At the end of this presentation, you will be able to:

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Completion
Agenda

• At the end of this presentation, you will be able
  to
• Define completion
• Describe the process of completion
• List and define the different types of completion
• Describe surface control equipments
• Define subsea completion

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Completion
Introduction

• After exploratory drilling confirms the presence
  of an oil or natural gas reservoir, the
  hydrocarbons are brought to the surface.
• Once the design well depth is reached, the
  formation is tested and evaluated to determine
  whether the well is to be completed for
  production, or plugged and abandoned.
• This decision is taken based on the information
  available on reservoir characteristics.
• To complete the well production, casing is
  installed and cemented, and the drilling rig is
  dismantled and moved to the next site.
• A service rig is brought in to perforate the
  production casing and run production tubing along
  with downhole equipments.
• The installation of surface safety equipments
  takes place and production begins.

Completion Process
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Completion
What is Completion?
Well completion creates a dependable pathway to
the surface for the hydrocarbons. Once the well
is drilled, it has to be made ready for the safe
and efficient production of oil. The term
completion describes the assembly of Down hole
tubulars and other safety equipments that is
required to enable the safe and
efficient production of oil or gas from the well
after it has been drilled.
Completion Process
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Completion
Well Completion Activities

• Well completion activities include
• Conducting drill stem test
• Setting production casing
• Running production tubing along with downhole
  equipments
• Installing surface safety equipments
• Starting production flow
• If it is decided that the well will not be
  completed,
• then it will be plugged and abandoned.

Completion Process
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Completion
Well Completion Activities

• Well completion activities include
• Conducting drill stem test
• Setting production casing
• Running production tubing along with downhole
  equipments
• Installing surface safety equipments
• Starting production flow

Conducting Drill Stem Test (DST) To determine the
potential of a producing formation, the operator
may order a drill stem test (DST). The DST crew
makes up the test tool on the bottom of the drill
stem, then lowers it to the bottom of the hole.
Weight is applied to the tool to expand a hard
rubber sealer called a packer. Opening the tool
ports allows the formation pressure to be tested.
This process enables workers to determine whether
the well can be produced.
Completion Process
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Completion
Well Completion Activities

• Well completion activities include
• Conducting drill stem test
• Setting production casing perforation
• Running production tubing along with downhole
  equipments
• Installing surface safety equipments
• Starting production flow

Setting Production Casing Production casing is
the final casing in a well. It can be set from
the bottom to the top. Sometimes a production
liner is installed. This casing is set the same
as other casings, then cemented in place.
Completion Process
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PLATFORM
WELL HEAD EQUIPMENT
Only this casing is visible from outside
SEA BED
30 CASING
PRODUCTION TUBING
20 CASING
13 3/8 CASING
Production casing (9 5/8)
9 5/8 CASING
7 LINER
RESEVOIR
BACK
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Completion
Well Completion Activities

• Well completion activities include
• Conducting drill stem test
• Setting production casing perforation
• Running production tubing along with downhole
  equipments
• Installing surface safety equipments
• Starting production flow

Running Production Tubing and Downhole
Equipments A well is usually produced through
tubing inserted down the production casing. Oil
and gas is produced more effectively through
this smaller-diameter tubing than through the
large-diameter production casing. Joints of
tubing are joined together with couplings to make
up a tubing string. Tubing is run into the well
similar to casing, but it is smaller in diameter
and is removable.
Completion Process
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Completion
Well Completion Activities

• Well completion activities include
• Conducting drill stem test
• Setting production casing perforation
• Running production tubing along with downhole
  equipments
• Installing surface safety equipments
• Starting production flow

Installing Surface Safety Equipments Though the
tubings and downhole equipments are present in
the well, production cannot start without
installing surface control equipments. They are
required to prevent uncontrolled oil flow out of
the well.
Completion Process
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Completion
Well Completion Activities

• Well completion activities include
• Conducting drill stem test
• Setting production casing perforation
• Running production tubing along with downhole
  equipments
• Installing surface safety equipments
• Starting production flow
• .

Starting Production Flow Production flow is
started by washing in the well and setting the
packer. The pumping in of water or brine to
flush out the drilling fluid is called washing
in. Usually this is enough to start the well
flowing. If this does not work then the flow
might be started by pumping high-pressure gas
into the well after setting the packer.
Completion Process
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Completion
Downhole Equipment
The parts of a downhole equipment are
Hydraulic Control Line
Safety Valve
Gas Lift Valve
Packer
Pump Out Plug
Completion Process
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Completion
Well Head
The surface termination of a wellbore that
incorporates facilities for installing casing
hangers during the well construction phase is the
well head. It is a means by which the
production tubing is hung, the Christmas tree and
the surface flow-control facilities are
installed, in preparation for the production
phase of the well. The BOP also sits on top of
well head. The well head is installed on top of
the casing before starting to drill. It has two
or three sections. Each section has two flanges
to facilitate the connections at both the ends.
well head Sections
Flanges

Surface Control Equipments
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Completion
Components of a Well Head

• Each well head section has three
• components
• Casing Bowl
• Casing Hanger
• Tubing Head

Surface Control Equipments
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Completion
Components of a Well Head

• Each well head section has three
• components
• Casing Bowl
• Casing Hanger
• Tubing Head

Casing Bowl The casing bowl consists of heavy
fittings that provide a seal between the casing
and the surface. It also supports the entire
length of casing that is run all the way down the
well. This piece of equipment typically contains
a gripping mechanism that ensures a tight seal
between the head and the casing itself.
Surface Control Equipments
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Completion
Components of a Well Head

• Each well head section has three components
• Casing Bowl
• Casing Hanger
• Tubing Head

Casing Hanger This is the sub-assembly of a
well head that supports the casing string when
it is run into the wellbore. The casing hanger
provides a means of ensuring that the string is
correctly located and generally incorporates a
sealing device or system to isolate the casing
annulus from upper well head components.
Surface Control Equipments
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Completion
Components of a Well Head

• Each well head section has three components
• Casing Bowl
• Casing Hanger
• Tubing Head

Tubing Head The tubing head is a well head
component that supports the tubing hanger and
provides a means of attaching the Christmas tree
to the well head.
Surface Control Equipments
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Completion
Tubing Hanger
The tubing hanger is a device attached to the
topmost tubing joint in the well head to support
the tubing string. The tubing hanger is located
in the tubing head, with both components
incorporating a sealing system to ensure that the
tubing conduit and annulus are hydraulically
isolated. The tubing hanger assembly supports
the weight of the tubing string and seals the
annulus from the upper well head and Christmas
tree components. It also provides connections at
the surface, which controls the flow of fluids
out of the well.
Anchor bolts to hold tubing hanger in place

Surface Control Equipments
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Tubing hanger comes here
Anchor Bolts
Well Head
C Section
30 Casing Remains Outside
Production Casing (9 5/8) terminates here
1.5 m
B Section
A Section
20 Casing Terminates Here
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Completion
Christmas Tree

• The assembly of valves, spools, pressure gauges,
  and chokes that are fitted to the well head of
  the completed well is called a Christmas Tree. It
  is used to control the flow of oil through the
  tubing hanger.
• The function of a christmas tree is to
• Prevent the release of oil or gas from an oil
  well into
• the environment
• Direct and control the flow of formati
• on fluids from the well
• When the well is ready to produce oil or gas,
  valves are opened and the release of the
  formation fluids is allowed through a pipeline
  leading to a refinery.

Surface Control Equipments
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Crown/ Swab Valve
Wing Valve
Oil which flows from the tubing is diverted
through this pipe to the main header and from
there to the process platforms
Upper Master Valve
Lower Master Valve
Tubing hanger comes up to this point
Top part of the C-section of well head
Surface Control Equipments
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Tubing hanger
Oil Well After Completion
Well Head
X-mas Tree
Hydraulic Control Line
Safety Valve
Production Tubing
Reservoir
Gas Lift Valve
Perforation
Packer
Pump Out Plug
Sump
Surface Control Equipments
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Completion
Types of Completion
The types of completion include Natural
Completions Natural completions are those in
which little or no stimulation is required for
production. Sandstone and carbonate systems with
good permeability and mechanical stability are
ideal for natural completions. Stimulated
Completions These completions are generally
applied to improve the natural drainage patterns
of hard, low-permeability formations. It is used
to remove barriers that prevent easy passage of
fluids into the wellbore. Sand-Control
Completions Sand-control completions support the
formation while allowing the flow of fluids. They
are performed in young, unconsolidated or less
mechanically competent sandstones.
Completion Process
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Completion
Subsea Completions
Subsea production systems are wells located on
the sea floor, as opposed to at the surface. The
safety equipments are installed underwater on the
seabed. They enable early production from
deepwater, remote, and marginal fields. The
evolution of subsea well completions has
attracted a lot of attention because they offer a
means of producing field extremities not
reachable by directional drilling from existing
platforms. They also offer production options
where field economics do not justify the
installation of one or more additional platforms.
Subsea Completion
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Completion
Downhole Equipment
The tubings along with the downhole equipment are
lowered into the 95/8 casing of the well. The
parts of a downhole equipment are
Packer Packer is a device consisting of a
sealing device, a holding or setting device and
an inside passage for fluids. It
expands externally to seal the well bore. It
helps in blocking the fluids through the annular
space between the pipe and the well bore wall.
Packers use flexible, electrometric elements that
expand. It is set hydraulically from the surface.
X
Completion Process
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Completion
Downhole Equipment
The parts of a downhole equipment are
Gas Lift Valve The gas lift valve is a device
installed on a gas lift cylinder or mandrel.
This device is used to control the flow of gas
between the exterior and interior of well
tubing. It consists of an inlet, outlet, a main
valve, a main chamber and so on. The design of
the side pocket is such that the components
that are installed do not obstruct the flow of
production. This enables access to the well bore
and the other components of completion.
X
Completion Process
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Completion
Downhole Equipment
The parts of a downhole equipment are
Safety Valve A safety valve is a device that is
installed in the upper well bore to provide
emergency closure of the channels that produce
oil. The valve has a housing and a movable
valve element that controls the flow of fluid in
the well.
X
Completion Process
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Completion
Downhole Equipment
The parts of a downhole equipment are
Hydraulic Control Line Hydraulic control line is
a device filled with hydraulic fluid and
connected to a hydraulic fluid source.
Hydraulic control line is used to operate the
safety valve. When the control line is
pressurized up to a certain pressure limit, the
safety valve opens. Its one end connects at the
top of the safety valve and the other end to a
pressurizing panel at the surface. It is lowered
along with the safety valve while lowering the
tubing string during completion.
X
Completion Process
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Completion
Downhole Equipment
The parts of a downhole equipment are
Pump Out Plug Since the tubing is open at the
bottom, the packer cannot be set as the whole
tubing string needs to be pressurized to set it.
So a pump out plug (POP) is used for this
purpose. A steel ball is dropped inside the
tubing string from the surface. This goes all
the way down and sits on the POP seat at the
bottom. When water is pumped from the top, the
ball is pressed against the POP seat and forms a
seal. When pressure in the tubing string reaches
a certain limit, the packer is set. This is
indicated in the pumping unit in the form of a
sharp fluctuation of the pressure reading. Then
the pressure is increased, further, to shear the
POP seat pins. This is done to remove the steel
ball. When the pins are sheared, the POP seat
drops along with the ball into the well sump.
X
Well Sump A well sump is the extra bore space
below the perforated zone that allows the
collection of junk for example steel ball.
Completion Process
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• In a traditional well, components such as valves
  control the flow of fluids.
• Screens or gravel packs stop sand from entering
  the well.
• Pipe joints and packers needed to ensure the well
  retains its integrity over its producing life.

• However traditional wells do not respond to
  changing conditions and all the fluids (oil,gas
  and water) have to be produced together and
  separated at the surface.

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• IQ for Intelligent Wells
• Intelligent Wells
• Automatic Surface Interaction/Continuous
• Monitoring/Automatic Flow control/Extensive
• Downhole communication
• Semi Intelligent Wells
• Manual Surface Interaction/Limited
• Downhole communication
• Conventional
• Limited Interaction

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Smart Wells

• Smart wells offer the possibility to respond to
  changing conditions.
• Smart wells combine existing state-of-the-art
  technologies such as wireless technologies,remote
  sensing capabilities, remote control mechanism
  and robotic tools.
• Remote sensors can immediately show what is going
  on in the down hole.
• Valves down the hole can be adjusted, controlling
  flow or shutting off production at one level and
  increasing it from another.
• Fluid processing can take place down the hole
  with gas and liquids being separated by devices
  such as hydro-cyclones

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Drivers

• Improved Reliability
• Optimum Production leading to longer well and
  reservoir life.
• Optimization of reservoir drainage
• No mechanical intervention is required freeing up
  resources.
• Lower Operating Cost
• Less number of work overs
• Decrease Water Production
• Better sand control
• Increase Reservoir Knowledge
• Monitoring of fluid/gas contact zone movements
• Improved reservoir characterization (saturation,
  structure,
• pressure, temperature)

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• Smart Well
• Packers
• Hydraulic or Electrical Control Lines
• Sensors
• Inflow Control Valves ICV
• Surface Control Unit (Monitoring and Remote
  Operation)

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Examples of Controls in Intelligent Wells
Controlling Commingled production Controlling
Down Hole Water Separation Controlling Down Hole
Gas Separation and Re-injection
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Application for Intelligent Wells

• Marginal Reserves
• Highly Deviated. Horizontal and MLW
• Deepwater Wells
• High Volume Wells

Shell has about 20 intelligent wells worldwide
and is working to increase that number. One of
its showcase pieces is a well in the North Seas
Brent field. The well produces oil but also has a
perforated gas zone up hole thats opened for a
short period each year to meet a gas contract.
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