1. Well Completion Functions And Applications

W e l l

c o m p l e t i o n

a n d

i n t e r v e n t i o n

Well Completion Functions & Applications

Eng. El Sayed Amer

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Schedule Time frame managing

Well completion introduction Completion string equipment Surface wellhead equipment Well intervention applications and techniques Wireline & coiled tubing Workover and well problems troubleshooting

Eng. El Sayed Amer

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About well completion

Welcome Introductions completion involves all of the operations designed to make the well produce, in particular connecting the borehole and the pay zone, treating the pay zone, equipping the well, putting it on stream and assessing it. By pay zone we mean a zone consisting of reservoir rocks which contain oil and/or gas that can be recovered.

Eng. El Sayed Amer

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01

Introduction Well Completion The objective of a completion is to convey fluids from the reservoir to the surface, in a safe and efficient manner. Process: The design, selection and installation of tubular, tools and equipment, located in the wellbore, for the purpose of conveying, pumping or controlling production (or injection) fluids.

Eng. El Sayed Amer

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01

Introduction

Completion History/Evolution 1814 First naturally flowing oil well – 475 ft 1822 Rudimentary art of drilling established 1905 Casing cemented 1911 First gas lift device 1913 First dual completion 1926 First electric submersible pump 1933 First gun perforation job 1969 Commercial coiled tubing services introduced

Eng. El Sayed Amer

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Petroleum system

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Typical flowing well.

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Typical Casing Program

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Completion cost completion costs generally fall in the range of $2.9 MM to $5.6 MM per well

wellhead equipment

completion liner and tubing

source water, water additives,

€ £ € £ £ € £ €

completion and perforating crews

pumping equipment rentals

completion Eng. El Sayed Amer

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Purpose of a Completion

7

•

To produce hydrocarbons in a

Injection well

•

the well

Eng. El Sayed Amer

To inject fluids in a safe and cost effective manner throughout the 2

safe and cost effective manner throughout the life of

9

6

Production Well:

life of the well •

For

disposal

maintenance

or

pressure

12

IDEAL COMPLETION

02 Eng. El Sayed Amer

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LOWEST COST

02

MEETS DEMANDS PLACED ON IT DURING PRODUCTION LIFE.

03

GENERALLY THE SIMPLER THE COMPLETION THE GREATER IT’S RELIABILITY.

04

WELL WORKOVER MAY ALSO BE CONSIDERED PART OF COMPLETION DESIGN.

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Well control and barriers barrier systems through the life of the well

Drilling a well

Primary barrier Overbalanced mud capable of building a filter cake

Primary barrier Running completion

Pulling the BOP

Eng. El Sayed Amer

Isolated and tested reservoir completion, for example inflow-tested cemented liner or pressure-tested isolation valve

Primary barrier

Secondry barrier Casing/wellhead and BOP

Secondry barrier Casing/wellhead and BOP

Secondry barrier

Packer and tubing

Casing, wellhead and tubing Hanger.

Isolated reservoir completion, for example deep-set plug

Tubing hanger plug. Possible additional barrier of downhole safety valve

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Well control and barriers barrier systems through the life of the well

Naturally flowing well

Operating a pumped well not capable of flowing naturally

Primary barrier

Secondry barrier

Christmas Packer and tubing

Downhole safety valve. Casing, wellhead and tubing hanger

Primary barrier

Secondry barrier

Christmas tree or surface valve Casing and wellhead

Primary barrier Pulling a completion

Eng. El Sayed Amer

Pump shut-down

Isolated and tested reservoir completion, for example deep-set plug and packer or overbalanced mud

Secondry barrier Casing/wellhead and BOP

Completion Functions

• The Starting Point

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Completion Functions

functions

Protect the Casing

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Section of corroded tubing from well in Oman

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Completion Functions

Contain the Reservoir

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functions

Protect the Casing

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Completion Functions

Contain the Reservoir

Allow Well Killing

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functions

Protect the Casing

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Completion Functions

Contain the Reservoir

Allow Well Killing

functions

Protect the Casing

Install the Tubing String

Eng. El Sayed Amer

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Completion Functions

functions

Limit Production Problems

Eng. El Sayed Amer

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Completion Functions

Enable Chemical Injection

functions

Enable Tubing to Casing Circulation

< 2,000 ft

Circa 9,740 ft Circa 9,770 ft

SPM With Chemical Injection Valve

Circa 9,800 ft

Circa 10,000 ft Eng. El Sayed Amer

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Completion Functions

Enable Chemical Injection

Enable Well Kill Can be Annulus to Tubing Or Tubing to Annulus

functions

Enable Tubing to Casing Circulation

Sliding Side Door (SSD)

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Factor affecting completion Design 02

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Factor affecting completion Design

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Artificial Lift Psurf = surface pressure psurf

Ph = hydrostatic pressure

Uses alternate sources to lift or lighten fluid column ph Artificial lift is required when reservoir pressure is not sufficient to lift fluids to surface.

Pwf = flowing well pressure pwf Eng. El Sayed Amer

MAIN FACTORS INFLUENCING COMPLETION DESIGN well’s purpose The purpose of drilling can vary depending on the well type.

environment well is located, whether on land (plain or mountain, desert, agricultural or inhabited area, etc.) or offshore (floating platform, development from a fixed platform or by subsea wellhead)

reservoir initial reservoir pressure, natural or artificial flow pattern.

production Flowing well or artificial lift, In addition to the separation pressure Anticipated measurement, maintenance or work over operations

Completion techniques the pay zone to borehole connection, •treatment of the formation if required

60 % Eng. El Sayed Amer

Completion cost around 60% of the well total cost and the Success or failure of well is related to success in well completion design and techniques

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Well Completion Down hole Environment Factors over which the operator has no control:

1

2

3

4

5

Formation Temperature

Formation Pressure

Corrosion due to H2S, CO2, or microbes

Scale buildup

Production type (Oil, Gas, Water

Eng. El Sayed Amer

6 Sand, paraffin, and asphaltines

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Well Completion Operator Variables

Factors which the operator can control:

1

2

3

4

5

Material Selection - Metallurgy, Elastomers

Reservoir Interface

Completion, disposal, and stimulation fluids

Applied and hydrostatic pressures

Injection temperature

Eng. El Sayed Amer

6 Tubular design, forces and stresses, dimensional contraints, etc.

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Well Completion Logging Data Known at time of drilling Angle of Dip (Dipmeter) Reservoir Pressure (P)

Porosity (Acoustic) Fluid Contacts Hole Size

(Calliper) Formation Boundaries (Gamma Ray)

Eng. El Sayed Amer

(Resistivity)

Reservoir Temperature (T)

Completion design criteria A. B. C. D.

Open Hole/Barefoot Cased Hole Horizontal Multilateral

Wellbore/Reservoir/Interface

01 Eng. El Sayed Amer

02 Producing Zones

A. B.

Single Zone Multiple Zone

A. B.

04

Natural Flow Artificially Induced

Production Method

03

Number of Tubing Strings

A. B.

I. Single String J. Multiple Strings

The Starting Point B OP S tac k Wellhead

C as ing

Inhibited Brine (KCl)

10,000 ft Eng. El Sayed Amer

Formation

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Types of Completions Well completion types

Interface between Wellbore and Reservoir

• Open hole • Cased hole Production Method

• Artificial lifting • Flowing

Eng. El Sayed Amer

Number of Zones Completed

• Single • Multiple zones

Completion design criteria 01

Eng. El Sayed Amer

Wellbore, Reservoir Interface Completion

A

Open Hole/Barefoot

B

Cased Hole

C

Horizontal

D

Multilateral

1st well completion introduction

Completion techniques and functions

Eng. El Sayed Amer

Completion design criteria Classification Criteria

Eng. El Sayed Amer

Wellbore/Reservoir/Interface

A. B. C. D.

Open Hole/Barefoot Cased Hole Horizontal Multilateral

Producing Zones

E. F.

Single Zone Multiple Zone

Production Method

G. Natural Flow H. Artificially Induced

Number of Tubing Strings

I. Single String J. Multiple Strings

Open hole completion Applications

Deep wells, consolidated with depletion drive

horizontal and multi lateral wells

Eng. El Sayed Amer

Naturally fractured reservoirs

Low cost completion budget

Open hole Completion summary

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Open hole Completion summary

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Advantages of Open Hole Completions The entire pay zone is open

Maximum wellbore diameter is

to the wellbore

opposite the pay zone

1

Perforation expense is

Expensive log analysis not

eliminated

required

1 2

Reduce casing cost

3 Eng. El Sayed Amer

4

5

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Disadvantages of Open Hole Completions 1 2

Excessive gas or water production difficult to control because the- .entire interval is open to flow

3 4

The casing may need to be set before the pay zone(s) are drilled and logged

Separate zones within the completion cannot be selectively fractured or acidized

Requires frequent cleanout if producing formations are not completely firm Eng. El Sayed Amer

Open Hole Completion

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Open Hole Completion

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Surface Casing Production Casing

Tubing Packer

RESERVOIR

Eng. El Sayed Amer

Open Hole Completion

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a. Slotted Liner Completion

SURFACE CASING

TUBING

PACKER PRODUCTION CASING

RESERVOIR

Eng. El Sayed Amer

LINER HANGER SLOTTED,PERFORATED OR SCREEN LINER

Open Hole Completion a. Slotted Liner Completion Cement Casing

Hanger (usually with a packer) Casing Shoe

Slotted Liner (shown diagrammatically) Oil Sand

Eng. El Sayed Amer

Liner Shoe

Open Hole Completion a. Slotted Liner Completion

Eng. El Sayed Amer

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Cased hole Completion summary

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Cased Hole Completion

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a. Cemented & Perforated casing

Perforations

Eng. El Sayed Amer

Cement Production Casing

Cased Hole Completion

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b. Cemented & Perforated Liner

Liner Hanger Cement

Eng. El Sayed Amer

Cement Production Casing Liner Perforations

Cased Hole Completion

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b. Cemented & Perforated Liner

Cement

Casing

Hanger (usually with a packer) Casing Shoe Cemented Liner

Oil Sand

Eng. El Sayed Amer

Liner Shoe

Cased Hole Completion

Eng. El Sayed Amer

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Gravel Pack Completion • What is a ‘Gravel Pack’?

• Placement of prepared gravel of a specific size against the reservoir interface to control the movement of formation solids into the well stream

• What is a ‘Frac Pack’?

• Placement of a slurry of efficient fluid and a properly sized proppant into a formation at pressures exceeding the frac gradient of the formation stone for the purpose of increasing the productivity of the completion and reducing the production related stresses on the formation

Eng. El Sayed Amer

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Gravel Pack Open Hole Completion SURFACE CASING

TUBING

PACKER PRODUCTION CASING GRAVEL PACK

RESERVOIR

Eng. El Sayed Amer

LINER HANGER SLOTTED,PERFORATED OR SCREEN LINER

Gravel Pack Cased Hole Completion

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Tubing

Liner Hanger Slotted, Perforated or Screen Liner RESERVOIR

Gravel Eng. El Sayed Amer

Packer Production Casing Perforations

Gravel Pack FRAC AND PACK COMPLETION

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Tubing

Liner Hanger Slotted, Perforated or Screen Liner

Packer Production Casing Perforations

RESERVOIR

Gravel Eng. El Sayed Amer

Hydraulic Fracture

Gravel Pack

GP Packer

Blank Pipe Screens Sump Packer

Eng. El Sayed Amer

Crossover Wash pipe

Gravel (sand) Fracture created and propped in some cases

WWW.BOX.COM

Eng. El Sayed Amer

Actual sand screen completion

Sand control and gravel pack INSIDE CASING GRAVEL PACK

Eng. El Sayed Amer

UNDERREAMED CASING GRAVEL PACK

SCREEN LINER IN OPEN HOLE

OPEN HOLE GRAVEL PACK

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UNDERREAMED OPEN HOLE GRAVEL PACK

Sand Screens

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Sand control completions

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Comparison of Completions Completion Type Cased Hole

Liner

-

Open Hole

-

Advantages Pressure control Isolation of zones Control of stimulation Wellbore Stability Less expensive than casing entire hole Pressure and stimulation control (when cemented) Wellbore stability Maximum flow area Minimize damage

-

Slimhole

- Lower Cost

-

Eng. El Sayed Amer

Disadvantages More expensive Limited communication to reservoir Possible cement damage Cementing more difficult No control of flow if not cemented Slots plugged w/formation Limited control of stimulation No control of flow Limited or no control of stimulation Hole collapse in weak formations Limited workover capability due to small hole Limited stimulation rate No zone isolation

Multi Lateral Completion

Eng. El Sayed Amer

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Multi Lateral Completion

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Horizontal Completion

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Surface Readout Conductor line

SCSSV

Eng. El Sayed Amer

Bull Nose

7” Slotted Liner (0.040”)

Seal Bore Receptacle

7” Pre-Packed Screens (Baker ‘Slim Pack’, 0.012”)

Gravel Pack Extension

SC-1LR Packer

Permanent Pressure Gauges

Horizontal Completion 65

41/2” Hanger

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Horizontal Completion OPEN HOLE

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SLOTTED LINER

PRE-PACK SCREEN

Production Casing Cement Sheath Open Hole Section

Slotted Liner

Pre-Pack Screen

◦◦ ◦◦◦ ◦◦ ◦◦◦ ◦◦ ◦◦◦ ◦◦

GRAVEL PACK

CMT & PERF LINER

Graded Gravel Gravel Pack Screen

• ••••••••••••••••••• • ••• •••••• •••• •••• Eng. El Sayed Amer

Perforations

Horizontal Completion

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Completion design criteria 02

Eng. El Sayed Amer

Producing Zones Completion

A

Single Zone

B

Multiple Zone

Single Zone / Single String Tubing

Packer

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Interval Co-Mingling

70

Tubing

Packer

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Selective Completion

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Producing a Zone between Packers 72

Top Packer OPEN

CLOSED

Sliding Sleeve

Perforated Interval Eng. El Sayed Amer

Bottom Packer

Dual Zone / Single String

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Dual Zone / Dual String

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Dual Zone / Dual String

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Dual Zone / Dual String

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Multi Zone / Multi String

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Triple Packer Flow Couplings Dual Packer Single Packer

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DUAL STRING SELECTIVE COMPLETION

This completion design increases the well’s functionality by using sliding sleeves to independently produce, stimulate, test or isolate one or more zones, using slickline or other methods to manipulate the sleeves. The example at the right highlights a quad zone completion.

Eng. El Sayed Amer

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CONCENTRIC STRING Tubing Strings Packers

Eng. El Sayed Amer

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INTERVAL SEGREGATION

SSDs

Eng. El Sayed Amer

Packers

80

MULTIPLE ZONE COMPLETION

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Completion design criteria 03

Eng. El Sayed Amer

Mode Of Production

A

Natural Flow

B

Artificially Induced

Natural flow completion Tubing-less

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Small OD Casing or Large Tubing Cement Perforations

Eng. El Sayed Amer

Natural flow completion Retrievable Completion / Temporary Tubing Retrievable Packer Wireline Nipple

Eng. El Sayed Amer

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Natural flow completion Permanent / High Pressure Completion Sliding Sleeve

No-Go Wireline Nipple

Eng. El Sayed Amer

Permanent Packer Millout Extension Perforated Joint

85

Natural flow completion High Rate Liner (Monobore) Polished Bore Receptacle Liner Hanger Liner

Eng. El Sayed Amer

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Large Tubing Sliding Side Door Cement

Artificial Lift Methods

Commonly used artificial lift methods include: Rod pump Gas lift Electric submersible pump Piston pump Jet pump

Plunger lift Other specialist or adapted systems

87 Eng. El Sayed Amer

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Artificial Lift Methods

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Artificial Lift Completion a. Rod Pump

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Artificial Lift Completion a. Rod Pump Walking beam

90

Horsehead

Stuffing box and polished rod Prime mover Production valve

Gearbox and counterbalance

Eng. El Sayed Amer

Artificial Lift Completion a. Rod Pump

• Rod pumps account for approximately 60% of onshore artificial lift completions • Industry accepted • Economic in ideal field • Not gas dependent • Limited efficiency • Maintenance intensive • Vertical wellbores

Eng. El Sayed Amer

91

Artificial Lift Completion a. Rod Pump

Eng. El Sayed Amer

92

Artificial Lift Completion b. Hydraulic Pump

93

Tubing

Pump Housing Standing Valve

Pump Seating Nipple

Piston Pump Eng. El Sayed Amer

Artificial Lift Completion c. Jet Pump

94

Tubing

Pump Pump Seating Nipple

Jet Pump Eng. El Sayed Amer

95

Eng. El Sayed Amer

Artificial Lift Completion d. Gas lift

Eng. El Sayed Amer

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97

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Artificial Lift Completion e. Plunger Lift

Piston pump system

Eng. El Sayed Amer

100

Jet pump system

101

Plunger Lift System Downhole Equipment

Plunger (with liquid load Intermitter or controller

Plunger catcher

Tubing stop Injection gas Production

Standing valve Tubing stop

Surface Equipment

Eng. El Sayed Amer

Artificial Lift Completion

f. Electrical Submersible Pump (ESP)

Armored cable Cable guard Sliding sleeve Dual string retrievable packer (modified)

Sliding sleeve No-go seating nipple

Eng. El Sayed Amer

Pump assembly (various) Pump Intake Protector Motor

102

103

Eng. El Sayed Amer

104

Surface power

enters through wellhead Power Cable

Electric Submersible Pump (ESP)

Run with tubing string Banded to tubing Pump

Hung below fluid level by discharge head Pump intake

Fluid Level

Fluids enter system Protector

Equalizes pressures Isolates motor from fluids Perforations

Eng. El Sayed Amer

Motor

Mounted above perforations for cooling

Artificial Lift Completion F. Electrical Submersible Pump (ESP)

Eng. El Sayed Amer

105

Artificial Lift Completion G. Progressive cavity Pump (PCP)

Eng. El Sayed Amer

106

Artificial Lift Completion

107

Electronic Controller Drive Head

Lubricator

Armored Cable

Plunger Pump

Rod Pump Hydraulic Pump

Eng. El Sayed Amer

Catcher w/ Arrival Sensor

Gas-Lift Valve

Pump

Rod Pump Tubing Anchor

Control Equipment

Electric Motor

Submersible Electric Pump

Gas Lift

Packer Standing Valve (Optional)

Bumper Spring Tubing Stop

Plunger Lift

Sucker Rod

Floater/ Stator

ProgressiveCavity Pump

Completion design criteria 04

Eng. El Sayed Amer

PRODUCING ZONES

A

Single Zone

B

Multi Zone

Single String Completion Single Completion

Eng. El Sayed Amer

Single Selective Interval

109

Single Selective Interval

Single Commingle

MULTIPLE Completion string Multiple Completion

Eng. El Sayed Amer

Concentric Completion

Multiple Commingle Completion

110

Multiple Selective Completion

Major COMPLETION TYPES OPEN ENDED (SUSPENDED) TUBING PRODUCTION

BASIC PACKER PRODUCTION

111

PACKER WITH NIPPLES, SLIDING SLEEVE AND SAFETY VALVE

PACKER WITH PERFORATED TAIL PIPE

Production safety valve

Downhole Isolation (plug) Downhole Instrumentatio n (gauges)

Well kill capability but no control of annular fluid level and possible exposure to corrosion Eng. El Sayed Amer

Well kill capability when packer is released

Downhole Isolation (plugs) above and below packer through sliding Circulate sleeve without packer release

Casing string protected from corrosion and production stresses by inhibited packer

112

Eng. El Sayed Amer