4

Wellbore Completion Concepts

CONTENTS
1 BOTTOM HOLE COMPLETION TECHNIQUES
1.1 Open Hole Completion
1.2 Screen or Pre-slotted Liner Completions
1.3 Cemented and Perforated Casing / Liner
2 SELECTION OF FLOW CONDUIT BETWEEN
RESERVOIR AND SURFACE
2.1 Tubing Casing Flow
2.2 Casing and Tubing Flow
2.3 Tubing Flow Without Annulus Isolation
2.4 Tubing Flow With Annular Isolation
3 COMPLETION STRING FACILITIES
3.1 Basic Completion String Functions and
Facilities
3.2 Additional Completion String Functions
3.3 Composite Completion String
4 COMPLETION STRING COMPONENTS
4.1 Wellhead / Xmas Tree
4.2 Production Tubing
4.3 Provision of an Annular Pressure Seal
4.4 Provision of a Seal Between Tubing and Packer
4.5 Sub-Surface Safety Valves
4.6 Side Pocket Mandrel (SPM)
4.7 Sliding Side Door (SSD)
4.8 Landing Nipples
4.9 Perforated Joint
5 WELL COMPLETION DESIGNS
5.1 Land or Platform Based Completions
5.2 Subsea Completions
SUMMARY

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LEARNING OBJECTIVES:
Having worked through this chapter the Student will be able to:
Evaluate for a given reservoir scenario the bottom hole completion options and
make a recommendation based on well integrity and reservoir management
requirements.
Assess and recommend geometrical configurations for drilled wellbores for
both production and injection applications.
Identify, evaluate and recommend functional capability of completion strings
for a variety of situations.
Describe the purpose and generic operating principles for major completion
equipment components.
Identify limitation of well completion schematical designs and potential
failure mechanisms/operational problems with equipment.
Assess well safety requirements and capabilities inherent in well design.

Wellbore Completion Concepts

INTRODUCTION
In the development of a hydrocarbon reservoir, a large number of wells are drilled and
require to be completed, to allow the structure to be depleted. However, the drilling
and completion operations are crucial to the long term viability of the wells in meeting
the specified objectives. The design and completion of both production and injection
wells are required to satisfy a number of objectives including:
1. Provision of optimum production/injection performance.
2. Ensure safety.
3. Maximise the integrity and reliability of the completion over the
envisaged life of the completed well
4. Minimise the total costs per unit volume of fluid produced or injected, i.e.
minimise the costs of initial completion, maintaining production and remedial
measures.
Depending upon the reservoir characteristics or development constraints, the
completion may be required to fulfil other criteria, e.g. to control sand production.
The design of a completion can therefore be assumed to proceed concurrently at two
different levels. The initial intention would be to produce a conceptual design, or a
series of alternatives. From these conceptual designs, one or more would be selected
for more detailed development. Thereafter, a detailed design process would be
pursued with the intention of producing a completion string design which specifies all
components and also assesses the sensitivity of the well and completion performance
to variations in the reservoir data used for the design.
The fundamental design of a completion consists of four principal decision
areas, namely:
1. Specification of the bottom hole completion technique.
2. Selection of the production conduit.
3. Assessment of completion string facilities.
4. Evaluation of well performance / productivity-injectivity
These four decision areas, as shown in Figure 1, should provide a conceptual design
for the completion of the wells. However, this design process normally is initiated on
the basis of data from exploration wells and considerable uncertainty may exist as to
the validity and accuracy of that data. Thus a number of alternative designs for well
completions will normally be selected and retained as a contingency.

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Subsequently, the detailed design and evaluation of the selected completion concept
will be undertaken. In this phase of the design the objectives will be to:
1. Specify all equipment and materials
2. Optimise completion performance
3. Optimise well performance.
It is essential that at both the conceptual and detailed design stages, an interactive
approach is adopted. The interactive nature of completion design and the diversity of
design data, e.g. reservoir rock and fluid properties, production constraints etc. and the
range of disciplines which have inputs to the decision making process, e.g. drilling
engineers, reservoir engineers and production technologists, necessitates a broad and
far reaching design process. A synergistic approach to completion design is essential.
In this chapter, the decision areas associated with the development of a conceptual
design for a well completion are discussed.

Initiate Design

Conceptual Design

Casing
String
Design

Detailed
Completion
String Design

Final Design(s)

Well
Productivity

Completion
String
Facilities

Selection of
Production
Conduit

Bottom Hole
Completion
Technique

Objective of
this chapter

Well
Performance
Optimisation

Figure 1
Completion Design
Strategy

Wellbore Completion Concepts

1. BOTTOM HOLE COMPLETION TECHNIQUES

Once the borehole has been drilled through the reservoir section of interest for
production or injection, the method by which fluid communication will occur between
the reservoir and the borehole, after completion, has to be decided. There are 3
alternative approaches for the completion of the reservoir zone:
1. Open hole completion
2. Pre-drilled / pre-slotted liner or screen completion (uncemented).
3. Casing or liner with annular cementation and subsequent perforation.

1.1 Open hole completion

The simplest approach to bottom hole completion would be to leave the entire drilled
reservoir section open after drilling, as shown in Fig 2. Such completions are
sometimes referred to as barefoot completions and the technique is widely applied.
Since no equipment requires to be installed there are savings in both costs and time.
However this type of completion does mean that the entire interval is open to
production and hence it often provides no real selective control over fluid production
or injection. It is therefore not recommended for production or injection wells where
distinctive variations in layeral permeability will detrimentally control the sweep
efficiency on zones under water flood or gas injection. Further, in an oil well if water/
gas breakthrough or migration into the wellbore occurs it is difficult to isolate unless
the entry is at the base of the well where isolation with a cement plug may be
successful. The possibility of interzonal cross flow or zonal back pressure dictating
multizone depletion cannot be corrected with this type of completion. This lack of
zonal control for production or injection is a major limitation on the application of this
technique.

OPEN HOLE

Figure 2
Open Hole Completion

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Open hole completions should only be applied in consolidated formations as the
borehole may become unstable once a drawdown in applied to induce the well to flow.
In such cases either total collapse of the formation or the production of sand may occur.
Currently open hole completions are applied in a range of environments
a)
b)
c)
d)

Low cost / multi well developments

Deep wells, consolidated with depletion drive
Naturally fractured reservoirs
Some horizontal and multi lateral wells

1.2 Screen or pre-slotted liner completions

In this technique, once the drilling through completed reservoir section has been
completed, a wire-wrapped screen or steel pipe which has slots or alternative sand
control screen, is installed (Fig 3). The principal purpose of the screen or liner is to
prevent any produced sand from migrating with the produced fluids, into the
production flow string. The success of the completion in controlling sand production
is dependent upon the screen or slot sizes and the sand particle sizes. The screen will
only become 100% effective if it totally restrains sand production which requires that
the slot size be equal to the size of the smallest particles. However, in such cases the
slots may quickly become plugged and impede flow resulting in a loss in productivity.
This system is sometimes used in inclined/high angle angles to prevent major borehole
collapse or facilitate the passage of logging tools.

PRE SLOTTED LINER

( or Alternative)

Figure 3
Well Completed with Wire
Wrapped Screen or Slotted
Liner

This technique also suffers from the same inability for zonal control of production or
injection as exists in the open hole completion and may only effectively control sand
production over a limited range of conditions. However, it is a low cost technique
since the cost of a screen to cover the reservoir interval is much less than the cost of
a casing string run to surface plus the cost of cementing and perforating. However in
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Wellbore Completion Concepts

the case of using premium sand exclusion screens, the cost saving will be reduced.
The technique is therefore only of application as an alternative to the open hole
completion in situations where the reservoir rock consists of relatively large and
homogenous sand grains.

1.3 Cemented and perforated casing/liner

The final choice is to install either a casing string which extends back to surface or a
liner which extends back into the shoe of the previous casing string, which would then
be cemented in place by the displacement of a cement slurry into the annular space
between the outside wall of the casing and the borehole wall (Fig 4). Subsequently,
to provide flow paths for fluid to enter the wellbore from the formation, or vice versa,
the casing and cement sheath will be perforated at selected locations using explosive
charges contained in a perforating gun.

CEMENTED AND
PERFORATED
LINER OR CASING

Figure 4
Cemented and Perforated
Production Casing or Liner

The integrity and selectivity of the completion depends to a great extent on an effective
hydraulic seal being located in the casing-formation annulus by the cement. For the
completion to be effective, a successful primary cement job must provide zonal
isolation behind the casing. The absence or failure of the cement can lead to either fluid
migration behind the casing to surface, into another zone or into perorations from
which it was assumed to be isolated. If required the perforations can subsequently be
closed off by a cement squeeze operation.
This type of completion involves considerably greater costs and time than the previous
options. The cost of a full length of casing from the surface to the base of the well can
be considerable, to which must be added the cost of perforating, cementing and the
additional time necessary to complete the borehole in this way. The use of a liner helps
to reduce the required length of tubular and hence the overall costs. However the
ability to control the depletion of individual zones, isolate the inflow of undesirable
produced fluids and control the injection of fluids into zones are essential to a large
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number of developments and this has resulted in the cemented and perforated liner or
casing being the most widely applied bottom hole completion technique in situations
where enhanced reservoir management capabilities are required.

2. SELECTION OF THE FLOW CONDUIT BETWEEN THE

RESERVOIR AND SURFACE
There are a number of optional methods by which fluid which enters the wellbore will
be allowed to flow to surface in a production well, or to the formation in an injection
well. In the selection of the method, a range of considerations may influence the
choice including: cost, flow stability, ability to control flow and ensure well safety or
isolation; ensuring that the integrity of the well will not be compromised by corrosion
or erosion. In the case of multizone reservoir, the zonal characteristics will determine
to a large extent the flow system selected.
However, for a single zone completion, the following alternatives exist:
1.

Tubingless casing flow.

2.

Casing and tubing flow.

3.

Tubing flow without annular isolation.

4.

Tubing flow with annular isolation.

These options are depicted in Fig 5

TUBINGLESS
COMPLETION

TUBING COMPLETION
WITHOUT PACKER
(with optional
annulus production)

Figure 5
Selection of Production
Condiut
TUBING COMPLETION
WITH ANNULUS PACKER

2.1 Tubingless casing flow

In this option, once the well has been drilled and the bottom hole completion technique
implemented, eg open hole or perforated casing, the well is induced to flow under
drawdown and fluid is produced up the inside of the casing. This technique is very
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Wellbore Completion Concepts

simple and minimises costs. However it is not without its disadvantages. Firstly, the
production casing may be of such a diameter that the flow area is so large that the fluid
superficial velocities are low enough for phase separation and slippage to occur,
resulting in unstable flow and increased flowing pressure loss in the casing. To be
effective, this approach is only applicable for high rate wells. Secondly, the fluid is
in direct contact with the casing and this could result in any of the following:
1.

Casing corrosion, if H2S or CO2 are present in produced fluids.

2.

Casing erosion, if sand is being produced.

3.

Potential burst on the casing at the wellhead if the well changed from oil to gas
production. (Note: This should have originally been considered in the design
of casing for burst but subsequent corrosion or wear may have reduced burst
capacity.)

When a well is required to be worked over, the first requirement is that the well be
hydraulically killed. In this type of completion, the reinstatement of a hydraulic head
of fluid which provides a bottom hole pressure greater than reservoir pressure can only
be accomplished by either squeezing the wellbore contents back into the formation,
or circulating across the wellhead using the Volumetric Technique. Squeezing large
volumes of fluids back into the formation is undesirable in many cases since any rust,
scale or other particulates will be lodged in the perforation or formation matrix. Thus
killing such wells will result in a compromise between safety and subsequent
productivity. In addition, in most squeeze operations, the required injection pressures
would increase as fluids are reinjected and this may cause concern over casing burst
limitations. For the large diameter casing, the heavier full weight fluid may under-run
the lighter hydrocarbon and inhibit the squeeze process.
For the majority of wells, either the productivity does not merit the use of such large
annular diameters or the difficulties in well killing are significant and hence the
application of this type of completion is limited to areas of very high well productivities.
However it can be a fairly reliable completion with a long life and minimal major
workover requirements in view of its very basic design, provided that it does not suffer
from abrasion or corrosion of the production casing.
A variant of this approach is sometimes applied to multiple zones whereby once the
borehole is drilled down through all the zones, individual tubing strings are located
opposite zone, the entire borehole cemented and each tubing string perforated with
orientated guns. This approach is the simplest method of completing a multi-zone
borehole but the drastic nature of its design precludes workovers if problems
subsequently arise. This type of completion is known as a "tubingless completion".

2.2 Casing and tubing flow

For highly productive wells where a large cross sectional area for flow is desirable,
an alternative to the tubingless casing flow would be to install a production tubing and
allow flow to occur up the tubing and the tubing- casing annulus. This type of
completion has the very important advantage of providing a circulation capability
deep in the well where reservoir fluids can be displaced to surface by an injected kill
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fluid of the required density to provide hydraulic overbalance on the reservoir. This
capability to U-tube fluid between the annulus and the tubing removes the necessity
for reinjection into the reservoir and would not require the high pressures associated
with squeeze operations. Provided no erosive or corrosive compounds exist in the
flow stream, this completion is very useful for high flow rate wells.

2.3 Tubing flow without annulus isolation

In situations where annular flow in a casing-string completion would result in
excessive phase slippage with consequent increased flowing pressure loss and
potential instability, the consideration could be given to merely closing the annulus
at surface and preventing flow. However, in reservoirs where the flowing bottom hole
pressure is at or below the bubble point, gas as it flows from the formation to the tubing
tailpipe will migrate upwards under buoyancy forces and some gas will accumulate
in the annulus. This will result in an increase in the casing head pressure at surface.
Gas build up in the annulus will continue until the gas fills the annulus and it will offload as a gas slug into the base of the tubing and be produced. This production
instability will be cyclical and is referred to as annulus heading.
In this type of completion the casing is exposed continuously to produced fluid with
the possibilities of erosion or corrosion. This, coupled with the potential for annular
heading, suggests that unless annular flow is required then the annulus should not be
left open to production, despite its simple design.

2.4 Tubing flow with annular isolation

For cases where a large cross sectional area for flow is not necessary, then an open
annulus can cause complications as discussed in 2.3 above. Therefore, in the majority
of cases where tubing flow will take place, the annulus is normally isolated by the
installation of a packer. The packer has a rubber element which when compressed or
inflated will expand to fill the annulus between the tubing and the casing. The packer
is normally located as close to the top of the reservoir as possible to minimise the
trapped annular volume beneath the packer and hence the volume of gas which could
accumulate there. However, if the packer is installed, the ability to U-tube or circulate
fluid between the tubing and annulus is removed. If such a circulation capability is
required then it is necessary to install a tubing component which will allow annulus
communication or alternatively rely upon the ability to perforate the tubing which
consequently would necessitate tubing replacement prior to the recommencement of
production. In both cases, the circulation point is normally as deep in the well as
possible, but above the packer.
This completion system is by far the most widely used and offers maximum well
security and control.

3 COMPLETION STRING FACILITIES

For any completion string we can define a range of operations or capabilities which
may be required. Some of the capabilities are considered to be essential, such as those
providing operational security or safety, whilst others can provide improved
performance or flexibility. However, as the degree of flexibility provided by the
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Wellbore Completion Concepts

completion is increased, the more complex is the design process and normally a
sophisticated design will result which includes a large number of string components.
With the inbuilt complexity, the reliability of the completion string becomes more
suspect. Thus in the majority of cases, the design process should be approached by
initially identifying the minimum functional requirements and any additional options
are assessed on the basis of incremental complexity versus incremental benefit. In
high operating cost areas, such as the North Sea, Alaska, The Gulf of Mexico and West
Africa, the primary objective is continuity of production and hence wherever possible,
simple designs which offer the basic operational facilities are favoured.

3.1 Basic completion string functions and facilities

The basic facilities provided by a completion string must allow it to continue the
production or injection of fluids over as long a period as possible without major
intervention to conduct well repairs. Further, at all times, the design must ensure the
safe operation of the well and reliably allow for its shutdown in a variety of situations.
The completion string, production casing and wellhead must act as a composite
pressure system which prevents formation fluids and pressure escaping from the
reservoir except via the production tubing and the Xmas Tree into the surface
processing facilities.
The following are considered to be the essential attributes for the majority of
completion string installations:
(a) The ability to contain anticipated flowing pressure and any hydraulic pressures
which may be employed in well operations and conduct fluid to surface
(production) or the reservoir (injection wells) with minimal flowing pressure
loss and optimal flow stability.
(b) The ability to isolate the annulus between the casing and the production tubing
if flow instability is likely or it is desirable to minimise reservoir fluid contact
with the production casing.
(c) The ability to affect downhole shut-in either by remote control or directly
activated by changing well flowing conditions, in the event that isolation at
surface is not possible.
(d) A means to communicate or circulate (selectively when required) between the
annulus and the tubing.
(e) A provision for physical isolation of the tubing by the installation of a plug to
allow routine isolation e.g. for pressure testing of the tubing.
The above would provide a completion string with the necessary features to allow the
well to produce in a safe, controllable manner. Consider each of the functions in turn:

(a) Pressure and flow containment

The pressure communicated between the wellbore and the reservoir is contained
within the production casing, production tubing, the wellhead and the surface valve
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closure system known as the Xmas tree. Further, if a packer is used then reservoir or
injection pressure will be retained beneath the packer.
Thus, both the casing and tubing will be designed to withstand the internal pressures
which could exist in the wellbore. Similarly the wellhead, from which each casing
string is suspended as the well is drilled, will be rated for maximum anticipated surface
pressures. Overall control of fluid production from, or injection into, the well is
provided by the valve system located on top of the wellhead. This Xmas tree usually
comprises an in-line valve with a backup valve to shut in the well and side outlets with
valves for both choke and kill line attachment during well killing procedures.
The production casing, packer and wellhead provide a backup to contain fluids and
pressures in the event of a hydraulic failure of the tubing system.
The tubing size must be selected such that well production rates are optimised and flow
is stable.

(b) Annulus Isolation

The concepts of annulus heading cycle and the potential damage which can be
occasioned to the production casing, mean that a method of annulus isolation is
required in the majority of production wells. For injection wells, it is frequently
necessary to isolate the annulus to prevent surface injection pressures being exerted
on the wellhead and possibly giving rise to burst of the production casing.
This annular isolation is normally effected by installing a packer in the completion
string which is lowered into the wellbore with an elastomeric element in the retracted
position. At the prescribed depth, the element is set by extrusion or inflation to fill the
annular space between the tubing and the annulus. To minimise the volume below the
packer and the length of casing exposed to well fluids, the packer is normally set quite
deep in the well.

(c) Downhole closure of the flow string

In the event that access cannot be gained to the Xmas tree to effect valve closure and
stop fluid flow or because of valve failure, it is advisable, and in most cases
mandatory, to have a secondary means of closure for all wells capable of natural flow
to surface. The installation of a sub-surface safety valve (SSSV) will provide this
emergency closure capability. The valve can be either remotely operated on a fail safe
principle from surface, or will be designed to close automatically when a predetermined
flow condition occurs in the well. The initiation of the closure of the latter system will
depend upon a predetermined flow rate being exceeded or the flowing bottom hole
pressure declining below a pre-set level.

(d) Circulation capability

In section 2.1 , the concept of using the production casing as a flow string without
production tubing was discussed and one of the major limitations identified was the
inability to kill the well by circulation. The alternative killing methods of squeezing
or the use of the Volumetric method are not always applicable or desirable. In many
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Wellbore Completion Concepts

cases a coiled tubing unit or snubing unit is unavailable to re-enter the tubing
concentrically. Hence for the majority of completions a specific piece of equipment
is installed to allow the opening and subsequent closure of a circulation port between
the tubing and the annulus. This can be provided by installing one or more of the
following devices:
(i)
(ii)
(iii)

Sliding side door (SSD) or sliding sleeve (SS)

Side pocket mandrel (SPM)
Ported nipple

An alternative but more drastic approach would be to use a tubing punch, but since the
circulation ports cannot be subsequently closed, it is only usually of use for circulation
prior to a workover.

(e) Tubing isolation

Normally a secondary means of physical isolation will be installed. This will usually
be required to supplement the downhole SSSV and also is intended to provide
isolation if the well is hydraulically dead and the SSSV is to be removed. Thus the
provision of this isolation is normally provided deep within the wellbore either just
above or just below the packer.
The isolation can normally be provided by lowering a plug on wireline down the inside
of the tubing string until it lands and locks into a wireline nipple which was
incorporated into the design of the tubing string at an appropriate depth.
A basic completion is depicted in Figure 6.

Surface Isolation

Tubing Isolation

Circulation between
Annulus & Tubing
Annulular Isolation
Tubing Isolation

Figure 6
Basic Well Completion
Schematic

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3.2 Additional completion string functions
A range of other functions may be necessary or considered worthwhile for incorporation
into the string design as a future contingency. Some of the more prevalent are
discussed below.

(a) Downhole tubing detachment

In the event of failure of the tubing string it may be necessary to pull the completion
from the well to effect replacement of completion components which are more prone
to failure and require more frequent replacement. However it would be useful in a
number of situations to minimise the amount of equipment which requires to be pulled
from the well. Thus a point of easy detachment and reconnection would be useful. This
detachment can be obtained by installing a removable locator device which seals with
the rest of the tubing string to be left in the well during normal conditions but which
can be pulled as required. In such cases a means of hydraulic isolation of the tubing
below the point of detachment is required. Examples of this are a packer seal system
which allows the tubing above the packer to be disconnected and retrieved, or a
downhole hanger system which suspends the tubing in the well beneath the wellhead.
Completion components which are more prone to failure and require frequent
replacement, e.g. SSSV, will be located above such devices.

(b) Tubing stresses

During the normal cycle of well operations, the tubing string can extend or contract in
length due to variations in both pressure and temperature subsurface. Since the string
is normally landed off in the wellhead and in contact downhole with the casing through
the packer, if the amount of movement were severe, it would give rise to damage to
the packer, wellhead or the tubing itself.
A moving seal system could be installed which would allow expansion and/or
contraction of the tubing without mechanical failure or disengagement from the packer
or seal bore. Various systems are available; however, they all feature a concentric
sleeve approach where seals are located in the concentric annulus and one of these
sleeves is stationary.

(c) Ability to suspend P & T monitoring equipment

It is frequently required to monitor the bottomhole pressure during production tests
and, in such cases, the requirement will exist to be able to run and install at a specific
location in the tubing a pressure or temperature gauge. This is normally accommodated
by the installation of a wireline nipple as a component of the completion string. Its
location is normally as deep in the well as possible.

(d) Controlled fluid injection from the annulus into tubing

Produced fluids can contain corrosive components such as CO2, or have high pour
points with attendant flowing pressure loss problems. In such cases, it may be
necessary to introduce specific chemicals into the flow string at a location deep within
the well to provide maximum benefit and counteract the impact of these characteristics.
Examples of this may be the injection of a corrosion inhibitor or pour point depressant.
In such cases one option would be to inject these fluids into the casing-tubing annulus
and by incorporating a side pocket mandrel with a valve which will open under
prescribed pressure conditions, the treatment fluid will then flow from the annulus into
the tubing either continuously or intermittently.
14

Wellbore Completion Concepts

Another example of this type of requirement, would be gas lift installations, where it
is necessary to inject gas into the produced fluids to lighten the hydrostatic head and
maintain production at economic levels

(e) Downhole pump system

The selection of a downhole pumping system, whether it be electrical or hydraulically
powered, will require the inclusion of the pump in the completion string design.
Important design issues will be:
1) the method of installation and retrieval of the pump upon failure
2) constraints on access to the tubing or wellbore beneath the pump

(f) Wireline entry guide

It will be necessary, in most wells, to conduct wireline or coiled tubing operations
below the bottom of the tubing string, eg across the perforated interval. In such cases,
whilst retrieving the wireline tool string, assistance must be given to guide the tools
back into the lower end of the tail pipe of the tubing string.

3.3. Composite completion string

It is clear that since the completion string design is influenced by a range of reservoir
and other parameters, many different designs exist and in reality, for each specific
situation, a number of designs can be considered. In most cases a generalised
completion can be considered as shown in Fig 7. Here an attempt has been made to
depict a completion string from top to bottom by identifying the components and
functions.

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COMPONENT

FUNCTIONALITY

XMAS TREE

Flow Control
and Isolation

WELLHEAD

Tubing & Casing

Suspension

S.S.S.V.

Safety Isolation
Downhole

SIDE POCKET
MANDREL(S)

Circulation or
Fluid Injection

SLIDING SIDE
DOOR

Circulation

SEAL ASSEMBLY

Accomodate
Tubing Stress

PACKER

Annular
Isolation

NIPPLE

Tubing
Isolation

PERFORATED
JOINT

Alternative
Entry for Flow

NIPPLE

Landing
Guages

W.E.G.

Wireline
Re-Entry

4. COMPLETION STRING COMPONENTS

The design of the completion string involves the selection and specification of all the
component parts of the string. There must be literally thousands of potential components
available if one considers that there are numerous components and variants and,
further, each of the equipment suppliers has their own particular designs. It therefore
is easy to understand how this part of design process can be somewhat bewildering to
the les experienced. As with all services, the alternatives are usually narrowed down
in that the operating company has historically used one particular supplier or has
considerable experience with specific types of components. Since the equipment is
specified as a certain size and with a certain type of threaded coupling, tubing
completion equipment is by neccesity fairly standard and comparable between
different suppliers.
In selecting equipment, this should be done on the basis that the component will
provide a specific facility deemed necessary to the successful performance and
operation of the well under a range of operating scenarios. Each component adds
undesirable complexity to the completion and this must be compensated for by the fact
that it is necessary or provides desirable flexibility. One approach to discussing the
subject is to postulate a typical or conventional well completion string in terms of the
facility that each component provides. The discussion of a particular completion
could then be made by considering whether that component or facility proposed for
the typical completion is required or is beneficial in this particular instance. In this
way the design is justified on an as needs basis and the benefits of incremental
complexity created by incremental flexibility can be assessed.
16

Figure 7
General Well Completion
String

Wellbore Completion Concepts

A typical completion was postulated in outline in Figure 6. Each component will be

discussed below in relation to what is mechanically its purpose in production
operations.

4.1 Wellhead/Xmas Tree

The wellhead provides the basis for the mechanical construction of the well at surface
or the sea-bed. It provides for:
1)

Suspension of all individual casings and tubulars, concentrically in the well

2)

Ability to instal a surface closure/flow control device on top of the well namely:
i)
A blow out preventer stack whilst drilling
ii)
A Xmas tree for production or injection

3)

Hydraulic access to the annuli between casing to allow cement placement and
between the production casing and tubing for well circulation

The purpose of the Xmas tree is to provide valve control of the fluids produced from
or injected into the well. The Xmas tree is normally flanged up to the wellhead system
after running the production tubing. The wellhead provides the facility for suspending
the casing strings and production tubing in the well. There are a number of basic
designs for Xmas trees, one of the simplest is shown in Figure 8. Briefly, it can be seen
that it comprises 2 wing valve outlets, normally one for production and the other for
injection, e.g. well killing. Additionally, the third outlet provides vertical access into
the tubing for wireline concentric conveyancing of wireline or coiled tubing tools.
The lower valve is the master valve and it controls all hydraulic and mechanical access
to the well. In some cases, the importance of this valve to well safety is so great that
it is duplicated. All outlets have valves which in some cases are manually operated or
in the case of sophisticated platform systems and subsea wellsare remotely controlled
hydraulic valves operated from a control room.

GAUGE VALVE

XMAS TREE

TOP CONNECTION
SWABBING VALVE
FLOW FITTING

CHOKE
WING VALVE
MASTER VALVE

TUBING HEAD ADAPTOR

TUBING HANGER
TUBING HEAD

Figure 8
Simple Wellhead Assembly
including Casing Spools
and Xmas Tree

WELLHEAD

TUBING
CASING HANGER
CASING HAED
INNER CASING
INTERMEDIATE CASING
SEALING MEDIUM
CASING HANGER
CASING HEAD
OUTER CASING

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4.2 Production Tubing
When selecting production tubing, the following data has to be specified:
(a) The grade of steel selected for the manufacture of the tubing, e.g. N80, C75 etc.
will be dependent on a number of factors such as the strength requirements for
the string and, the possible presence of corrosive components such as CO2 or
H2S.
(b) The wall thickness of the tubing referred to as a weight/foot of tubing, has to
be specified and this parameter controls the tubing bodys capacity to withstand
tensile/compressive stresses and differences between internal and external
pressures, e.g. 7" tubing is available as 26, 29, 32 lb/ft. etc.
(c) The threaded coupling is an important part of the design specification as it
defines both the tensile strength and the hydraulic integrity of the completion
string. The types of couplings available vary from API standard couplings such
as Buttress BTC, Extreme Line EL, Long Threaded Coupling LTC, etc.to the
specialised or premium threads commonly selected for production tubing such
as Hydril, VAM, etc. These latter proprietary designs offer specific advan
tages, e.g. VAM was developed for completing high pressure gas wells, where
rigorous sealing and pressure integrity is difficult to achieve but essential.

4.3 Provision of an Annular Pressure Seal

In the previous discussion of completion types it was suggested that the provision of
an annular seal or pack-off in production wells was necessary for one of the following
reasons:
(a) To improve flow stability and production control
(b) Protection of the outer containment system/equipment such as the production
casing and the wellhead.
(c) To provide the facility to select or isolate various zones during stimulation or
production, e.g. to isolate two producing zones having different fluid properties,
GOR, pressure or permeability (especially relevant for injection) or to
stimulate or pressure maintenance.

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Wellbore Completion Concepts

Upper Seal

Sealing Element

Bypass
Upper Cone
Slips
Lower Cone

Left - Hand
Screw Head
Inner Mandrel
Friction Blocks

Upper Split Nut

Lower Split Nut

Figure 9
Major Components of a
Typical Production Packer

The most common method to provide an annular seal is the use of a packer. There are
numerous manufacturers, each offering a variety of designs; however, Figure 9
illustrates a basic packer. The pack-off is accomplished by expanding or extending
the elastomer element outwards from the packer body until it contacts the casing wall.
There are four main characteristics which classify the various packer types:
(a) Retrievability
Here, the consideration is how easy is it to release the packer after setting. This aspect
is of importance since it not only affects the degree of difficulty in working over a well,
it may also reduce the applicability by introducing design limitations in terms of the
differential pressure it can withstand. However, in general terms, the following
categories are available:
(1)

Retrievable Packer which, as its name implies, can be easily retrieved after
installation. The packer can be run as an integral part of the tubing string to
the setting depth where the setting mechanism is actuated.

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(2) Permanent Packer which, as its name indicates, cannot be easily retrieved. It
is usually run and set separately with or without the tailpipe, and the tubing
string is subsequently run and engages the packer to achieve a pressure seal
within the central bore of the packer. To retrieve the packer it is necessary to
mill away the packer internal sleeves to allow the rubber element to collapse.
(b) Setting Mechanism
The setting of packers can be accomplished by a number of mechanisms, all of which
cause compression and extrusion of the rubber element:
(1) Mechanically - one example of such mechanisms is rotation of the tubing
string.
(2) Compression or Tension (based on suspended tubing weight). Normally, some
mechanical device is required which when activated at the setting depth allows
for example, string weight to be transferred to the packer to compress the rubber
element. See Figure 10. These packers are simple but often unidirectional in
terms of the setting force and ability to withstand a differential pressure

Lower Cone

Sealing Elements
Lower Slips
Figure 10
Schematic of a
Compression Set Packer

(3) Hydraulic - this mechanism utilises hydraulic pressure generated inside the
completion string. By necessity, the tubing string is isolated or plugged below
the packer to prevent pressure being exerted on the formation or the annulus
during setting.
(4) Electrical - with this mechanism a special adaptor and setting tool is connected
to the packer which allows the packer (plus tailpipe) assembly to be lowered
into the casing on electrical conductor cable and at the required setting depth
a small explosive charge can be detonated, thus actuating the setting mechanism.
(c) Ability to Withstand Differential Pressure
(1) Compression Packers (e.g. weight set) In the case of normal producing wells,
higher pressure below the packer compared to above counteracts the setting
mechanism. This type of packer is thus suitable for injection wells where the
differential pressure supports the setting mechanism.
20

Wellbore Completion Concepts

(2) Tension Packer This is the opposite to the compression packer and hence a
higher pressure below compared to above (as in production wells) supports the
setting mechanisms.
(3) Compression and Tension Set Packers These packers can withstand pressure
from either direction.
(d) Packer Bore
As indicated above, it is necessary to have a bore through the packer for each
tubing string. Single, dual or triple bore packers are available for multiple tubing string
completions (refer to Ch. 7).

4.4 Provision of a Seal between Tubing and Packer (where necessary)

When a retrievable packer is run, it is made up as an integral component of the tubing
string and the seal is effected by the tubular connection between packer and tubing.
In other cases, it is necessary to introduce a component into the tubing string which
will be run into the internal packer bore and establish a pressure seal. For these
applications, there are a number of options available, the designs of which depend on
whether or not it is necessary to compensate for thermal expansion and contraction for
the tubing string by allowing movement of the tubing to occur. The completion string
is fixed mechanically by both the packer and the tubing hanger landed in the wellhead.
Thus, changes in the flowing temperature and tubing pressure can cause elongation
or contraction of the tubing string which may result in buckling between the packer
and wellhead or tensile failure respectively. Thus, seal assemblies can be classified
according to whether they allow tubular movement or not, i.e. dynamic or static seal
assemblies respectively. The various types are shown schematically in Figure 11.
(a)

(b)

Anchor Seal
Assembly
(d)

Figure 11
Schematic Views of Various
Tubing Seal Assemblies

(c)

Locator Seal
Assembly
(e)

Tubing Seal
Receptacle

Locator Seal Assembly

with Seal Bore Extension
(f)

Travel Joint

Polished Bore Receptacle

On Line Production

(a) Static Seal Assembly- no provision for Tubing Movement

In its simplest form, this is accomplished by a small tubular component which has
external elastomer seal elements along its length. This component obviously does not
allow for any tubing movements as contraction could easily pull it out of the sealing
bore. As a precaution against this, the seal assembly is normally run with a mechanical
latch assembly which lands inside the seal bore (Figure 11a).

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(b) Dynamic Seal Assemblies - accommodate Tubing Movement
(1)

Locator Seal Assembly (Figure 11b) This consists of a tubular component

which has seal elements at regular intervals along its length. The length can be
varied by coupling together standard sized lengths. To provide a greater seal
contact area, a seal bore extension can be run with the packer (Figure 11c). The
device has a shoulder at the top whose outside diameter is greater than the packer base.

(2) Extra Long Tubing Seal Receptacle (Figure 11d) This device consists of two
concentric cylinders with elastomer seals between them. The outer cylinder
is attached to the tubing string by a threaded coupling. The inner cylinder
is latched into the packer with an anchor seal assembly as described above. The
length of ELTSR is normally 10 - 30 ft but can be varied to suit the particular
requirements.
(3) Travel Joint (Figure 11e) This device is very similar to the ELTSR but in its
conventional running mode is like an inverted ELTSR.
(4) Polished Bore Receptacle PBR (Figure 11f). This completion component
simultaneously provides both an annular pressure seal and a locator seal which
permits tubing movement. The PBR consists of a receptacle with a polished
internal bore normally run on top of a production liner. A seal assembly can
then be run on tubing and located inside the PBR.

4.5 Sub-Surface Safety Valves

These can be sub-divided into remotely controlled and directly controlled systems.
Their function is to provide remote sub-surface isolation in the event of a catastrophic
failure of the Xmas tree or as a failsafe shutdown system

(a) Remotely Controlled SSSV

This is the more widely employed and more reliable method. The valves normally rely
on hydraulic pressure, supplied to the downhole valve by a small 1/4" monel control
line run in the annulus and strapped to the tubing, to keep the valve open. The valve
itself is normally either a ball type valve (Figures 12 and 13) or a flapper device . As
an alternative an electricially operated valve can be used. There are 2 options as to the
method of deploying and retrieving the valve:
(1) Tubing retrievable where the valve is run as an integral part of the tubing string
and can only be retrieved by pulling the tubing.
(2) Wireline retrievable where the valve nipple is run as an integral part of the
tubing and the internal valve assembly can be subsequently run and retrieved
on wireline cable. The valves normally open due to the hydraulic pressure
acting on a piston which moves a flow tube against the ball or through the
flapper. On bleeding off pressure, a spring ensures reverse movement of the
piston and the flow tube, and this allows valve closure.

22

Wellbore Completion Concepts

OPEN

CLOSED
Landing
Nipple
Sheer Pin

Control
Line

Snap Ring
Shifting Sleeve
Spring

Ball

Spring

Figure 12
Remote Controlled Sub
Surface Safety Valve

Figure 13 RCSSSV
Showing Operation of the
Valve

Equalising

Open

Closed

(b) Direct Controlled Sub Surface Safety Valves

This type of valve is designed to remain open provided either a preset differential
pressure occurring through a fixed size orifice in the valve is not exceeded or the
flowing bottomhole pressure is maintained above a preset value. Any increase in the
differential pressure causes a spring to close the valve. These valves have fewer
limitations on setting depth and are typically set deeper than the remotely controlled
valves, e.g. in the tailpipe.

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4.6 Side Pocket Mandrel (SPM)
This component, as depicted in Figure 14, contains an offcentre pocket with ports into
the annulus. Using wireline or coiled tubing, a valve can be installed in the packer
which allows fluid flow between tubing and annulus, e.g.:
(a) Gas Lift Valves
This type of valve when landed in the SPM responds to the pressure of gas injected
into the annulus, or tubing pressure at the valve depth, to open the valve and allow gas
injection into the tubing.
(b) Chemical Injection Valves
These valves allow the injection of chemicals such as corrosion inhibitors, pour point
depressants, etc. The valve is again opened by annular pressure.
(c) Circulation
To allow circulation of kill fluids or the placement of a lower density fluid cushion,
a valve can be installed which can be sheared by pressure allowing communication.
The port can then only be reclosed by replacing the shear valve by wireline or coiled
tubing.

Orienting Sleeve

Tool Discriminator

Polish Bore
Polish Bore
Pocket Assembly

Figure 14
Side Pocket Mandrel
24

Wellbore Completion Concepts

4.7 Sliding Side Door (SSD) (Figure 15)

This device permits communication between tubing and annulus. It consists of two
concentric sleeves with elastomeric seals between them and each with slots or holes.
Using wireline or coiled tubing, the inner sleeve can be moved upwards or downwards
to align the openings on both sleeves. Its application is for well killing and placement
of fluids in the tubing or annulus by circulation.

4.8 Landing Nipples

A landing nipple is a short tubular device which has an internally machined profile,
capable of accommodating and securing a mandrel run into its bore on wireline or
coiled tubing. The nipple provides a recess to mechanically lock the mandrel in place
using a set of expandible keys a pressure seal against the internal bore of the nipple
and the outer surface of the mandrel. Some typical nipples and mandrels are shown
in Figure 16.

Sliding
Inner
Sleeve

Ports

Circulation
Permitted

Seals

CLOSED

OPEN

Figure 15
Wireline Operating Sliding
Side Door

Department of Petroleum Engineering, Heriot-Watt University

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Bottom No Go
used
Locks
with

Seating
Nipples

No Go
Base

No Go
Base
Optional Bottom

Nipples are installed at various points in the string to facilitate one or

more of the following operations:
(a) Plugging the tubing for:
(i) pressure testing
(ii) setting hydraulic set packers
(iii) zonal isolation
(b) Installing flow control equipment such as:
(i) downhole chokes, regulators, SSVs, etc
(ii) landing off bottom hole pressure recorders.
Nipples can be classified into three basic designs:
(1) Top No-go where the No-go shoulder is located above the seal bore.
(2) Bottom No-go where the No-go shoulder is located below the seal bore. In
this
design the No-go shoulder obviously restricts the diameter of the seal
bore.
(3) Selective Nipples In the above two types, the nipple sizes must progressively
diminish with the depth of the string. Then it is possible to run only one of
each
size and type in the string. With selective nipples as required can be
installed
since the locking mechanism is selective and has to be
specifically actuated by
the wireline tool.
Nipple profiles consist of the following:

26

Figure 16
Wireline Nipple and
Mandrel Systems

Wellbore Completion Concepts

i) Lock mandrel recess profile

ii) Seal bore (below lock profile)
iii) No-go shoulder which is optional but has a minimum through bore and provides
positive positioning of the lock mandrel.

4.9 Perforated Joint

This allows for flow to enter the string even if the base of the tubing string is plugged
by, say, pressure gauges.

5. WELL COMPLETION DESIGNS

There are numerous well completion designs as is to be expected from the e wide range
of operating areas and environments. The variety of designs which exist reflect some
of the following factors:
(1) Well characteristics such as:
(a)
(b)
(c)
(d)

pressure
productivity or injectivity index
fluid properties
rock properties and geological data.

(2) Geographical factors, e.g.:

(a)
(b)
(c)
(d)

location
water depth (if offshore)
weather conditions
accessibility.

(3) Operational design constraints, e.g.:

(a) environmental regulations
(b) safety aspects
(4) The number of producing zones.
A number of typical completion types are presented below and are subdivided into two
categories, namely, land or platform type completions or subsea completions. These
designs are intended to stress the functional similarities and provision in a range of
well environments.

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5.1 Land or Platform Based Completions

Sub Surface Safety Valve

with Flow Couplings
7" Casing
3 1/2" Tubing
Wireline Operated Sliding Side Door

31/2 in Otis 'X' Nipple

Baker Anchor Seal Assembly

Baker 'DB' Packer
Millout Extension
Crossover 51/2 in x 31/2 in
31/2 Hydril EU Tubing
31/2 in Otis 'X' Nipple
Perforated Flow Tube
31/2 in Otis 'X' Landing Nipple
Wireline Entry Guide

COMPLETION NO. 1 (Figure 17)

This completion type features the use of VAM tubing with an anchor seal assembly
latched into a permanent packer. The VAM tubing is required due to the production
or injection of gas with relatively high closed in surface tubing pressures. The
permanent packer would be made up with its tailpipe and run in and set on drillpipe
or with electric wireline cable. The absence of a moving seal assembly infers that little
expansion/contraction will occur, or that the need for good differential pressure
sealing integrity is paramount.

28

Figure 17
Single Zone Completion
with no Provision
forTubing Movement

Wellbore Completion Concepts

Casing

Sub Surface Safety Valve

Tubing

Nipple

Wireline Operated S.S.D.

Locator Seal Assembly

Permanent Packer
Seal Bore Protector

Millout Extension

Nipple

Perforated Flow Tube

Figure 18
Single Zone Completion
Utilising a Locator Seal
Assembly

No Go Nipple
W.E.G
Liner

COMPLETION NO. 2 (Figure 18)

This design provides for production through a tubing string utilising a moving seal
assembly located inside a permanent packer. Additional features include 2 nipples
located in the tailpipe, the upper one for pressure isolation if the tubing string is
retrieved and the lower for landing bottom hole pressure survey gauges.

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9 5/8" Casing

S.S.S.V. Nipple with

Flow Coupling

7" Hydril Production Tubing

Wireline Operated
Sliding Side Door
Extra Long Tubing Seal
Receptacle with Nipple and
Anchor Seals on the Slick Joint

Permanent Packer Wireline Set

Mill-out Extension

4 in VAM/Hydril Tailpipe
Nipple

Perforated Tube
Landing Nipple

7" Liner

COMPLETION NO. 3 (Figure 19)

This design has been frequently used in high production rate areas, where its large bore
tubing minimises pressure drop in the tubing. The packer and tailpipe can be set on
electric cable or coiled tubing and the tubing string subsequently latched into the
packer with an anchor seal assembly at the base of an extra long tubing seal receptacle
ELTSR. The range of tubing movement is typically anticipated to be 5 -15 ft but
depends on the range of operational temperatures. Rates of 20,000 - 30,000 bbl/d can
be typical for this type of completion.

30

Figure 19
SingleHigh Flowrate Zone
Completion Utilising an
Extra Long Tubing Seal
Receptacle for Tubing
Movement

Wellbore Completion Concepts

9 5/8" Casing
S.S.S.V. Nipple with
Flow Coupling
7" Production Tubing
Side Pocket Mandrel for
Chemical Injection or with
Shear Valve to Permit
Circulation
Nipple
Polished Bore Receptacle
Liner Packer and Hanger
Assembly

7" Liner

Figure 20
Single Zone High Flowrate
Injection/Production
Completion Utilising a
Polished Bore Receptacle

COMPLETION NO. 4 (Figure 20)

This design again is specifically for high flowrate production/injection and is an
alternative to Fig 19. It is referred to as a Monobore as it has a large, relatively constant
diameter from surface through the reservoir and this facilitates concentric access and
intervention. It utilises a polished bore receptacle at the top of the 7" liner which
accepts a seal assembly at the base of the tubing string. The seal assembly provides
a moving seal area to accommodate expansion and/or contraction of the tubing. This
design thus offers a continuous 7" O.D. conduit for flow from the wellhead to the
perforations. As shown here, there is no facility for isolating below the PBR but this
can be achieved if the well is completed below the PBR with a packer and small
tailpipe containing a wireline nipple to accept a plug or more reliably by running a
thru-tubing bridge plug. Circulation to kill the well is preferred using a shear valve
in a side pocket mandrel instead of a sliding side door.

Department of Petroleum Engineering, Heriot-Watt University

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9 5/8" Casing
S.S.S.V. Nipple with
Flow Coupling
7" VAM/Hydril Production Tubing
Nipple
Side Pocket Mandrels
for Subsequent Gas Lift
Nipple
Retrievable Packer

Nipple
Perforated flow Tube

Landing Nipple

7" Liner

COMPLETION NO. 5 (Figure 21)

This illustrates a completion which utilises gas lift to allow production to occur or to
increase production rates. The string comprises several side pocket mandrels containing
injection valves at various depths which are designed to open and allow gas to enter
the tubing from the annulus. The design utilises a retrievable packer which is
preferable if it is suspected that a completion will require mechanical repair at frequent
intervals, e.g. to replace non-operating gas lift valves.

32

Figure 21
Single Zone Completion
Utilising a Gas Lift Facility

Wellbore Completion Concepts

Junction
Box

Surface
Power
Cable

Tubing Production

Annulus Production

Wellhead Incorporating
Boll Weevil Hanger

Retrievable Hydraulic Set Packer

Production Tubing
(3 1/2")

Downhole Cable

Y-Tool Block

Motor Lead Extension

Selective Nipple
Bypass Tubing (2 3/8")

Pothead Connection

Pump (5.44" OD)

ESP / Bypass Tubing Clamps
Motor (5.44" OD)
Pressure Sensors

Figure 22
Single Zone Completion
Utilising an lectriccaly
Powered Submersile Pump

Bypass Tubing (3 1/2")

9 5/8" Casing

COMPLETION NO. 6 (Figure 22)

Here the reservoir may have insufficient pressure to lift the crude to surface or the
crude may be too viscous or possess a low pour point and thus assisted flow is required.
The design features a downhole electrically operated pump in a side leg tailpipe. The
advantage of locating the pump in the side leg is to allow access to the producing zone
below the tailpipe, say for production logging surveys, etc. Note that a retrievable
hydraulic set packer is used which reduces the difficulties in pulling the string should
the pump need replacing regularly typical run life for a large capacity ESP is
currently 1-3 years, but this depends upon installation efficiency and the actual
operating environment.

Department of Petroleum Engineering, Heriot-Watt University

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9 5/8" Casing
3 1/2" EU Tubing
2 x S.S.S.V. with Flow Couplings
Crossover 3 1/2" x 2 7/8"

2 7/8" EU Tubing

3 1/2" Otis 'XO' SSD

3 1/2" Otis Flow Coupling
2 7/8" Otis 'XO' SSD
Collet Latch
Otis RDH Packer
2 7/8" Otis 'XO' SSD
2 7/8" Otis Flow Coupling
2 7/8" Otis 'XN' Landing Nipple
2 7/8" Perforated Tube
2 7/8" Baker 'R' Nipple
2 7/8" Mule Shoe

3 1/2" Otis Blast Joint

3 1/2" Baker Locator Tubing Seal Assembly

Baker 'D' Packer
Crossover 3 1/2" x 2 7/8"
2 7/8" Otis 'XO' SSD
2 7/8" EU Tubing
2 7/8" Otis 'XN' Landing Nipple

COMPLETION NO. 7 (Figure 23)

This completion utilises two tubing strings allowing separated production from each
zone with a significant degree or reservoir management. The lower packer is a
permanent packer and the longer tubing string is connected to it using a seal assembly.
The upper packer is a retrievable dual packer. All equipment is duplicated, e.g. 2 subsurface safety valves, 2 circulating devices, etc. To combat erosion on the longer
string at the point of entry of fluid from the upper zone into the wellbore, thick walled
joints known as Blast Joints are used. This design can be extended to 3 strings with
3 packers allowing for production from 3 zones or, if production occurs up the annulus,
from 4 zones. However such a well is not overly common because of its high degree
of mechanical complexity.

34

Figure 23
Dual Completion allowing
Segregated Production

Wellbore Completion Concepts

4 1/2" VAM Production Tubing

S.S.S.V (x2)
Hydraulic Set Retrievable
Dual Packer
Nipple

Gas Lift Mandrels

31/2" VAM Production Tubing

Travel Joint
Locator Seal Assembly
Wireline Set Permanent Packer

.
Wireline Operated S.S.D
Wireline Set Permanent Packer
Nipple

Figure 24
Selective Dual Zone
Producer with optional Gas
Lift Facility

Wireline Entry Guide

9 5/8" Casing

COMPLETION NO. 8 (Figure 24)

This complex design introduces flexibility into the completion since it allows for
selective production from either or both of the zones with continuous gas lift using gas
injected down a separate string or for concurrent production of both zones using the
two tubing strings. In this design, the gas is injected using the tubing to avoid
excessive gas pressures being exerted on the production casing, which can be
especially serious at surface with the possibility of casing burst if the casing has
deteriorated.

Department of Petroleum Engineering, Heriot-Watt University

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Casing

Wireline Isolating Nipple

Direct Controled S.S.S.V

Perforations on Upper Zone
Wireline Isolating Nipple
Borehole Wall
Direct Controled S.S.S.V
Perforations
Cement Sheath

COMPLETION NO. 9 ( Figure 25)

Although the title of this type of completion is somewhat of a misnomer, it offers
advantages in both cost and simplicity over the previous completions but potentially
suffers from some basic limitations as discussed earlier. However, this type of
completion has been applied in some areas, for example, the Middle East and the USA.
It can either take the form of a single, dual or a triple completion.

5.2 SUBSEA COMPLETIONS

The following two tubular completion designs, illustrate two different philosophies
for the servicing of subsea completions. Obviously some of the facilities and tubular
components incorporated in the previous completions can be incorporated into subsea
completions. The over-riding design philosophy is based on the high cost of well
intervention and thus requires minimal planned (Figure 27) or facilitated (Figure 26)
intervention.

36

Figure 25
A "Tubingless" Dual
Completion

Wellbore Completion Concepts

Tubing Retrievable S.S.S.Vs

with Flow Couplings
Dual Production Tubing
2 3/8" x 2 3/8", 2 7/8" x 2 7/8",
3 1/2" x 3 1/2" Hydril

H-Member with Dual Bypass

No-Go Nipples (x2)

Travel Joint
Hydraulic Set
Permanent Packer

Figure 26
Subsea Completion
Serviced by Through
Flowline Techniques (TFL)

4 1/2" Hydril Tailpipe

9 5/8" Casing

COMPLETION NO. 10 (Figure 26)

Serviced by the through flowline techniques TFL (pump down)
In this design, routine operations such as setting plugs, downhole valve (even
perforating), etc. can be accomplished by displacing the required tools down the
tubing by pumping fluid behind the tool string. By necessity, an H member and second
tubing is required to allow for the flow of displaced fluid to back to the pumpdown
control room and also to allow for reverse displacement for the recovery of the tools
using the U-tube principle.
A well of this nature can be serviced remotely from a platform or other location using
2 production flow lines connected from the wellhead to the platform. Despite the
initial capital costs, the potential benefits are that there is no necessity to mobilise a
work boat or semi-submersible to carry out minor repairs and operations over the well.
Currently few new TFL completions are being installed due to the development of
more economical subsea wireline/CT intervention techniques.
Department of Petroleum Engineering, Heriot-Watt University

37

Wireline Lubricator
and BOP
21" Riser to Servicing Rig
5 1/2" Tubing Tie Back to Servicing Rig
2 3/8" Annulus Tieback
Tubing to Servicing Rig
Tie Back Tool
Hydraulic Connector
Flowline to Platform

3
8

Wet Subsea Xmas Tree

Nipples for Landing

Tubing Hanger Check
Valves

S.S.S.V Control Line

DPTT Sentry Line
Tree Connector
Tubing Hanger

1 Joint of 1.66
Annulus Tubing
Valve Identification:

Downhole S.S.S.V. with

Flow Couplings

(1) Manual Tubing Master Valve

(2) Tubing Hydraulkic Master Valve
(3) Tubing Swab Valve
(4) Tubing Wing Valve
(5) Tubing Annulus Master Valve
(6) Annulus Swab Valve
(7) Annulus Wing Valve
(8) Annulus Crossover Valve
(9) Manual Flowline Valve

Downhole Pressure and

Temperature Transmitter (DPTT)
Wireline Operated Sliding
Side Door
Locator Seal Assembly
Permanent Production Packer
Millout Extension Packer/
Seal Bore Protector
Tailpipe
9 5/8" Casing

COMPLETION NO. 11 (Figure 27)

Serviced by conventional wireline techniques
The philosophy behind this completion is to improve the reliability of the completion
such that even though wireline techniques are to be used, the necessity for such work
is minimised. This is partly accomplished by using a simple completion design and
by duplicating essential items such as Xmas tree control valves. Although the initial
capital costs for TFL facility are not required, should work be required, a work boat
or drilling rig, e.g. a semi submersible or drillship, has to be mobilised.

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Figure 27
Subsea Completion
Serviced by Conventional
Wireline Techniques from a
Workboat or Mobile
Drilling Rig

Wellbore Completion Concepts

Summary
In this chapter we have covered the basic principles of well completion design.
Emphasis has been placed on: Selection of the most appropriate bottom hole completion design for a specific
production or injection scenario. This is primarily influenced by lost, life of well
and reservoir management considerations.
Selection of the conduit for production or injection giving regard to well integrity
and longevity.
Specification of completion string components based upon their operational
function ability. The basic approach which has been recommended stresses
simplicity but attempting to focus on operational efficiency throughout the
envisaged life of the well.
The purpose and need for :Annulus isolation
Annular tubing circulation
Subsurface safety system
Surface control and isolation
Flow and pressure isolation
Downhole monitoring accommodating L downhole tubular stress.
General concepts of completion architecture.

Department of Petroleum Engineering, Heriot-Watt University

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