CAN PREVENT

THIS

WELL INTERVENTION CERTIFICATION COURSE

Chapter 1

COMPLETION EQUIPMENT

1

Well Completion

Last process of completing a petroleum well after the installation of casing, cementing job & perforation.

Series of tubular (tubing & completion accessories) are run & placed to enable the well to produce or inject, accordingly.

Xmas tree is positioned on top to regulate or isolate flow.

Single or multiple string determined by the reservoirs.

Vertical or horizontal completion determined by reservoir geological aspects.

Conventional or monobore completion determined by the fields economics.

2

Completion Equipment

Various type of equipment installed with production tubing string & each of them with its specific function.

The essential type of equipments install in completion string are:

1. Production Packer

2. Circulation Device

3. Sub-Surface Safety Valve (SSSV)

4. Landing Nipple

5. Other Accessories

6. Tubing Hanger

7. Wellhead & Xmas Tree

NOTE:

All illustration are not to scale3

PRODUCTION PACKER

4

A mechanical device connected with production tubing serves as downhole barrier.

Production PackerFunction

Seal between tubing & casing.

Prevent fluids movement due to pressure differential.

Seal between multiple zones

Contained reservoir fluid within tubing.

Isolates casing from reservoir fluids & corrosion fromwell effluents or injection fluids

Application

Use in high pressure & highly corrosive reservoirs.

Placement

Position above perforation & away from casing collar.

NEVER set packer across casing collar.

EOT of tailpipe shall be 10ft above perforation.

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Perforation

Casing

Casing Collar

Tubing

Packer

Production Packer

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Slips

Slips

Packer

Seal Element

Body

Construction

Body

Hardened Slips

Packing Element

Shear Pins

Setting Mechanism

Mechanical (Manipulation of string)

Wireline Set (Electrical & Explosive)

Hydraulically Set (Using Pressure)

Production Packer

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Permanent Packer

Single Retrievable Packer

Dual Retrievable Packer

Production Packer Variant

1. Permanent Packer

Single String

2. Retrievable Packer

Single String

Dual Strings

Permanent Packer

Integral part of casing.

Removed by milling operation.

Wireline set.

Retrievable Packer

Integral part of tubing.

Can be retrieved & redressed.

Hydraulically set

Packer Installations

8

Single Zone Completion

Single String Multi Zones Completion

Dual Completion

Retrievable Packer Accessory

Travel Joint

To compensate tubing movement due to temperature and/or pressure changes during treating or production.

Install on the short string for dual completion.

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Permanent Packer Accessories

10

ATA LTSTSR

PBRLocator Tubing Seal (LTS) Seals assembly with locator

providing effective tubing/packer seal.

Anchor Tubing Assemblies (ATA) Seal assembly with anchoring

feature.

Polished Bore Receptacle (PBR) Polished ID tubular installed on

top of packer to accept male tubing seal assembly.

Tubing Seals Receptacles (TSR) PBR Inverted version attached on top

of packer to accept female tubing seal assembly.

Seal Bore Extension Same packer ID tubular connected to the bottom of packer to

accept male seal assembly & milling spear or tool.

CIRCULATION DEVICE

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A mechanical device serves to provide communication between tubing & annulus.

Circulation DeviceFunction

Provide communication between tubing & annulus or reservoir.

Eliminate false production data.

Application

Fluids circulation.

Fluids displacement.

Gas lift.

Production access.

Well killing.

Production data acquisition

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Variants of Circulation Devices

1. Sliding Side Door (SSD).

2. Side Pocket Mandrel (SPM).

3. Perforated Joint.

4. Ported Nipple.

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SPM

Ported Nipple

SSD

PERFORATED JOINT

Circulation Device

Function Provide communication between tubing &

annulus or reservoir.

Application

Fluids Circulation Fluids Displacement Well Killing Production Access.

Construction

Seal Bores Inner Sleeve Nipple Profile Self Equalizing Ports

Placement

As close as possible above top production packer. Above each reservoirs perforation

SSD

14

SSD

Nipple Profile

Seal Bore

Equalizing Port

Flow Port

Inner Sleeve

Seal Bore

SSD

15

Straddle Tool

Equalizing Sub

Mandrel Extension

Lower PackingAssembly

Lock MandrelAssembly

Isolation Tool

Isolation Sub

Variants

Jar To Open

Jar To Open

Larger Flow Ports

Smaller Flow Ports

Disadvantage

Inner sleeve may stuck due to sand or other substance sticking.

Advantage

More than one SSD can be installed in one tubing string.

Can set Straddle Tool. Can set Isolation Tool.

Straddle Tool

Blank off top zone & bottom zone to flow.

Tool Construction:

Lock Mandrel Equalizing Sub Mandrel Extension Lower Packing Assembly

Separation Tool

Blank off bottom zone & top zone to flow.

Tool Construction:

Lock Mandrel Separation Sub Mandrel Extension Lower Packing Assembly

SSD Accessories

Side Pocket MandrelOriginally designed for gas lift system but it also

used for communication device.

Feature:

Full tubing bore

Orientating sleeve

Discriminator

1 or 1 valve pocket

Valve Type:

Dummy Valve (DV)

Gas Lift Valve (GLV)

Chemical Injection Valve (CIV)

Circulation Valve (CV)

Differential Dump Kill Valve (DDKV)

Equalizing Valve (EV)

All valve utilize Latch to lock in pocket. 17

SPM

Full Tubing Bore & Pocket

Orientating Sleeve

Discriminator

Receptacle

DVGLVLATCH

Perforated JointFunction

Eliminate flow restrictions. Provide true downhole readings. Prevent instrument vibration.

Application

True production data acquisition

Construction

Tubing pup joint perforated with greater flow areas than tubing.

Placement

Installed above gauge hanger landing nipple.

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Perforated Holes

Collar

PERFORATED JOINT

Perforated Joint Application

19

With Perforated JointWith Out Perforated Joint

Gauge Gauge

Nipple Nipple

Flow Flow

Flow turbulence created in nipple. Gauge vibrate (gauge damage). False data acquisition.

Flow thru nipple & perforated joint. No vibration (gauge safe). True data acquisition.

FlowFlow

Ported NippleFunction

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

20

PORTED NIPPLE

Port

Seal Bore

Seal Bore

Profile

DHSV

21

A mechanical downhole barrier serves toprevent uncontrollable hydrocarbon flow

possible cause by surface impact or explosion

Downhole Safety ValveFunction

Permit flow during normal conditions but would isolate formation pressure from wellhead to prevent damage during emergency.

Application

Medium or high pressure well.

DHSV Type

DCSSV

SCSSV

Valve Closure

Ball Flapper Poppet

22

Remote controlled by hydraulic pressure, set only in designated nipple & can be integrated with pilots, ESD & surface safety manifolds.

Direct activated by surrounding pressure & can be set anywhere in tubing string.

Closed Open

BALL TYPE

Closed

Open

FLAPPER TYPE POPPET TYPE

Closed Open

DCSSVThese valves are installed in appropriate landing nipples with

wireline lock mandrel.

Types of DCSSV (Closure Mechanism - Poppet or Ball Valve )

1. Pressure Differential Safety Valve

2. Ambient Safety Valve

3. Injection Valve

4. Bottom Hole Regulator

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A Normally Open valve utilizes pressure-differential to close valve. Pressure differential exceeded pre-set spring & forces it to close. Adjustable bean size can be set for pressure differential. Surface pressure will equalize & open valve.

A Fail Safe valve utilizes pre-charged dome pressure. Well pressure reaches the pre-set dome pressure & open the valve. When well pressure drops below pre-set dome pressure the valve will close.

A Normally Close valve. It serves like a check valve allowing passage of injected fluid but close when injection ceased.

A throttling valve installed downhole to enhance overall well safety where high surface pressure & hydrates formation present problems. In gas well it increase downhole temperature & prevent hydrates formation. In oil well it liberate gas & lighten oil column to increase flow velocity.

STORM CHOKE

Pre-Charge Connection

Spring

Ball Valve

Lock Mandrel

Connection

SCSSV

24

SCSSV Variants

WRSV

TRSV

SCSSV Construction

Body Piston Spring Flow Tube Valve (Ball or Flapper)

SCSSV Placement

Set below crater depth Above control line hydraulic fluid

hydrostatic head.

WRSV

Lock Mandrel

Piston

Spring

Flow Tube

Flapper

Packing

Fluid Inlet Port

WRSV

25

WRSV SV Nipple

TRSV

26

TRSV With Insert ValveTRSV Close TRSV Open TRSV Lock Open

Flapper

Spring

Flow Tube

Lock Open Sleeve

Lock Open Profile

Ratchet Profile

Nipple Profile

Safety Valve Integrity Test

Integrity Test

Leak test are performed immediately after DHSV are installed & periodically to accomplish 3 functions;

1. Integrity of safety valve seals

2. Integrity of WRSV lock assembly

3. To cycle valve prevent freezing after setting for extended periods of time.

NOTE:

Only authorized personnel should conduct all the above test on all SSSV.

27

Annulus Safety Valve

A Fail Safe Close device that isolate flow of gas between above & below the tubing/casing annulus.

Function

Provide control in annulus if tubing hanger is breached.

Application

Artificial lift or secondary recovery production wells.

Closure Mechanism

Sliding sleeve Poppet Flapper

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29

Annular Safety Valve

Surface Control Manifold

Function

Provide & control the hydraulic pressure required to hold SCSSV & SSV open.

Construction & Operation

One or more pneumatic hydraulic pumps to maintain hydraulic operating pressure for the safety valve.

3 way valve controlled by remote pressure pilots & fire sensors which is controlling the safety valve hydraulic pressure

Pilots, sensors or manual activation removes the hydraulic pressure thus close the safety valve.

Sequential Opening & closing Logic

1. Closing

SSV 1st

SCSSV 2nd

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2. Re-Opening SCSSV 1st

SSV 2nd

LANDING NIPPLE

31

A receptacle in tubing string for FCD.

Landing NippleFunction

Receptacle for Flow Control Device (FCD).

Application

Production wells.

Construction

Profile (to secure locking mechanism) Seal Bore No-Go shoulder (provide positive location in highly deviated well).

Type

Non-Selective Nipple Selective Nipple Ported Nipple Safety Valve Nipple

32NON SELECTIVE NIPPLE

(Bottom No-Go)

Profile

Seal Bore

No-Go Shoulder

SELECTIVE NIPPLE

(Top No-Go)

PORTED NIPPLE

Port

SV NIPPLE

Control Line Port

Landing NippleNon-Selective Type

Smallest ID in tubing string.

Only one installed in tubing

Bottom No-Go

Selective Type

Several nipples of same size installed

Top No-Go

Placement

Non-Selective

Bottom most nipple

Selective

Strategic point for FCD

Immediately below production packer

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OTHER ACCESSORY

34

Wireline Entry Guide

35

HALF MULE SHOE WEG

45 Angle

BELL GUIDE WEG

45 Taper

Function Provides safe re-entry of WL tools.

Construction

Its chamfered internal end prevent tool hung-up.

Placement

Attached at the end of tubing or tail pipe.

Type

1. Half Mule Shoe

Incorporate large 45 angle cut on one side to facilitate entry of permanent packer top.

2. Bell Guide

Incorporate 45 lead in taper to allow re-entry of WL tools into tubing.

Blast Joint

Function

Withstand external abrasive action from formation fluids.

Construction

Medium length (20) with SS heavy-wall.

Placement

Installed opposite perforations (for non-gravel pack completion).

36

BLAST JOINT

Flow Coupling

Function

Withstand internal corrosion caused by flow turbulence.

Construction

Short tubular with SS heavy wall.

Placement

Installed DS FCD which caused turbulence e.g. Nipple, SSD, SCSSV.

High velocity & high pressures wells installed both US & DS.

37

FLOW COUPLING

DS Flow Coupling

US Flow Coupling

Landing Nipple

with FCD

Control Line

Function 1 conduit connected to SVLN or TRSV that supplies

hydraulic fluid to SCSSV & terminated at tubing hanger.

Application

Clamp to tubing external by protector

Materials

316 SS for sweet service INCONEL or ELGILOY alloys for sour service

Note

NOT recommended to splice control line.

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Tubing

Function

Medium to convey well fluids from wellbore to surface or vise versa & prevent well effluents expose to casing.

Thread Connections

API: Tapered thread & rely on thread compound to effect seal

Premium: Metal-to-Metal seal

Tubing Selection Governed By:

Well peak production rate

Well depth

Use of WL tools

Pressure & temperature

Annulus differential pressure etc

39HYDRIL CS Connection

Metal to Metal Seal

API EUE Connection

Tapered Thread

TUBING HANGER

40

Function Suspend tubing string with threaded

connection Isolate casing tubing annular Provide access to annular space (A

annulus) & control line. Receptacle for BPV

Hanger Type

1. Bowl & Mandrel Tubing Hanger Combination of Tubing Head &

Hanger

2. Multiple Mandrel Tubing Hanger

Use in multiple completion. Similar to No 1

3. Ram Tubing Hanger

Tubing manipulation is necessary to locate/latch & maintain tension

41

TUBING SPOOL

TUBING HANGER

RAM TUBING HANGER

Tubing Hanger

Tubing Hanger

Feature

1. Landing Threads

Uppermost threads on the hanger & support the entire tubing string weight during landing operations.

2. Bottom Thread

Support entire tubing string weight & seal producing conduit from the tubing/casing annulus.

3. Sealing Area

Provide compression type sealing between hanger seal OD & tubing spool ID. Sealing is accomplished by energizing elastomer seals or metal-to-metal seals by tubing weight action on various load bearing surfaces,

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Seal Neck

Seal

Tubing Connection

Profile

Control Line Connection

Landing Thread

Tubing Spool Features1. Connections

Size & pressure rating must be compatible of joining connections.

2. Upper Bowl Provides seal area for tubing hanger

3. Lower Bowl Provide isolation seal

4. Tie Down Bolt Secure & prevent upward movement due to

pressure surges. Energizes body seal on tubing hanger.

5. Outlets Access to A annulus (pressure monitoring or

gas lift).6. Test Port

Permit pressure testing to hanger seal, lock-down screw packing connection between flanges & secondary (isolation) seal.

TUBING SPOOLUpper Bowl

Lower Bowl

Outlet

Test Port

Tie Down Bolts

Tubing Spool

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WELLHEAD & XMAS TREE

44

WellheadWellhead is the assembly of casing spools & tubing spool on top of a well.

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.

Wellhead Types

Conventional Wellhead (modular)

Compact Wellhead (sub-sea)

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CasingAt drilling stage, various casing strings are run & cemented in a well.

1. Conductor

2. Surface Casing

3. Intermediate Casing

4. Production Casing

5. Liner

Function of Casing

Protect against borehole collapse

Prevent unwanted leakage into or from formations

Provide concentric bore for future operations

Provide wellhead foundation

Each type of casing string is suspended in CHH & assembled on module stack that forms wellhead.

46

Casing Type

1 Conductor Pipe

Prevents unconsolidated formations being eroded.

Provides flow path for drilling fluids.

Cemented in pre-drilled hole or pile driven.

Sizes ranging from 16 30 OD.

Depth varies from surface to 40 400.

CONDUCTOR PIPE

Surface Casing

2 Surface Casing

Protection in case of blowout & Acts as wellhead foundation.

Isolates shallow consolidated & fresh water formations.

Cemented along its whole length.

Sizes ranging from 13 20 OD.

Setting depth up to 1 500 below surface.

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SURFACE CASING

Intermediate Casing

3 Intermediate Casing

Seals off problem zones, loss circulation zones, high pressure gas pockets & soft formations encountered.

Protects production casing from corrosive fluids.

Cemented up to surface casing shoe.

Sizes ranging from 7 13 OD.

Depth depends on total well depth & conditions encountered, shallow wells not necessary to set this.

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INTERMEDIATE CASING

Production Casing

4 Production Casing

Isolates reservoir from other fluid bearing formations.

Set above or through producing formations.

Cemented from intermediate casing shoe to its bottom.

Sizes ranging from 5 9 OD.

50

PRODUCTION CASING

Liner

5 Liner

Used when geological & pressure conditions make it hazardous to penetrate the producing formation without the hole being protected by casing.

Shortened casing hangs from bottom of previous casing through producing formations.

Cemented along its length.

Cost effective

51

Liner

Production casing

Intermediate Casing

Conductor PipeSurface Casing

Conventional (Modular) WellheadIts a built up of casing spools. During drilling, drilling BOP is installed above this

casing spool. The drilling BOP must be removed each time a new casing

spool to be installed for next stage of drilling & position the drilling BOP on

top of this new casing spool before drilling commence.

Features:

1 Starter Spool (Conductor Pipe)

2 Surface Casing Spool

3 Surface Casing Hanger

4 Production Casing Spool

5 Production Casing Hanger

6 Tubing Spool

7 Tubing Hanger A Annulus

B Annulus

C Annulus

(Zero Reference point)

VETCOGRAY Subsea Wellhead MS-800

Advantages:

Utilized in shallow water and deep wells

Full-Bore enables to run one extra casing string under BOP control

Option to run 18 and 16 casing strings below the mud line.

Larger completion options, by reaching total depth with a larger production string.

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Energizing RingRetainer Nut

Wicker Profile

Support Ring

Casing Hanger

Debris Trap Area

Compact Wellhead (subsea)

Surface valves manifold to control flow of well fluids & access for well

intervention activities.

Features

1 Lower Master Valve (LMV)

Manual, NOT working valve optimum conditions.

2 Upper Master Valve (UMV or SSV)

Emergency valve

3 Flow Wing Valve (FWV)

Permits passage of well fluids to CV.

4 Choke Valve (CV)

Restrict, control or regulate flow of well fluids.

5 Kill Wing Valve (KWV)

Permits entry of kill fluids into tubing or equalize.

6 Swab Valve (SV)

Permits entry of well interventions.

Xmas Tree

54

The valves used in Xmas tree are invariably of the gate type providing full bore access to the well. These valves must be operated in the fully open or fully closed position.

Xmas Tree Type

1 Solid Block

2 Composite Block

3 Horizontal Xmas Tree

Solid Block Xmas Tree

Contains fewer components (for high pressure gas wells).

SV

KWV WV

CV

LMV

UMV

Tree Cap

Xmas Tree Type

Composite Block Xmas Tree

Valves are located on separate block & jointed by API flange (for medium pressure oil well).

56

SV

LMV

UMV

KWV WVCV

Tree Cap

Horizontal Xmas Tree

New concept used for subsea completion.

57

2nd MV

KV

CV

Tree Cap

Wellhead

Tubing Hanger with double

plugs

1st MV

AV

Xmas Tree

Wellhead spools, valves, chokes etc are installed by means of the

following connection types:

1 Screwed Type

Low pressure application (5000 psi)

API Flanged type are mostly used by Oil Companies even in low pressure

application because its less susceptible to leakage & easier oriented.

What does API Flange specification of 9 5000 psi means?

9 is the ID of the flange & 5000 psi is the WP58

Xmas Tree Valve Operating Sequence

Sequence during RIH & POOH

1 RIH

Close WV & KWV Open UMV Open LMV Open SV

2 POOH

Close SV Close LMV Close UMV

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End of Chapter 1

Any Question?

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