Devising Integral Plan for Efficient Well Completion

• Well completion is the selection and installation of

equipment in a well to achieve the optimum production at
minimum possible cost throughout the entire life of a well.

• To have the optimal production at minimum cost, the

completion must be designed to comply the following
conditions:

 Maximum reservoir protection

• Minimum remedial work

Devising Integral Plan for Efficient Well Completion

• Ease of workover operations

• Maximum operational effectiveness

• Minimum lifting cost of produced fluids

• Maximum ecological protection

• Maximum degree of safety all the times

• Maximum protection in corrosive environments

Reservoir Considerations of Well Completion (Effect
of reservoir Drive Mechanism):

• The two most important characteristics that affect the

well completion are Drive Mechanisms of reservoir,
andReservoir Homogeneity & Heterogeneity

• Drive Mechanisms of reservoir:

1. Dissolved gas drive (fig-1): The source of pressure

is due to liberation & expansion of dissolved gas from
oil as pressure is reduced due to exploitation of the
reservoir.
Reservoir Considerations of Well Completion (Effect
of reservoir Drive Mechanism):

2.Gas cap drive (fig-2): The source of pressure is due

to expansion of free gas available above the oil zone.

3.Water drive (fig-3): The source of pressure is due to

expansion or influx of water from outside and below
the reservoir.

• Most reservoirs produce through some combination

of each drive mechanism
 DRIVE MECHANISM
• The reservoir drive mechanism influences
producing well characteristics and therefore, they
are given due importance while designing &
selecting initial well completion and later in
recompilation of wells.

1)Dissolved gas drive

 DRIVE MECHANISM

2)Gas cap drive 3)Water drive

 reservoir pressure vs. production
• Fig – 4 and 5 show typical reservoir pressure vs.
production and gas oil ratio vs. production for the three
basic drive mechanisms.

• Fig-4 Reservoir pressure trends

GOR trends for for various drives
• Fig-5
 DRIVE MECHANISM

• The dissolved gas drive reservoir shows a rapid

pressure decline, initial rapid gas oil ratio (GOR)
increases followed by rapid decline of GOR. This
type of drive results in relatively low hydrocarbon
recovery and further recompletion cannot reduce
GOR to accepted level.

• Gas cap drive reservoir pressure decline is rapidly

less than the dissolved drive. GOR increase is the
result of gas cap expansion in interval.

• Thus recompletion creates opportunity for GOR

control under limits.
 DRIVE MECHANISM

• Water drive reservoir pressure does not substantially

change and remain relatively high, low GOR. But
down structure wells in this type of reservoir are
expected to produce water in early stage. In such
case recompletion or shut in the wells results in water
production control.

• Apart from reservoir pressure, well spacing and well

location, are also important factors. Thus after
identification of drive mechanism of the reservoir,
optimum well spacing is planned for development
drilling.
 Dissolved-Gas-Drive Reservoirs:
• Completions in a dissolved –gas-drive reservoir with low
structural relief can be made in a regularly spaced pattern
throughout the reservoir, and provided the rock is not
stratified, can be made low in a reservoir bed, Fig-6 .

• Fig 6: Dissolved gas drive- high angle of dip

 Dissolved-Gas-Drive Reservoirs:

• A regular spacing pattern could also be used for a

dissolved gas-drive reservoir with a high angle of dip Fig -
7.
 Dissolved gas drive

• It is expected that the oil will drain down-structure in

time so that higher-than-usual oil recovery will be
realized with minimum investment in wells. The
operator must recognize the reservoir situation soon
enough to eliminate drilling the structurally high
wells.

• The oil will drain down-structure in time so that

higher-than-usual oil recovery will be realized with
minimum investment in wells.
 Dissolved gas drive
• The operator must recognize the reservoir situation
soon enough to eliminate drilling the structurally
high wells.

• As primary recovery by dissolved gas mechanism

usually low means of secondary recovery will be
needed in future. Thus initial well completion should
incorporate this consideration in gas drive reservoir.
 Gas-Cap-Drive Reservoirs:
• Gas cap drive reservoir having thick pay zone, and dip
angle is low and gas cap is entirely underlain by oil pool,
wells may be completed and spaced on a regular pattern.
• Completions should be made low in the section to permit
the gas cap to expand and drive oil down to the completion
intervals for maximum recovery with a minimum gas
production.
Gas cap low angle of dip
 Gas-Cap-Drive Reservoirs:

Gas cap high angle of dip

 Gas-Cap-Drive Reservoirs:
• A gas-cap-drive reservoir in thin sand with a high angle of dip is
likely to be more efficiently controlled by having completion
spaced irregularly but low on the structure to conform to the
shape of the reservoir

• Regular spacing pattern may cause much completion to be

located too near the gas-oil contact due to high angle of dip
reservoir. Such an oil reservoir is common where multiple thin
sands are found on a single structure and the oil column is only
a fraction of the total productive reservoir.
 Water-Drive Reservoirs
• The spaced of well may be done Water drive low angle of dip
on a regular pattern in a water-
drive reservoir having a thick
sand and low angle of dip.

• Completion intervals should be

selected high on the structure to
permit long producing life while
oil is displaced up to the
completion intervals by invading
water from below.

• A thin pay sand having high

angle of dip may be best
developed with regular well
spacing due to the structural
characterises.
 Water-Drive Reservoirs

• Water drive high angle of dip

 WATER DRIVE RESERVOIR

• The completion, however, should be made high on

the structure to delay encroachment of water into the
producing wells.
• Spotting the wells on a regular spacing pattern not
only may cause a number of wells to produce water
early in the life of the reservoir and result in their
early abandonment, but also may reduce the
effectiveness of the water drive through excessive
early water production.
 WATER DRIVE RESERVOIR

• ewer wells would remain to produce the remainder of

the oil, thus lengthening unnecessarily the length of
time required to deplete the reservoir.

• For maximization of recovery from the reservoir a lot

of water required to be produced with oil in later
stage of production life of field.
 Reservoir Homogeneity & Heterogeneity:
• Completing with a adequate numbers of wells structurally
high in case of water drive and structurally low for
dissolved gas and gas-cap-drive reservoirs is beneficial if
reservoir concern is reasonably uniform through out.

• Generally, reservoirs have stratified layers of varying

porosity and permeability. As various layers of the
formation has different porosity & permeability fluids flow
through these layers with different degrees of ease, and
many times impermeable zones separate the permeable
beds so that no fluid can move from bed to bed.

• This phenomenon is illustrated Fig 12 and 13

 Reservoir Homogeneity & Heterogeneity

Fig-13: High GOR

production due to early
encroachment of gas
rough high permeability
layer of stratified reservoir

Fig -12: Irregular water

encroachment and premature
water breakthrough in high
permeability layer of reservoir.
 Reservoir Homogeneity & Heterogeneity
• In highly stratified (thin) beds, movement of fluid parallel to
bedding planes (fingering) of free gas down from a gas cap, or
water up from a water basin is always a possibility when short
completion intervals combined with high rates of production are
encountered. These problems are shown in fig 14 and 15.

• Fig -14 Fingering of free gas into

into the well along bedding planes.
 Reservoir Homogeneity & Heterogeneity

• Fig -15 Fingering of water

the well along bending planes
 Reservoir Homogeneity & Heterogeneity

• If the reservoir is stratified either by shale breaks or by variations

in permeability, it probably will be necessary to stagger the
completion intervals in various members of the reservoir to be
sure that each member is drained. Some vertical staggering of
completion intervals can be effected during development to
secure proportionate withdrawals from the various layers of the
formation.
• In later stage of exploitation additional distribution of
completions between the various members of this type of
formation may be made by workover, based on experience and
operational conditions observed. Multizone completions may
be needed for low permeability reservoirs, which require long
completion intervals for obtaining economic quantities of
production.
•
 Completion efficiency considerations:
• Partial penetration effect:
• In a "partially penetrating" well only a fractional of the total
productive section is open to the well bore. This type of
situation can be achieved both in open hole and cased hole
completions.
• Partial penetration effect (open hole)
 Completion efficiency considerations

• Partial penetration effect ( cased hole)

 Liquid flow rate:
• For a constant gas oil ratio, as liquid rate increases, total mass
being lifted increases and fluid velocity increases. This
increases both the elevation and friction loss . Effect of liquid
flow rate on flowing pressure gradient is shown in fig-18.
 Reduced Producing Rate effect

• It has been shown by Muskat (fig 19) that the productive

capacity of a partially penetrating well is related directly to the
percentage of the total section penetrated. Note that for a 130-
foot bed, fractional penetrations of 0.2 (26 feet) and 0.85 (100
feet) would result in productivity ratios of 30% and 90%,
respectively.
• Well with 110 feet of perforations would have a production
capacity three times as great as that of the well with only 26 feet
of perforations. Therefore, productive capacity of a well depends
on how much perforation is opened.
•
 Reduced Producing Rate effect:

• Production ratio for a partially penetrating well

 Reduced bottom hole pressure effect

• Bottom hole pressure induced in a partially penetrating well is

less than what it would be in totally penetrating conditions.
• Effects of partial penetration and skin damage on BHP
 Skin damage effect

• The effect of partial penetration is similar to that produced by

skin damage. Skin damage is defined as a thin layer of
impaired permeability occurring immediately around the
wellbore and extending vertically over the entire productive
interval penetrated by the well.

• Effect of tubing size:

• There are certain reservoir associated variables which must be

at least closely approximated in order to accurately perform
tubing sizing calculations. These are (1) gas/liquid ratio, (2)
liquid density, (3) liquid viscosity, (4) liquid surface tension and
(5) kinetic energy.
 Effect of tubing size:

• Figure illustrates the effect of tubing size on required flowing

bottom hole pressure at various flow rates in an 8,00 foot oil well
 Effect of Gas/Liquid Ratio

• As gas/liquid ratio increases, the density of the produced fluid

decreases which
• Lowering of required flowing bottom hole pressure. Effect of
gas/liquid ratio on required flowing bottom hole pressure for a
flow rate of 200 STB/D through 1-1/4” tubing in a 10,000' well
has been shown in Figure
•
 Water oil ratio:

• water cut and causes a well to die and thus it should be

anticipated in planning. As water is heavier than oil, the water
cut or water oil ratio increases the density of the mixture of the
both. Due to this the pressure gradient increases which is
shown in fig 23.
 Effect of Liquid Density:

• As liquid density decrease, required flowing bottom hole pressure

decreases. Figure 24 (a) shows the effect of API gravity crude to
fresh and salt water. Figure 24 (b) shows the effect of water/oil ratio
or density change due to changing water percentage on required
flowing bottom hole pressure.
• Fig-24a fig-24b
 Effect of Liquid viscosity:

• As liquid viscosity increases, higher flowing bottom hole

pressures are required in the well, which is shown in fig
 Effect of slippage:

• In event of too small fluid velocity in the tubing, the liquid tends
to fall back and increases the density of fluid in the wellbore.
The Fig shows this effect or various GLR for a fixed tubing size.
Effect of GLR on slippage
 Effect of liquid Surface tension /kinetic energy

• The flowing bottom hole pressure increases if surface tension of

the produced fluid increases.
• For small diameter tubing with high gas/liquid ratios and low-
pressure levels, kinetic energy effect on flowing pressure
becomes important. As the kinetic energy increases with
increase in GLR, the bottom hole pressure decreases.
 Effect of Subsurface Choke

• Subsurface Choke is the second major item of pressure

reduction within the producing equipment.
• Subsurface chokes are installed at various depths within the
tubing string and its Installation depth is largely dependent upon
the service function the choke performs.
• Fig-27 shows pressure drop effect for five different choke sizes
at various flow rates in 2" tubing size. The chokes are installed
at 10,000 ft in example "A" and 2500 ft in example "B". It should
be noted that pressure drop is consistently grater for the more
shallow installation, even though flowing bottom-hole pressure is
set at 5000 psi in both examples.
 Effect of Subsurface Choke

• Fig-27 shows pressure drop effect for five different choke sizes
at various flow rates in 2" tubing size. The chokes are installed
at 10,000 ft in example "A" and 2500 ft in example "B". It should
be noted that pressure drop is consistently grater for the more
shallow installation, even though flowing bottom-hole pressure is
set at 5000 psi in both examples.
 Effect of Surface Choke
• Surface choke is the next major point of pressure loss within the
producing completion system. In Figure 28 pressure drop is
plotted as a function of upstream pressure in the choke for three
different surface choke sizes.
» dp Across choke ( 100 psi)
 Effect of Surface Choke

• Pressure drop decreases as upstream pressure increases for a

constant flow rate. In figure 29 upstream pressure is constant at
5000 psi, and flow rate is variable. This plot shows the effect of
choke size on both pressure drop and maximum potential flow
rate.Fig shows effect of choke size on pressure drop and flow
rate dp Across choke ( 100 psi)
 Effect of Flowline Size at Surface:

• The next area of major pressure loss is the surface flow line.
Fig-30 shows the effect of flow line size and length upon
required flowing pressure gradient for a 1000 STB/D water well.
• Fig - Effect of flow line
 Effect of Separator Pressure:

• The third major point of pressure drop in the producing system

is the separator. Separator pressure is set at a fixed and
constant level. Under given conditions, small changes in
separator backpressure can cause pronounced effects on flow
rate.
 Overall effect of a Integrated Completion System

• Equipment of various sizes (production tubing, the subsurface

choke, the surface choke, the flow line and the separator) is used
in the completion system and hence they create pressure drop
individually.
• Equipment systems create pressure drops, they influence
production rate potential of the well to the degree that they
reduce available pressure.
• The "total" pressure loss occurring at a given flow rate within a
given equipment system is actually a "summation" of the
pressure drops across the individual. Therefore, selection and
sizing of production equipment can have a pronounced effect on
producing rate.
• Figure presents a step-by-step summation of pressure drop
effect for two different equipment systems. Reservoir
parameters are identical in both cases. Flowing bottom hole
pressure is constant at 5000 psi.
 Overall effect of a Integrated Completion System

Curves (1) through (5) represent the same values in both examples
• Curves (1) show the effect
of tubing size (and length)
on pressure drop at various
flow rates.
• Curves (2) consider the
effect of both tubing size
and subsurface choke size
• Curves (3) are a plot of the
combined effect of tubing
size, subsurface choke
size, and surface choke
size.
• Curve (4).The effect of flow
line size is added in.
• Curve (5) combines to all
previously described effects
the additional effect of
separator pressure.
 Future Stimulation Considerations
• Present and future stimulation
requirements of each well
must be considered at the time
of initial completion itself.
• For example figure 33
presents two approaches of
simultaneous stimulation of a
multiple zones.
• The limited perforation
technique applied in the well
on the left side of the figure
results itself to high rate
fracture treatment and needs
zone isolation of stages.
• The "blanket" perforation
approach for the well on the
right side, however, would be
more applicable for a well for
which no fracture stimulation is
anticipated.
 Which well needs Stimulation:

• 1. Good wells are generally the best candidates for

stimulation.
• 2. Wells in non-prorated areas are prime candidates for
stimulation.
• 3.Wells having known formation damage are good stimulation
prospects.
• 4.AA well, which has been previously fractured, is normally a
poor candidate for further stimulation
 Completion Selection and Design Criteria

 Gross production rate

Well Design Implications
 Well pressure and depth Parameters
 Rock properties High Volume

 Fluid properties Liquid: 1500- Significant frictional

 Well location 10,000 b/d
(160-16,000 m3/d) Pressure losses
• Typical ranges for various classes
of completions and the design Gas: 35-140 Large diameter tubing
MMscf/d
implications are presented in Table (1-4 106
I. represents a partial list of well m3/d)
(>2 7/8 in. or 73 mm)
parameters; Given the variety of Large diameter casing
production conditions around the
world, definition of the thresholds is (>5 1/2 in. or 140 mm)
naturally somewhat nebulous (a low
production rate in a Middle Eastern Special artificial lift
equipment
well would be considered a very Thermal contraction/expansion
respectable rate in many North equipment

American fields). However, this Erosion control equipment

table gives a general idea of the
range of design considerations:
 Low Volume / Very High Pressure
• Low volume Very high pressure
Liquid: Artificial lift 10,000- Special stress checks required
<30 b/d required 25,000
(5 psi
m3/d)
(70-175
MPa)
Gas: <1 Paraffin buildup
MMscf/ problems
d during completion
•High-strength tubulars
required
•Special high-performance
(30 -103 Special attention to packers/accessories required
m3/d ) operating costs •Problems with H2S aggravated
required by high pressure requiring
special tubular steel
 Selection criteria

• High Pressure
3000-10,000 psi Flanged, rather than threaded, wellheads required

20-70 MPa)
.Special tubing and coupling designs required
•Well-killing capabilities required

• Low Pressure
<1000 psi (<7 MPa)

Threaded wellheads may be used

•Artificial lift required
•Greater risk of damage/fracturing during completion
process

• Deep Wells
>10,000 ft (>3000 m)
Problems associated with high pressures
•Tubular weight/tension must be considered
•Casing size/liner usage must be considered
•Hydraulic piston pumps or gas lift more likely to be
used as artificial lift
External corrosion of tubulars may be a problem
due to higher pressure and temperature
 Selection criteria

• Rock Properties permeability (table below )

All carbonates

Acid wash required upon completion

•Difficulty identifying water contact; need formation or
drillstem tests

Very Low (<1 Fracturing required upon completion

md)
Low (1-50 md) May need fracturing upon completion High pressure draw down
across perforations
Moderate (>50
md)
Little benefit from fracturing
•Matrix acidizing may be necessary
•Formation damage risks greater due to permeability
•Moderate pressure drawdown across perforations
High (>1 D)
High (>1 D)
Lost circulation a problem
•Sand strength may not be great enough to support high
velocity flow
•Easily damaged
 Selection criteria
• Fluid Properties
Hydrogen sulfide Special regulations/procedures
Corrosion inhibitors may be required
Gas usually considered sour if H2S
partial pressure is 70.05 psia (0.3 kPa)
Carbon dioxide Consider inhibitor or special steel if
CO2 partial pressure is >10 psi (70 kPa)

Water production Scaling may be a problem

Special artificial lift equipment may be
req'd
Water injection Consider oxygen corrosion prevention
reqs. Consider backflush requirements

• Well Location
Offshore Special regulations must be followed
Subsurface safety valve requirements
Consider well servicing & access
constraints
Urban areas Special safety requirements
Noise and height limits

Mountainous areas Consider wellhead damage by

landslides/avalanches
 Functional and Well Service Requirements
• Definition of the functional and Completion Importance or Completion
well servicing requirements at Considerations Need Design
the outset can considerably Implications
simplify selection of preliminary Rates

completion concepts and will

High None
highlight the key trade-offs
needing further evaluation. Moderate High Favors two
• The completions engineer will w/chokes small tubing
prepare the initial input at the strings
Low Possible
concept stage, to quantify the
requirements Variable Critical
• Table II below is a checklist for
identifying the critical concerns Pressures
for a completion design; it
illustrates the use of such a High None
checklist in designing a specific
Low Probable Artificial lift
subsea oil well. required
•
 Producing Characteristics

• Selection criteria

Multiple zones Possible stack completions

Minimize costs Moderate review costs

Access difficulty High TFL/new technology

Uptime High minimize difficulty of

future workovers

Rate control Critical chokes needed

Rate stability Critical wellhead chokes needed

Long life Unlikely carbon steel sufficient

Density of kill fluid Moderate kickoff w/gas lift

Safety during vessel Critical 2 SSSVs and kill system

reentry
Wellhead damage Possible annular SSSV
 Selection criteria

• Monitoring
Test frequency High Critical choke bean or dedicated flow line

Pressure measurement Moderate TFL access for down hole tools

Special BHP surveys Some TFL access for down hole tools
needed
Log contacts Critical Vertical access required
Production logs Some Vertical access required
needed
Tubing investigation High TFL access &/or vertical access
• Artificial Lift
Intermittent w/maintenance High gas lift is optimal method via TFL and
vertical access

Continuous Possible

Increasing gross rate High

Pressure depletion Possible

 Selection criteria

• Kick-off
Initial completion Moderate Use gas lift system
Routine operations High Gas compressor supply required
Depleted conditions Possible
High water cut High
Critical rate High GLV maintenance system
Frequency High
Gas supply volume Moderate Gas compressor special requirements

• Repairs
Cement High Future concurrent production
and Workover operations; easy
access; Robust tubing joints
Gravel pack Critical

SSSV Probable

Tubulars Low

New interval Possible Multizone completion design

 Selection criteria

• Recompletions
Uphole Moderate Large casing preferable
Deepen None Limit depth of rathole
Sidetrack Possible Maximize casing size
Function change Moderate Large CSG preferable

• Production Problems
Sand control Critical Gravel pack required

Paraffin Possible TFL access for scraping

Emulsions Possible Chemical injection capability

Water cut High Artificial lift required

Scale Possible TFL access

Corrosion Moderate Carbon steel & down hole chemical

inhibitor injection
Erosion Low

Fines Probable Frequent acid jobs required

GP failure Moderate TFL w/annular kill valve

 Subsea oilwell functional requirements

• It is important for the completion design engineer to have some

appreciation for the relative impact of production revenue,
capital costs, and operating costs on project economics. In a
high tax environment they are usually in the order of importance
• Installation costs are only significant to the extent that special
completion requirements have a significant impact on the overall
drilling and completion time
• Subsea developments in hostile environments, it is reasonable
to assume that a premium can be paid for minimizing the
frequency of reentry and for equipment reliability and durability.
• Reservoir, geological, and economic considerations will dictate
the functional requirements of a completion and the relative
significance of major and minor workovers.
• Requirements have to be anticipated at an early stage such as
(wireline, service rig reentry, TFL, coiled tubing, etc.) are limited
by the tubing design and packer/tubing configurations of the
completion.
 Subsea oilwell functional requirements

• The completion design of a well is also influenced by the well

service requirements.ie the following five major functions
1 Routine monitoring (e.g., being able to run production logs,
shoot fluid levels, etc.)
2. Wellhead and flow line servicing (e.g., designing components for
easy isolation)
3.Minor workovers (e.g., through-tubing operations, wireline work,
TFL)
4. Major workovers (e.g., tubing-pulling operations)
5. Emergency situations (e.g., well-killing operations)
To some extent these apply to all oil and gas developments, their
relative importance, frequency, complexity, and cost are functions
of reservoir conditions, governmental regulations, operating
philosophy, and geographic and environmental considerations
 Subsea oilwell functional requirements

• For example, it should be self-evident that the options for reentry

of subsea wells in deep water are limited and are going to be
expensive.
• The designer must therefore look carefully at the functions that
can be built into the completion and wellhead to minimize well
service requirements.
• All wells have the potential for "bull-heading" kill or treatment
fluids through the tubing, although it becomes more difficult to
control the operation and ensure an efficient displacement as
the tubing size and deviation increases. Similarly, with relatively
shallow dry gas wells
• it should be possible to estimate the bottomhole pressure fairly
accurately from tubing head pressure measurements, avoiding
the need to run bottomhole surveys.
• Another built-in function in all offshore wells is the ability to
achieve a subsurface shut-off using the government-regulation-
required subsurface safety valve.
 Subsea oilwell functional requirements

• As completion designs become more sophisticated, they can

provide an increased number of integrated service functions, up
to the ultimate multizone, full TFL completion with downhole
pressure monitoring capability.
• The economic and technical justification for this type of
completion must be based on a detailed functional analysis of
the reservoir, completion lifetime, and well service economics.
• Moreover, increased sophistication also introduces higher risks
of completion problems or subsequent failures, requiring
improved quality control and materials selection.
 Drilling Considerations
• Drilling considerations can influence the type of completion
installed, particularly for exploration and delineation wells.
• Conversely, completion considerations will help to determine
drilling practices in development and infill wells. Factors to be
considered include
1. Probable extent of drilling damage and the resulting
requirements for special perforating or stimulation techniques, or
the selection of special drilling fluids, or both.
2. The evaluation program, particularly the need for
precompletion testing, to determine if special logs or tools like
the repeat formation tester (RFT) can reduce testing
requirements.
3. The size and weight of the production casing. The
heavyweight tubular casing used in high pressure wells has
reduced drift diameters (internal diameters, or IDs) , which
imposes limitations on the packers and accessories that can be
used
 production casing

• For example, the use of 7-in (178-mm) production casing

precludes the use of a dual tubing string with 2 7/8 x 2 7/8-in
(73 73-mm) or larger tubing diameter.
• Depending on the production capacities and reserves of the
various producing zones, a single-string, multizone completion
with larger diameter tubing may be better .
• Maximum Tubing Capacity of Flowing and Gas Lift Wells
Casing Size Maximum tubing Maximum Theor. Maximum Theor.
(in) size Liquid Rate* Gas Rate*
(in) (b/d) (MMScf/d)
4 2 3/8 2000 15

4 1/2 2 7/8 5000 25

5 1/2 3 1/2 7500 40

6 5/8 4 1/2 15,000 80

7 5/8 5 1/2 20,000 120

9 5/8 7 60,000 »100

*IPR, THP, GLR, and conduit length often prevent such high rates being achieved in specific cases.
 production casing

• 4. The burst and collapse strength of the production casing. The

casing must be able to withstand the maximum closed-in tubing
pressures in case of a tubing break at surface.
• If the well is to be pumped off with an open annulus, the casing
must have adequate collapse strength. Casing strength often
dictates stimulation design, kill procedures, and selection of
annulus pressure operated tools.
• 5. Wear or corrosion of the production casing must be evaluated in
liner completions, especially for deep wells, and, if necessary, a
tie-back string must be installed. However, use of a tie-back string
may limit throughput capacity by limiting the diameter of the
production tubing
• 6. In sour (H2S) environments, production casing materials should
conform to NACE specifications. This is critical in deep, high
pressure wells where very small amounts of H2S can result in a
stress cracking risk
 Production casing

• 7. The coupling used on the production casing needs to be

carefully selected where high differential pressures (>5000 psi
or >34 MPa), high temperatures (>300° F or >422 K), or high
compressional or tensional loads are expected (e.g., deep wells,
high rate wells, thermal wells).
• Where a gas-tight seal is essential (e.g., sour or high pressure
gas wells or wells with high pressure gas-lift systems), premium
couplings are generally recommended
• 8. Proper cementation of the production casing is the key to
successful zonal isolation and avoidance of many production
problems.
 Production casing

• Casing Requirements for Dual Tubing

Casing Maximum Dual Tubing
(in) (in)

9 5/8 3 1/2 x 3 1/2

8 5/8 3 1/2 x 2 7/8

7 5/8 2 7/8 x 2 7/8

7 2 7/8 x 2 3/8

2 7/8 x 5 concentric

5 1/2 2 1/16 x 1.9

 Artificial Lift Requirements
• Artificial Lift Requirements

Casing Size Tubing Maximum Capacity

Tubing Size Pump Size
(in) (in) (mm) (b/d)
Rod Pumps

3 1/2 1.9 48 550

4 2 3/8 60 800

4 1/2 2 7/8 73 1300

4 1/2 3 1/2 89 1900

5 1/2

Electrical 2 7/8 73 1750

Submersible§
4 1/2 3 1/2 89 4000

5 1/2 5 127 10,000

7 7 178 35,000

9 5/8
 Specifications and Regulations :

• In many well completion situations (e.g., high pressure wells,

deep wells, sour gas wells, and offshore and subsea
completions) the design options are constrained by government
regulations, company operating philosophies, and company
design specifications
• In addition, designers are expected to conform to the standards
of "good oilfield practice," which are often embodied in
agreements and regulations.
• Generally, this is interpreted to mean keeping the well under
control with two lines of defense, so that a single failure or
human error will not cause serious injury or environmental
damage.
• 1. During Production (a-Surface)Internal: Xmas-tree wing and
master valves and offshore Xmas tree and SSSV (External:)
packer and wellhead
• b. Subsurface: tubing and casing (check valve and casing for
side pocket mandrel devices)
 Specifications and Regulations :
2. During Drilling and Workover (a. Surface)Internal: mud/workover fluid and
BOPs (External:) cement and wellhead
b. Subsurface: mud/workover fluid and casing/shoe strength

3. During Lifting BOPs/Xmas Tree (a. Surface)Internal: two plugs or SSSV

and plug (External:) packer and wellhead, including annular access
shutoff via a valve, plugs, or annular SSSV
b. Subsurface: As in 1b

4. Long-Term Suspension of Completed Well (a. Surface)Internal: deep-set

plug and SSSV (External): deep-set plug and packer
b. Subsurface: as in 1b

5. Long-term Suspension of Uncompleted Well (a. surface)Internal: two

cement and/or bridge plugs (External:) as in 2a (external)
b. Subsurface: plug and casing/shoe strength

6. Temporary Suspension of Uncompleted Well (a. Internal) as in

5a(internal); or casing/cement and a kill string/tubing hanger
 Specifications and Regulations

• Even if the well has such low pressures that it tends to kill itself,
wellsite personnel should always be able to rely on a second
line of defense (wellhead, BOP, etc.).
• Switching off the artificial lift system or lift gas supply can
sometimes be considered a line of defense in pressure control,
if this action would normally cause the well to die.
• The major design specifications commonly used by the oil
industry are by the American Petroleum Institute (API).
• In general the specifications address the manufacture and
testing of components;
• Bulletins and Recommended Practices address the
performance that can be assumed for design purposes and the
procedures to be adopted in implementing that design.
• The API specifications of particular relevance to completion
design are detailed in Appendix A. Materials used in sour wells
should conform to NACE Specification MR-01-75.