages
TYPES OF WCP: OPEN
HOLE No perforation Excessive water or
expenses gas production is
difficult to control
Maximum diameter Open hole section
opposite pay zone may require frequent
clean out
Easy to convert to Not suitable for
screen liner unconsolidated
completion formation
Easy to deepen the Pay zone cannot be
well selectively
stimulated
 TYPES OF WCP: • Once drilling through is completed – wire-
TYPES OF WCP:
SCREEN OR PRE- wrapped screen/steel pipe (has slots)/alternative
SCREEN OR PRE- sand control screen will be installed
SLOTTED LINER
SLOTTED LINER • Principal purpose – to prevent any produced
sand from migrating with produced fluids into
production flow string
• Success of completion in controlling sand
production – depend on screen or slot sizes and
the sand particles sizes
• But slots may quickly become plugged and
impede flow resulting - loss in productivity
• Sometimes system used in inclined/high angle to
prevent major borehole collapse or facilitate the
passage of logging tools
 • Low cost technique (cost of a screen to cover the
TYPES OF WCP: reservoir interval <cost of a casing string run to
SCREEN OR PRE- surface & cost of cementing and perforating)
SLOTTED LINER • Drawback – all zones open to flow, no control
• Application - control production of formation
particles from weaker formations:
• Reservoir with large & homogeneous sand
grains
• Some horizontal & multilateral wells
• Open hole Gravel pack
 • Common type of completion
• Install either a casing string (extend back to surface)
TYPES OF WCP: @ a liner (extend back into the shoe of the previous
CEMENTED AND casing string)
PERFORATED • Cemented in place by the displacement of a cement
slurry into annular space between the outside wall of
CASING/LINER casing and the borehole wall
• Casing and cement sheath will be perforated at selected
locations using explosive charges contained in a
perforating gun
• Provide flow paths for fluid to enter the wellbore from
formation or vice versa
• Effective completion
• hydraulic seal being located in the casing-formation
annulus by the cement
• Success primary cement job – provide zonal isolation
behind casing
• Failure of cement – lead to fluid migration behind
casing to surface into another zone
 • Involves greater costs and time
• Full length of casing (from surface to the base of well)
TYPES OF WCP: • Cost of perforating, cementing and additional time to
CEMENTED AND complete the borehole
PERFORATED • Use of liner – reduce the required length of tubular &
CASING/LINER overall cost
• Ability
• Control depletion of individual zones
• Isolate the inflow of undesirable produced fluids
• Control the injection of fluids into zones are essential
to a large number of development
 TYPES OF WELL COMPLETION-
SUMMARY
Open Hole Gravel Pack Perforated Perforated
Open Hole Casing Liner
 COMPLETION STRING DESIGN
It is the practice of completing a well so that hydrocarbons from two or more formations may be produced
Multiple Zone simultaneously or separately.

Completions
 COMPLETION STRING DESIGN

Downhole
Comingling
 FACTORS AFFECTING WELL COMPLETION
DESIGN

• Location of the field

1) Natural • Depth of the reservoir
Occurrences
• Physical Condition of the reservoir (Thickness, no. of layers, connection)
of the field
• Reservoir Pressure (Artificial lift?)
• Drive mechanism (Determine whether completion interval will have to be adjusted
as gas-oil or water-oil contacts move)
• Water drive - indicate water production problems
• Dissolved gas drive – indicate artificial lift
• Dissolved gas and gas drive – declining productivity index and increasing gas-
oil ratio
• Fluid Properties (Commingled or separate zone)
• Rock Properties (Consolidated or Unconsolidated?)
 FACTORS AFFECTING WELL COMPLETION
DESIGN

• Production rates – Determine tubing size

2) Potential of
• Type of production – Use primary drive mechanism or artificial lift
Oil
production • Future workover – Dictate a completion conducive to wireline or through-tubing
type recompletion systems
and the
planning of • Stimulation jobs – Consider material used and avoid using screen and liner
completions
tertiary
recovery • Secondary recovery – Producer can be converted to injector at minimum cost -
Require a completion method conducive to selective injection or production
• Tertiary recovery – Ensure materials used in the well can resist chemical attack
• Thermal Recovery – Check temperature rating of the equipment, require special
casing and casing cementing materials
 FACTORS AFFECTING WELL COMPLETION
DESIGN

• Subsurface equipment – Selection of completion depends on the type and number of

3) Limitations subsurface equipment used, i.e.: single tubing to dual tubing strings
within the • Quality of primary cementing – Cementing in screen and liner completions is more critical
operation and than primary cementing
the field • Deviation of hole – Minimize the no. of subsurface equipment used in the well.
• Water or gas coning – Perforated casing or perforated liner completions could be use to
face this problem.
• Formation damage - Perforated casing or perforated liner completions may cause serious
formation damage. Extra precaution need to be carried out.
WELL COMPLETION
COMPONENTS

Surface
Equipment

Sub-surface
Equipment
 SURFACE EQUIPMENT
• X-mas tree
• Wellhead
• Surface Safety Valve
 SUB-SURFACE EQUIPMENT
Sub-surface Equipment

Subsurface Safety Flow Control

Equipment Equipment Communication
Auxiliary Equipment
Equipment

SCSSV Flow Couplings

Sliding Sleeve Double Pin Sub
Safety Valve Landing Blast Joint Straight-Slot or J-slot
Nipple body
Side Pocket Gas LIft Mandrel
Choke/ Regulator
Production Mule/ Guide shoe
Packer
No-go landing
nipple Rigid Blade tubing
centralizer
Tubing Plug

Seal Units

Check valve for

injector

Selecting
Landing Nipple
 • Design of the completion string involves the selection
CPL STRING and specification of all component parts of the string
COMPONENTS/ • Selecting equipment should be done on the basis that
ACCESSORIES the component will provide a specific facility deemed
necessary to the successful performance and
operation of the well under range of operating
scenarios
• Primary completion string functions:
1. Withstands anticipated pressures during
production and well operations (e.g. stimulation)
2. Produce or inject into the reservoir with minimal
loss of flowing pressure
3. Minimize reservoir fluid contact with the
production casing (annulus isolated from the
production tubing)
4. Remote downhole shut-in when required
5. Selective circulation between annulus & tubing
6. Install a plug in the tubing (e.g. for pressure testing)
CPL STRING COMPONENTS/ACCESSORIES

Wellhead /
Xmas Tree
CPL STRING COMPONENTS/ACCESSORIES

• A typical well head assembly for a 3-string casing

Wellhead consists of:-
1. A-section: casing head (or Braden head)
2. B-section: casing spool (or intermediate head)
3. C-section: tubing head (or production head)
4. X-mas tree (or production tree)
• Wellhead provides the basis for the mechanical
construction of the well at surface or the sea-bed:-
• Suspension of all individual casings and tubulars,
concentrically in the well
• Ability to install a surface closure/flow control device on the
top of well
• A blowout preventer stack whilst drilling
• A Xmas tree for production or injection
• Hydraulic access to the annulus between casing to allow
cement placement and between the production casing and
tubing for well circulation.
CPL STRING COMPONENTS/ACCESSORIES

• Purpose of the Xmas is to provide ;

Xmas Tree
• Valve control of the fluids produced from @ injected into the well
(normally flanged up to the wellhead system after running the
production tubing)
• Facility for suspending casing strings and production tubing in the
well
• Comprises 2 wing valve outlets ( 1-production & 1 injection)
 3rd outlet – provides vertical access to tubing – wireline
• Lower valve (master valve) –controls all hydraulic and mechanical access
to the well
• Manually operated or in sophisticated platform systems and subsea
remotely controlled by hydraulic valves operated from a control room
CPL STRING COMPONENTS/ACCESSORIES

Xmas Tree • Features and access

(Cont.) requirements
• Outflow from well – production
• Inflow to well – injection or killing
• Vertical access to tubing – wireline
• Access for electrical cable or
hydraulic conduits
• e.g. safety valve
CPL STRING COMPONENTS/ACCESSORIES

• There are many designs and configuration of trees commonly in

Xmas Tree
use. However, almost all will be assemble with the following
Components
components:
1. Pressure gauges – allow well pressure to be monitored. Tubing
head pressure, casing or annular pressure are generally
monitored with permanent gauges fitted to the Xmas tree
2. Gauge flange / tree cap – provides a seal for the top of the tree
but is removed when access to the tubing is required (e.g. slick
line work)
3. Swab valve – upper most valve of the tree, used to isolate
pressure and allow access to the well for intervention tools such
as wireline or coiled tubing
CPL STRING COMPONENTS/ACCESSORIES

Xmas Tree 4. Production wing valve – first valve on the production

Components wing used to isolate the well for most routine
(Cont.)
operations (the easiest to replace in the event of
damage or cutting out of the valve)
5. Kill wing valve – enables connection of pumping
equipment for treatment without interfering with the
production wing.
6. Choke – controls the rate of flow from the well (may
be remotely controlled)
CPL STRING COMPONENTS/ACCESSORIES

7. Master valves – the main isolation valves for the well. The master
Xmas Tree valves are open for most of the well’s life and used as little as
Components possible since any fault would require an interruption in production.
Two master valves are generally required (legislative requirement)
-Cont.
• Upper Master Valve – often a hydraulically controlled valve
which is often linked to emergency production shutdown
systems  which used in preference to the Lower Master
Valve due to ease of repair or replacement
• Lower Master Valve – commonly a manually operated valve
and remains open in order not to wear it out. It is considered as
back up for the Upper Master gate Valve
CPL STRING COMPONENTS/ACCESSORIES

Flanged
Xmas Tree
CPL STRING COMPONENTS/ACCESSORIES

• A monoblock tree comprises an inline or “Y” shaped of a single casting/forging. It has less external
Monoblock seal area than a flanged Xmas tree. The valves arrangement:

Xmas Tree • Lower valve – a manual master gate valve

• Upper master valve – a remotely controlled master valve
• Y piece or side outlet flange – houses both choke and kill wing valves. Normally the production
flow wing is a remotely controlled valve. The kill wing valve is either manually or remotely
operated
• Uppermost valve – manually operated swab valve
CPL STRING COMPONENTS/ACCESSORIES

Xmas Tree
Selection
CPL STRING COMPONENTS/ACCESSORIES

Multiple
Completions -
Xmas Tree
https://production-technology.org/tag/the-difference-between-a-wellhead-christmas-tree/
CPL STRING COMPONENTS/ACCESSORIES

• Control devices that are used to

Sub-surface interrupt well production when
safety valves there is an emergency
• Purpose : to prevent uncontrolled
flow from a well if either the
wellhead is damaged or is unable to
control the flow of fluids from the
well
• Why install?? Protect people,
property and the environment in
case of blowout from human error,
collision, equipment failure, fire or
leaks
Example of SSCV: (Source:
CPL STRING COMPONENTS/ACCESSORIES

• Remotely controlled and directly controlled systems.

Sub-surface • To provide remote sub-surface isolation in the event of a catastrophic failure of Xmas tree
safety valves or as a failsafe shutdown system.
• Type of SSSV
-Cont.
1. SC-SSV (Surface Controlled Subsurface Safety Valve)
• Remotely controlled from the surface
• Widely employed and more reliable.
2. SSC-SSV (Subsurface Controlled Subsurface Safety Valve)
• Actuated by the flow characteristic of the well
• Installed by wireline.
CPL STRING COMPONENTS/ACCESSORIES

• Production Tubing (not just a “piece of pipe”).

Production • Special equipment manufactured to a high standard to withstand for long periods in an often
corrosive environment with high mechanical stress & fluid pressure and temperatures.
Tubing
• Failure to select & correctly install a suitable tubing results in expensive workovers or loss of
the well.
• Grade of steel: e.g. N80,C75 – define tubing strength requirements, CO2 & H2S.
• Tubing wall thickness (weight/foot of tubing). Control tubing tensile strength to resist
different in internal an external pressures.
• Coupling. Define the completion string’s tensile strength.
CPL STRING COMPONENTS/ACCESSORIES

• Contains an off-center pocket with ports into the annulus. Using

Side pocket wireline or coiled tubing, a valve can be installed in the packer which
mandrel allows fluid between tubing and annulus, e.g.:

(SPM)/ Side • Gas lift: when landed in, the SPM responds to the pressure of gas
injected into the annulus, or tubing pressure at the valve depth, to
pocket side open the valve and allow gas injection into the tubing
door • Chemical injection valves. Valves allow the injection of chemicals
such as corrosion inhibitors  valve opened by annular pressure
• Circulation : To allow circulation of kill fluids at the placement of
a lower density fluid cushion  valve installed can be sheared by
pressure allowing communication
• Permanent Downhole Gauge.  Gauge to measure pressure (tubing
pressure and/or annulus pressure) and/or temperature, which help
to increase productivity life of the well production.
CPL STRING COMPONENTS/ACCESSORIES

• Purpose
Slide sleeve • To enable communication between tubing and annulus
door or to enable circulation or production of fluid.
sliding side • To equalize tubing pressure and the annulus pressure
door • Features
• Cylindrical device with an internal sleeve mechanism.
• Both the inner sleeve and outer body are bored to
provide matching openings.
• Communication is established when the slots of the
inner sleeve is aligned with the opening on the outer
body.
• The sleeve is packed off by 2 sets of packing which
isolate the annular fluids and pressure when closed.
• It has a nipple profile at the upper end
CPL STRING COMPONENTS/ACCESSORIES

• Sleeve has to moved down to open

Slide sleeve communication with annulus –
door or depending on type – some move up
sliding side to open
door • To open sleeve a shifting tool is used

-Cont. • Some sliding side doors have a

landing nipple as part of device
CPL STRING COMPONENTS/ACCESSORIES

• Most common method to provide an annular

Annular seal. Functions:
pressure seal • Improves flow stability and
(Packer) production control
• Protects the outer containment system
/equipment such as the production
casing and the wellhead
• Selectively isolate zones e.g. 2
producing zones having different fluid
properties, GOR, pressures.
• The pack-off is accomplished by expanding
the elastomer element outwards from the
packer body until it contacts the casing wall
CPL STRING COMPONENTS/ACCESSORIES

• Packer Retrievability
Annular 1. Retrievable packers : can be easily retrieved, the packer is integrated in the tubing string, the
pressure seal packer is run to the setting depth
(Packer) 2. Permanent Packer: cannot be easily retrieved, usually run & set separately (on wireline), the
tubing string is run later & engages the packer to achieves a pressure seal

-Cont. • Three types of packers

1. Permanent packers : are widely used as the only packer in a well or as the bottom-most packer
2. Hydraulically – set packers : are normally used as intermediate packer or top-most packer.
3. Mechanically – set packers : are hardly used in production well
• The two most important basic component of a packer construction are the slips and the
sealing/packing elements
• Slip – designed to resist force for either direction
• Sealing elements – must be compressed to affect a seal against the casing wall
CPL STRING COMPONENTS/ACCESSORIES

Annular • It is a sub surface equipment used to seal the

pressure seal annulus between the tubing string and production
Production casing
Packer • Used as an isolation packer- to isolate non-
productive zone and also equipment above the
topmost packer from reservoir fluid and pressure
• Elimination of surging or heading
• To separate multiple zone
CPL STRING COMPONENTS/ACCESSORIES

• A landing nipple is a short device with internally machined profile that can secure plug
Landing run on wireline or coiled tubing
nipples • Purpose : To provide receptacle to locate, lock and seal sub- surface flow controls
equipment.
• Features : Short sections of thick-walled tubulars that are machined internally to
provide a locking profile and at least one packing bore.
• Installation : It can be installed at any location within the tubing string & completion
can have as many landing nipples as desired in the tubing string.
• Nipples installed at various points in the string for: (1) Plugging the tubing for pressure
testing, hydraulic packer setting & zonal isolation. (2) Installing flow control
equipment for downhole chokes, SSSVs & pressure recorders
CPL STRING COMPONENTS/ACCESSORIES

Perforated
• This is a length of tubing with holes punched
Joint into it.
• If used, it will normally be positioned below
the packer and will offer an alternative entry
path for reservoir fluids into the tubing in case
the shoe becomes blocked, for example, by a
stuck perforation gun.

Example of PJ:
(Source: Internet)
CPL STRING COMPONENTS/ACCESSORIES

• This component is often installed at the end of the tubing, or "the shoe".
Wireline • It is intended to make pulling out wireline tools easier by offering a guiding surface for the
Entry Guide toolstring to re-enter the tubing without getting caught on the side of the shoe.

Example of
WEG: (Source:
 • Discuss the application of the following
EXERCISES components in well completion
operation:
1. Wellhead / Xmas Tree
2. Sub-surface safety valves
3. Side pocket mandrel (SPM)
4. Slide sleeve door @ sliding side door
5. Packer
6. Landing nipples
7. Perforated Joint
8. Wireline Entry Guide
 EXAMPLE: WCP
DUAL STRING
DESIGN

List all the equipment/assembly according to the

string:
• Short String:

• Long String: