WELL COMPLETION EQUIPMENT

Lecture 4

Chemical Corrosion Agents

H2S

Weak acid, source of H+ Very corrosive, especially at low pressure Different regions of corrosion with temperature
CO2

Weak acid, (must hydrate to become acid) Leads to pitting damage Chlorides Principally sourced from formation and seawater Strong acids HCL, HCL/HF, Acetic, Formic Brines Chlorides and zinc are the most damaging

Material Selection
Options

Metallurgy - balance strength and corrosion resistance Carbon steels worked required Alloy steels - Cr, Ni etc. Plastic - good corrosion resistance but limited burst Tubular linings economic but susceptible to damage Internal cladding - good for well heads / special areas Inhibition - economics depend on flowrate and completion modification requirements Selection depends upon: Anticipated well life Location and intervention costs Material costs Well configuration particularly if inhibitor injection is used Uncertainties both present and future e.g. souring?

Materials Recommendations
For H2S use low yield C-Steel or Stainless For CO2 use Chrome

Cr alloy is 3-6x cost of carbon steel Select and need specialized handling For H2S/CO2 and Chlorides use Ni-Cr alloy if appropriate Ni alloy could be 100x cost of carbon steel For injectors Consider the use of plastic coated pipe

Production Tubing
Design considerations

Strength Metallurgy corrosion and erosion Sealing capacity Internal diameter/through bore Handling concerns/constraints Options Thread/coupling type API couplings Premium couplings Integral versus external coupling Upset or non-upset

Tubing Thread/Connector Options

API Threads
Conventional round or rectangular

Premium Threads
Creates 360o seal in profile

profile STC or LTC no. of threads per inch Buttress Higher tensile strength Easier make up Extreme line Requires dope to seal Lower tem/pressure rating 230oF <3000 psi Not preferred for gas wells Made up to specified torque

Elastomeric ring compression Metal to metal shoulder Wedge Shoulder Taper More reliable Does not need dope to seal May require a lubricant More expensive Many different proprietary designs Hydril VAM Fox Made up to torque but also turn counter

Coupling types External and Integral

External coupling uses male threads cut into

each pipe end and female; female collar

Often higher strength Larger external OD
Integral coupling has male and female threads

cut into pipe body at each

May require upset to assure adequate strength and thicker residual wall

Upset in tubular threads

Upset options

Non upset External Internal External upset can give greater strength Internal upset not desirable or production tubing Wireline and through tubing work may be compromised

Function of the Wellhead System

Allow suspension of casing and tubing in the well Allow installation of surface barrier

BOP stack whilst drilling X-mas Tree for production/injection Allow hydraulic accesses to annuli between tubular systems

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Wellhead Types
Conventional spooled wellhead

Most common Studded flanges or C-clamp make-up Compact spools Used primarily where available height or makeup procedures are issued Mud Line Suspension System Split locations of main wellhead functions Subsea wellheads Complex, remote installation, high cost

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Critical areas of the wellhead system

Seal surfaces and seal system rings, gaskets etc. Landing shoulders Flanges faces and ring recesses

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Compact Spool Type Wellhead

Benefits

Less height Minimal stack manipulation drill and case last 2 casing strings and suspend production tubing Problems Less flexible Internal sealing is more complex

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Advantages of metal to metal seals

More resilient to mechanical damage it can still be

easily damaged! Higher ratings in terms of pressure and temperature Usually chemically more resistant

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SSSV
Function

Well closure in event of the loss of the surface barrier Options Remotely (surface) controlled Wireline/CT retrievable Tubing retrievable Pressure, acoustic or electrically operated Sub-surface controlled Wireline/CT retrievable Ambient valves actuated by reduced BHP Differential valves actuated by increased flowrate

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How to choose Safety valves?

Design factors for consideration Retrieval requirements type and location of well Setting depth Pressure Temperature Tubing and casing dimensions Sand in production fluid Price Reliability data

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SSSV setting depth

Recommendations vary

RC valves (SC) shallower set - normally 100-300 ft minimum below land or seabed DC valves (SSC) less restriction no control line
In all cases they must be below the depth to which an explosion or

fire at surface could cause damage to the valve

Influenced by

Pressure drop of flow stream in passing through the valve Valve access/retrieval Inventory of hydrocarbons in tubing in the event of closure Potential for plugging hydrates, wax, scale etc. Erosional conserns Cratering/subsidence gravity, jack-up or fixed platforms Integrity/reliability of equipment below the valve Control line integrity/ease to installation/response time

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Control Line Protector Clamps

Protect control lines from damage whilst running the

completion
Support control line weight Keep control lines tight to tubing string

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SSSV Installation
Make up Safety Valve Assembly Shop test equipment Deck test Drill Floor Test Run Equipment While RIH, monitor Control line Pressure Conduct Final Test at Setting Depth Make Final check of Control line Pressure

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Dual Control line RC SSSV

Balances effects of hydrostatic head Applications

Deep set valves Problems Control line complexity

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Differential Pressure Storm Chokes (SC SSSV)

Storm chokes close in only when predetermined

conditions are met and do not offer protection until these conditions are met Valves are wireline or coil retrievable Storm chokes are NOT considered a preferred equivalent/alternative to SC SSSV systems

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Production Packers
Purposes Protect the casing from reservoir fluids and pressures
Separation of zones to avoid

Components Seal assembly Slips Cone assembly

Friction element

crossflow control

Subsurface pressure and fluid

Not on permanent or hydraulic set units

Setting and releasing

Artificial lift efficiency gas lift

mechanism Not on permanent units

Mandrel assembly Control head or bypass

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Retrievable Packers
Can act as a bridge plug prior to production Connect to tubing via On/Off tool with blanking plug Tubing can be landed in tension, compression or neutral Slips above and below the elements Triple element pack off system Pressure up to 10,000 psi Fluid bypass needed for pressure equalization Retrieved on tubing Secondary shear release needed

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Packer setting - considerations

Obstacles/considerations to successful set Burrs on perforations and pipe above packer set point Internal profile of tubing wall at setting depth Cement behind pipe at packer set point General condition of the pipe Amount of pressure to be applied above/below Amount of weight applied to packer Slip design and contact area Hardness of casing relative to packer slips Debris on the casing wall (also on slip teeth) Clearance between packer and casing (casing weight

range of packer)

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Recommendations packer setting

Drift and crape casing Care should be taken to set the packer In well cemented

casing (integrity of cement checked by log) Areas in which to avoid setting of packer Sidetracks and windows Milling areas Casing connections Previous packer set points Areas of corrosion, including cracking and embrittlement Areas of wear (above and through doglegs, etc.)

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Circulation Devices
Options SSD large flow area/less control of flow rate SPM with shear valve more control or rate but

limitations on rate 2-4 bpm Ported nipple creates tubular internal restriction Tubing punch destroys tubing integrity need to plan for internal straddle or plug tubing Considerations Circulation rate Preparation/delay How to affect closure? Reliability Need for a back up contingency?

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Flow coupling
Important part of life-of-the-well completion planning Wall thickness greater than the corresponding tubing to inhibit erosion

caused by flow turbulence

Should be installed above and below landing nipples or other

restrictions that may cause turbulent flow

Applications
Help inhibit erosion caused by flow turbulence Installed above and below landing nipples, tubing retrievable safety

valves, or any other restriction that may cause turbulent flow Benefits
Help extend the life of the well completion

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Side Pocket Mandrel

Side Pocket mandrel can be fitted with: Dummy Gas lift valve Injection valve Shear valve