completion training next bali june 2010

8/22/2019 Completion Training NEXT Bali June 2010

1/98

Completions

Ricardo Gomez S.

Technical Mana er Schlumber er Com letions and Sand Mana ement

Copyright 2009, NExT, All rights reserved

Services - Indonesia

1


2/98

Outline

1:00 to 1:50pm Session 1 Completion Engineering

Introduction to Completions Well Completion Planning

Completion Design and Engineering


: to : o ee rea

2:00 to 2:50 Session 2 Core Completion

Packers, accessories and Safety Valves

2:50 to 3:00 coffee break

3:00 to 3:50 Session 3 Special Completions

Sand Control, Monitoring, Intelligent completions, Subsea

4:00 to 4:30 Quiz 2


3/98

Session 1 Completion Engineering


3


4/98

Introduction to Completions


4


5/98

What is Completion?

The methodology and technology installed in wellbore after

drilling to allow safe, efficient and economic production


large amount of engineering

and planning in the operations

5


6/98

Types Of Completion

By Wellbore/reservoir interface

open-hole or cased hole completion


6


7/98

Types Of Completion

Production method

natural flowing

artificial lift production

Rod pump


Gas lift Electric submersible pump

Plunger lift

Jet pump

7


8/98

Types Of Completion

Producing zones

single zone

multiple zone


8


9/98

Planning, Design and Engineering


9


10/98

Phases of Well Completion


10


11/98

Selection Of Completion Components


11


12/98

Metallurgy and Elastomer Selection

Completion components are

exposed to multipleenvironments

Temperature

Completions Failure Frequency

CO2 Related 28%

H2S Related 18%


Electrostatic currents

Corrosion

Erosion

Fluids

Pitting and crevice 15%

Erosion, corrosion,

impingement

12%

Galvanic 6%

Stress corrosion 3%

12


13/98

Definition of Alloys

Fe + C Steel

Fe + Cr Stainless Steel


Fe + Cr + Ni + Mo Austenitic Stainless Steel

Ni + Fe + Cr + Mo Incoloy

Ni + Cr + Mo Inconel

13


14/98

Materials Selection Guide

Environment Alloy Recommended

Non-Corrosive Service 4130/4140 (polished bores 9 Cr-1 Mo)

Slightly Corrosive to ModeratelyCorrosive Low H2S, CO2 + Water Low

Temperatures,


15/98

Material Selection for Completion Equipment

17-4PH or 25Cr

Oxygen kept to

a minimum.

925/718 f.w. Or

all 925/718 (for

duplex or 825

tubing)

13CR fl wet

4140 ext or (all

13CR for 13CR

tubing)

9CR, fl. Wet

4140 ext.

SSSV

Water injection

service

Severe and/or

H2S-CO2service

Intermediate

and/or CO2service

General and/or

sour service


4140 ext., 17-

4PH or 25Cr f.w.

parts

925/718 f.w.

4140 ext.

13CR f.w. 4140

ext.

4130/4140Packer

17-4PH,

Custom 450,

25Cr

925/7184104130SPM

17-4PH or 25Cr925/71813CR9CRNipple

15


16/98

Completion Tubulars Design

Deterministic

Conventional (>30 yr. & outdated)

Service Life (>15 yr. )


es gn ac orsProbabilistic

Future of casing & tubing design

Probability of Failure (10-2-10-6)

16


17/98

Elastomers

Elastomers can be stretched twice its original size and return

back to its original size

Nitrile


HSN

Viton

Aflas

Chemraz

17


18/98


19/98

Loads On Completion Components

After the completion components and materials are selected,

the effects of loads should be accounted for:

Pressure-Burst & Collapse

Axial-Tension & Compression


Bending-Trajectory/BucklingShear-Rotation

Non-axisymmetric

Completion Tubulars are Similarly designed as wellconstruction tubulars

19


20/98

Tubing Movement

Forces acting during installation, production and intervention

Piston High pressures, large areas


Large temperature changes

Ballooning

High pressuresBuckling

Small tubing inside large casing, large packer seal

20


21/98

Tubing Movement-Piston

F1

F1

Po Po

F2

F2

TubingID

TubingOD

LFL

p

p

= Po Po

Tubing ID

Tubing OD

F1 F1

F2 F2

F4 F4


F1

F1

Pi

PackerSeal

p

)()( ipkriopkrop AAPAAPF =

PackerSeal

F3 F3

21


22/98

Tubing Movement-Temperature

LengthWhenOriginal

Len th LTL =


engWhen

Heated

Original

Length

16109.6

= Fsteel

22


23/98

Tubing Movement-Ballooning

L 2


HIGHPRESSUR

E

LOWPRESSURE ooii

pbal EA

=

3.0=steel

psiEsteel61030 =

23


24/98

Tubing Movement-Buckling

NeutralPoint

=

baseeff

effb

loadeff

effbcbuckw

F

w

F

EIrL

222

8


Packer

n

ooiieff AAww +=

( )Dholerc = 5.0

24


25/98

Packer to Casing and Packer to Tubing Force

d

Fa

PoAox

ixiptoxoay APFAPFF +== 0

ixioxoapt APAPFF +=

2

4DAA pkrox

=

2

4dAA pkrix

=


+

+

Ac

D

Apkr

Fpc

Fpt PoAx

PiAx

Ax=Ac-Apkr

pcxixopty FAPAPFF +== 0

xixoptpc APAPFF +=

Fpt

PiAix

25


26/98

Tubular Design And Analysis


26


27/98

Session 2 Core Completion


27


28/98

Packers and Packer accessories


28


29/98

Packer Function

Isolation and control of hydrocarbon production

Basic Functions: Zonal Isolation

PACKER


Casing Protection

Flow Control

Primary Load Bearing Member

29


30/98


30


31/98

Packer Key Components

ElementsSlip Slip MandrelRatchet


Gauge Ring Gauge Ring

31

ISO 14310 Packer Performance Characteristics


32/98

ISO 14310 Packer Performance Characteristics


Packer Test ConditionsPacker Test ConditionsPacker Test ConditionsPacker Test Conditions

Unplugged Plugged IsolatedUnplugged Plugged IsolatedUnplugged Plugged IsolatedUnplugged Plugged Isolated 32

ISO 14310 St d d


33/98

ISO 14310 Standard

Seven design validation grades of increasing severity:

V6 : Supplier/manufacturer defined

V5 : Liquid test

V4 : Liquid test + axial loads


V2 : Gas test + axial loads

V1 : Gas test + axial loads + temperature cycling

V0 : V1 + zero bubble acceptance criteria

33

P k F ili


34/98

Mechanical PackersMechanical PackersMechanical PackersMechanical PackersTubing MountedTubing MountedTubing MountedTubing Mounted

Hydraulic Set PackersHydraulic Set PackersHydraulic Set PackersHydraulic Set Packers

Seal Bore PackersSeal Bore PackersSeal Bore PackersSeal Bore Packers

(Retrievable)(Retrievable)(Retrievable)(Retrievable)

Dual String PackersDual String PackersDual String PackersDual String PackersSeal Bore PackersSeal Bore PackersSeal Bore PackersSeal Bore Packers

(Permanent)(Permanent)(Permanent)(Permanent)

Packer Families


34

W/L S tti A bl CPST AA


35/98

W/L Setting Assembly CPST-AA

Features/Benefits/Limitations

Accurate, Fast & Reliable

Expanding Gas vs hydraulic setting

mode.

W/L

Adapter Kit


Pressure balanced designPacker Assembly Weight Limitations

Trajectory Limitations

CPST

35


36/98

Hydraulic Setting Method

Hydraulic Setting Dropped Ball or Closed System

Immediate Packer Testing After SettingDesign Allows Higher Setting Forces

-


Primarily Use Sand Control Applications

Trajectory Insensitive

Round Trip w/ Workstring Required

Setting Depth Inaccuracy vs. E-Line

36


37/98

Hydraulic Set Packers

T icall used in a lications where multi-zone, and/or


one-trip completions are required.Also used in high pressure/high temperature applications

and in highly deviated wells

Packer is hydraulic set, tubing conveyed

No Setting Tool Required

37

Typical Tailpipe Assembly


38/98

Typical Tailpipe AssemblyFor Lower Seal Bore Packer


38

Locator Seal Assemblies


39/98

Locator - Seal Assemblies

Types:

Locator TypeSnap Latch

Locator Snap Latchor

Anchor Latch


nap- n nap- u

Anchor Latch

Snap-In/Rotate-Out

Self-AligningGuide Shoe

MuleShoe

39

Production Expansion


40/98

Production Expansion

Joints

LOAD CASE


40


41/98

Packer Milling

Rapid Mill & Removal

Tungsten-Carbide tipped milling shoe

can mill out the largest packer in a

single trip


extensionsMilling tool features a safety release

from the packer if the packer

cannot be retrieved

41


42/98

Milling Tools

Used to quickly and safely mill over and/or retrieve packers,permanent bridge plugs, and cement retainers from thewell.

Millout time is reduced to the minimum due to specificallydesigned milling shoes.


42

Retrievable Service Packers


43/98

Retrievable Service Packers

Omegamatic & Omegamatic Long Stroke

High Pressure/Medium Temperature

Suitable for Stimulation, Remediation, Perforating, Testing & Short TermProduction

Mechanical Actuation & Compression Set

Resettable Downhole


Omegamatic LS used for Single Trip Perforate and Frac Pack for

fracturing.

Not suitable for shallow applications

43


44/98

Safety Valves


44

Overview of Subsurface Safety Valves


45/98


Primary Purpose

Emergency well flow control device

Prevents losses

personnel, environment, reserves, image


Secondary Purpose

Down hole flow control

allows for wellhead problem corrections

serves as a secondary barrier

45



46/98


Applications

Offshore wells Platform


FPS, etc.

Environmentally sensitive wells

Marsh lands

H2s /C02 containing land wells

46

API-14 A Specifications


47/98

API 14 A Specifications

Class:

1 = Sweet Well

2 = High Sand


3 = Sour Service

47

O i f S b f S f t V l


48/98


Types of SSSVs

Surface Controlled tubing retrievable


Subsurface controlled

Velocity

Injection

48

Application Basics


49/98

Application Basics

Key Issues

Nominal dimensions and sizing

Pressure ratings

Profiles and polished bores (dimensions)


Setting depths (calculations)Lock-open systems

Environmental concerns (materials)

Where and how will it be used?

Design selection criteria

Commercial factors49

Application Basics


50/98

Application Basics

Maximum Fail-Safe Setting Depth

Where:

FSSD = FC - FSMFG *FS = 0.15FC


FSSD = The fail-safe setting depth of the valve.FC = The minimum closing pressure in psi.

FS = The safety factor in psi.

(*The safety factor should never be less than 75 psi)

MFG = The Maximum fluid gradient in psi/ft.

50

Application Basics


51/98

Application Basics

Recommended Hydraulic Pressure

Where:PSO (min) = Minimum Recommended Hydraulic. Operating

PSO

(min) = Pt

+ Po

+ Psf

- Ph

Minimum recommended Hydraulic Operating Pressure (Surface)


Pt = Tubing pressure at valve depth.

Po = Opening pressure (zero bore)

Psf

= Safety Factor to ensure valve is fully open

(400 psi for Elastomeric / Plastic Seals and 1500 psi

for Metal to Metal Seals)

Ph = Pressure of the hydraulic fluid. 51

Application Basics


52/98

Application Basics

Recommended Hydraulic Pressure

Where:

PSO (max) = Maximum Recommended Hydraulic. Operating

PSO (max) = Pt + Po Ph + 5000 psi

Maximum recommended Hydraulic Operating Pressure (Surface)


Pt = Tubing pressure at valve depth.

Po = Opening pressure (zero bore)

Ph = Pressure of the hydraulic fluid.

52

Product Design Issues


53/98

g

Operating Envelopes

More realistic prediction of products performance.

Account for influence of pressure to generate tensile forces invalve.


53

How Sub Surface Safety Valves Work


54/98

y

Safety Valve Animation


54

Flapper Closure Systems


55/98

pp y

+20,000 psi

More Reliable then ball type closure systems

Mechanically Simple


Can Pump Through

Flappers have high pressure ratings(> 20,000 psi)

55

High Strength Flapper Hinge System


56/98


56

High Strength Flapper Hinge System


57/98


57

Flapper Closure Mechanisms


58/98

pp

Curved Flapper Design

Metal to Metal Primary Seal Non-Elastomeric Secondary Seal


Torsion spring closure

Applications

Maximized Valve I.D. / Minimized O.D.

Working Pressures to 7500 psi

58

Curved Flapper Systems


59/98


59

Ball Closure Systems Components


60/98


60

Valve Equalization Techniques


61/98

Two methods

API Recommended Internal Equalization


61

API Preferred Equalization Method


62/98

1. Shut in the well at the wellhead

2. Pressure the tubing above the valve until the pump

pressure levels out indicating equalization across theflapper.


. ,

Opening Pressure equation to maintain the valve in fullyopen position

62

Internal Equalization Method


63/98

Valve equalizes above and below the flapper before opening.

To equalize the valve the valve must go from the closed to

open position


63

TRM-4HPE Internal Equalizing Dart


64/98


64

Secondary Safety Valves


65/98

Cost-effective, reliable solution.Working pressures to from 7500 to 15000 psi


2000 feet.

Internal self equalization.

Rugged flapper mechanism, proven

performance for the life of the well.

API Class 2 Monogrammed

65

Secondary Equipment


66/98

Velocity Valves

Working pressures to 10,000 psi.

Flapper closure system, normally openAll setting depths.


x raor nary range o e proven es gns an s zes

available

Differential pressure closes the valve at a

predetermined rate of flow.

Adjustable flow rates by changing the spring, spring

spacers, or varying the choke bean I.D.

66

Secondary Equipment


67/98

Injection Valves

Working pressures to 10,000 psi.

Flapper closure system, is normally closedAll setting depths.


Extraordinary range of field proven designs and sizes

available

Differential pressure opens the valve at a predetermined

rate of flow.

Adjustable flow rates for opening by changing the spring,

spring spacers, or varying the choke bean I.D.

67

Subsurface Safety Valve Accessories


68/98

No-go Permanent Lock-out Tools

Permanently locks-open safety valve while establishinghydraulic communication.


.

No-go locator.Simple, robust design.

Hydraulically assisted.

68


69/98

Session 3 Special Completions


69


70/98

Sand Control


70

Fundamental Cause of Sand Production


71/98

Destabilizing forces overcome formation strength

formation matrix fails

if sand is mobile - sand transport (production) will occur sand production is a function of rock strength and/or fluid


ow e ec s

Stage 1Stage 1Stage 1Stage 1 ---- FailureFailureFailureFailure StageStageStageStage 2222 ---- TransportationTransportationTransportationTransportation

71

Sand Control Methods


72/98

Restrict Production Rate

In Situ Consolidation (Injecting resins to make artificialconsolidated sandstone)


Resin Coated Gravel

Standalone Screens

Gravel Pack

Fracture ( StimPAC*)

72

Restrictive Production Rate


73/98

Some weak formations have enough strength

to produce sand-free at low rates.Selective perforations placed in the strongest


formation (based on logs)

Rock properties may change during the

production (i.e..., water production).

73

In Situ Consolidation


74/98

Resin material is pumped

into the formation .

Furan Resin glues

formation grain-grain into a


consolidated structure

Compressive strength

>1,000 psi with 60-75%

retained permeability.

74

Resin Coated Gravel


75/98

Resin

Gravel

Proppant ( Gravel ) is precoated with resin

material.

Particles are mixed with viscous gel andpumped into the formation.

Particles are contacted rain-to- rain.


Formation

(Unconsolidated)

Temperature + H2O fuses the particlestogether into a consolidated permeable,

drillable network.

Main WS system: Sandlock V

75

Standalone Screens (SAS) or Natural Sand Pack


76/98

Installation of a screen system without gravel

cased or open hole applications

premium screens are preferred


76

Screens and slotted liners


77/98


77

Gravel Packing


78/98

PackerPackerPackerPacker

TubingTubingTubingTubing

CasingCasingCasingCasing


Blank PipeBlank PipeBlank PipeBlank Pipe

Sump PackerSump PackerSump PackerSump Packer

ProppantProppantProppantProppant

(gravel)(gravel)(gravel)(gravel)

Seal AssemblySeal AssemblySeal AssemblySeal Assembly

78

Open Hole Gravel Packing


79/98


79

Screenless FracPack


80/98

Combined fracturing and gravel

packing

Screenless completion solutions Optimized perforating and fracturing


(new wells)

Consolidation followed by fracturing

(existing perfs).

80


81/98

Reservoir Monitoring & Intelligentcompletions, Subsea


81

Flow Control why do we do it?


82/98

It allows us to monitor and control reservoir performance inreal time without intervention.

It allows us to produce from, or inject into, multiple


reservoirs or zones through a single wellbore

This type of completion is often referred to as an

Intelligent CompletionIntelligent CompletionIntelligent CompletionIntelligent Completion.

82

MainApplications


83/98

Natural Gas-Lift

Virgin gas zone, gas-cap

Commingled Production or Injection


Fewer wellbores, accelerated production, minimal intervention

Daisy chained or multilateral

Zonal Control

Improved Drainage

Improved reservoir sweep (high permeability)

83

Flow Control Tools


84/98


HydraulicHydraulicHydraulicHydraulicallyallyallyally ControlControlControlControlledledledled

ValvesValvesValvesValves

ElectricElectricElectricElectricallyallyallyally

Controlled ValvesControlled ValvesControlled ValvesControlled Valves 84

Flow Control Valve Application


85/98

ArtificialLift

Sand Control Multilateral Injection Natural GasLift

Multizone Subsea

On / Off

TRFC-H


TRFC-HN

WRFC-H

TRFC-E

WRFC-E

Not applicable

Will require modifications

Applicable. means commercial job done

May require minor modifications

85

Choke Description


86/98

Open Position


Choke Position

Closed Position

86

Tubing Retrievable Flow Control Hydraulic : In-

Line


87/98

All TR valves availableIn-Line

Path offluid flow

TRFCTRFCTRFCTRFC----HHHH TLFCTLFCTLFCTLFC----HHHH


Standard slicklineretrievable PCE Plug utilized

Path offluid flow

87


88/98

Subsea


88

Subsea SystemsSubsea SystemsSubsea SystemsSubsea Systems


89/98


89

Subsea Systems


90/98


90

SUBSEA TREE CONFIGURATIONS


91/98

Horizontal Tree Conventional Tree

Tree Cap

Crown Plugs

Tubing Hanger

Tree Cap

Master Valve Block


ree ea

Tree Connector

Wellhead

Tree Connector

Tubing Hanger

Wellhead

91

Conventional Tree


92/98

Installing hanger in the wellhead using a THROT (TubingInstalling hanger in the wellhead using a THROT (TubingInstalling hanger in the wellhead using a THROT (TubingInstalling hanger in the wellhead using a THROT (Tubing

Hanger Running Orientation Tool).Hanger Running Orientation Tool).Hanger Running Orientation Tool).Hanger Running Orientation Tool).

Well perforation and cleanWell perforation and cleanWell perforation and cleanWell perforation and clean----up are performed via a Riser,up are performed via a Riser,up are performed via a Riser,up are performed via a Riser,

deployed with the tree in open waterdeployed with the tree in open waterdeployed with the tree in open waterdeployed with the tree in open water


92

Horizontal Trees


93/98

Features :Features :Features :Features :Features :Features :Features :Features :--------

Completions up to 7 tubing.Completions up to 7 tubing.Completions up to 7 tubing.Completions up to 7 tubing.

Can reduce the total number ofCan reduce the total number ofCan reduce the total number ofCan reduce the total number ofcompletions per field.completions per field.completions per field.completions per field.

Reduced overall tree size and cost ofReduced overall tree size and cost ofReduced overall tree size and cost ofReduced overall tree size and cost of


manufacture.manufacture.manufacture.manufacture.

Total number of valves reduced.Total number of valves reduced.Total number of valves reduced.Total number of valves reduced.

Tubing hanger is landed in the treeTubing hanger is landed in the treeTubing hanger is landed in the treeTubing hanger is landed in the tree

giving access for work over withoutgiving access for work over withoutgiving access for work over withoutgiving access for work over without

tree removal.tree removal.tree removal.tree removal.

Tubing hanger orientates in the treeTubing hanger orientates in the treeTubing hanger orientates in the treeTubing hanger orientates in the tree

eliminating BOP modifications usedeliminating BOP modifications usedeliminating BOP modifications usedeliminating BOP modifications used

in conventional completion systems.in conventional completion systems.in conventional completion systems.in conventional completion systems.

93

Control Systems


94/98

ElectroElectroElectroElectro----Hydraulic control systemHydraulic control systemHydraulic control systemHydraulic control system


linked to the platform/FPSO SAS system vialinked to the platform/FPSO SAS system vialinked to the platform/FPSO SAS system vialinked to the platform/FPSO SAS system viaumbilicals.umbilicals.umbilicals.umbilicals.

Hydraulically control the subsea valves locatedHydraulically control the subsea valves locatedHydraulically control the subsea valves locatedHydraulically control the subsea valves located

on trees, manifolds and downholeon trees, manifolds and downholeon trees, manifolds and downholeon trees, manifolds and downhole

94

KOP (Kvaerner) Horizontal CHRISTMAS TREE


95/98


Other

type of

POD(SCM)

POD(SCM)

95

Control SystemsControl Systems


96/98


Main Workover UmbilicalUtility Umbilical

SheaveControl Panel

96

ROV INTERFACESROV INTERFACESROV INTERFACESROV INTERFACES REMOTELY OPERATED VEHICLE


97/98

Type MRV (Multi-role Vehicle)

Core vehicle to which options are added to perform the task


In addition to itsown weight canhandle workpackages of up

to 5000 kg.

97

ROV INTERFACESROV INTERFACESROV INTERFACESROV INTERFACES

OPERATIONS PERFORMED BY ROV


98/98

Establishment of guidelines

Operation of manual lower master valve

Override of hydraulic valves

OPERATIONS PERFORMED BY ROV


Change out of choke inserts

Change out of control pods

Flowline connection/umbilical connection Unplanned interventions

Monitoring role.98

completion training next bali june 2010

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