ARPO

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ORGANIZING
DEPARTMENT

TYPE OF
ACTIVITY'

ISSUING
DEPT.

DOC.
TYPE

REF. N.

PAG.
OF

TEAP

1
25

8790

TITLE
Well Completion & Workover Course

Volume 1

CHAPTER 1
-WELL COMPLETIO DESIGN DISTRIBUTION LIST
TEAP
STAP Archive

LIST of CONTENTS (authors)

Cap. 01
Cap. 02
Cap. 03
Cap. 04
Cap. 05
Cap. 06
Cap. 07
Cap. 08
Cap. 09
Cap. 10
Cap. 11

- Well Completion Design M. Marangoni

- Material Selection - M. Marangoni
- Tubing Design - B. Maggioni
- Tubing Stress Analysis - B. Maggioni
- Packers - M. Marangoni
- Surface Wellhead - M. Marangoni
- Safety Valves and Miscellaneous - M. Marangoni
- Perforating - M. Marangoni
- Formation Damage - M. Viti
- Sand Control - M. Viti
- Workover - G. Treglia

Date of issue:

Issued by: S. Pilone

Issued by

REVISIONS

10/03/1999
see list
28/01/98
see list

10/03/1999
M. Marangoni
28/01/98
M. Marangoni

10/03/1999
A. Calderoni
28/01/98
A. Calderoni

PREP'D

CHK'D

APPR'D

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INDEX
1. COMPLETION DESIGN ..................................................................................................................3
1.1 GENERAL .................................................................................................................................3
1.2 ENGINEERING APPROACH .....................................................................................................3
1.2.1 INPUT DATA....................................................................................................................3
1.2.2 OUTPUT RESULTS .........................................................................................................4
1.3 COMPLETION CONFIGURATIONS ..........................................................................................4
1.3.1 SINGLE COMPLETION....................................................................................................5
1.3.2 SINGLE SELECTIVE COMPLETION ...............................................................................8
1.3.3 DUAL COMPLETION .....................................................................................................11
1.3.4 ESP COMPLETION .......................................................................................................18
1.3.5 GAS LIFT COMPLETION...............................................................................................20
1.3.6 BEAN PUMP COMPLETION..........................................................................................21
1.3.7 SLIMHOLE .....................................................................................................................24
1.3.8 (FUTURE) INTELLIGENT COMPLETION ......................................................................25

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COMPLETION DESIGN

GENERAL

Well Completion Design is a very important activity in the Upstream Engineering part of the
Hydrocarbon exploitation which interfaces the Sand Face of the reservoir with the Topside
Facilities to the Production Network.
Generally speaking the activity itself is a part of the well design and sequentially follows the Drilling
Engineering side of it.
In real terms it is an integrated activity which deals with Drilling Engineering from day one of well
design and in most cases fixes the Statement of Requirements for the overall well configuration
setting geometrical constraints also for the Drilling Engineer.

1.2

ENGINEERING APPROACH

1.2.1

INPUT DATA

A series of Input Data are required to perform the activity and the better the data the more detailed
the design output will be.
Having established the downhole interface being the Reservoir, the first set of input data required is
the Reservoir Development Study which should be completed with Individual Wells Fluid Rates(Oil,
Gas, Condensate) and Water Cut versus each individual well life.
Also very important is the individual well Flowing Bottom Hole Pressure, Static Bottom Hole
Reservoir Pressure/Temperature versus field life and individual well Minimum Required Wellhead
Flowing Pressure to verify the need of Artificial Lift throughout the field life. The bottom hole data
can sometime be substituted by Productivity Index in which case this need to be specified for the
fluid it is related to. Most of above data comes from Agip Reservoir Department, while Minimum
Flowing Wellhead Pressure are fixed by Agip Topside Engineering Department.
The second set of data is relevant to the Reservoir Rock Mechanics and Geophysics to determine
better development schemes in terms of Sand Control if necessary, of Development Scheme if
formation has good porosity and permeability by its own or if the development needs to consider
possible Stimulation/Fracturing to be economically done. These data generally comes from Agip
Laboratories from Core Evaluation studies or from specifically required analysis; from these set of
data/studies, information are derived also for better selection of drilling/completion/packer fluids.
The third fundamental set of input data comes also from Agip Laboratories and is related to fluid
characterisation. These data are Pressure, Volume, Temperature (PVT) Reports and are relevant to
the analysis done on fluids produced and sampled according to Agip Minimum Requirements
during exploration and appraisal well testing. Data are complemented with Fluids Composition
Analysis and other specific reports (especially for Oil Wells) which identify the possible presence of
Aspahltenes, Paraffin or other products (Elemental Sulphur); these products, together with the
presence of Hydrogen Sulphide and Carbon Dioxide can have a heavy impact on downhole tubular
and equipment metallurgy (corrosion problems) and/or configuration (injection of inhibitors, solvents,
depressant).

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In particular to correctly evaluate corrosion it is fundamental to have available an accurate

Formation Water Analysis. This seems quite obvious but it is generally very difficult to have since
during exploration/appraisal well testing it is judged too expensive to make specific tests for
sampling formation water, which instead is very important also for water flooding compatibility
studies (scale formation). Corrosion evaluation is generally done as a first screening within Agip
Completion department; final studies are issued by Agip Corrosion Department.
The last set of data comes from Agip Drilling Department and is relevant to the well configuration;
nonetheless, as already said, these data can result from an iterative process between Well
Completion and Drilling to determine the best geometrical combination of casing profiles which
satisfies the Safety during drilling and Safety Requirements of an economically sound completion
configuration.
Not coming as set of data but acting to impact on design are Local Set of Legislation and
Regulations in terms of Safety and Environment, which shall be taken in due account during design.

1.2.2

OUTPUT RESULTS

The output of the Well Completion Engineering Design in its most comprehensive form is usually a
report including:
- Corrosive Environment Evaluation
- Material Selection (C.R.A., Elastomers etc.)
- Tubing Size Selection (P&T profiles Vs rates)
- Downhole Completion Configuration
- Tubing Stress Analysis
- Perforating Methods Selection
- Completion/Packer Fluids Selection
- Stimulation Recommended Techniques
- List of Downhole Equipment with relevant Purchase Specifications
- Wellhead Selection and Specification (only Surface Installations)
- Installation Procedures
Depending on Clients requirements only part of above mentioned issues can form the final report.
Following chapter will deal in more details with individual topics listed in the last paragraph.

1.3

COMPLETION CONFIGURATIONS

With the objective of designing a completion which could satisfy all above requirements in an
economical and safe way, different configurations can be identified and are here following
illustrated based on Agip world wide experience: they will not be explained in detail at this stage but
their characteristics will become clear the deeper will be the growing knowledge of the matter.

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SINGLE COMPLETION
a. cased hole (Toni subsea)
b. HP/HT (Bouri Field)

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Cased Hole Single Completion:

Toni subsea
Tubing Hanger
Control Line
Flow coupling

SCSSV - Surface Controlled Subsurface Safety Valve

Tubing 4 1/2" 12,6 lbs/ft 25% Cr

Special clearance Pup Joint

Downhole gauge mandrel

Chemical injection mandrel

Flow coupling
Seating nipple
X -Over
Anchor 7" Straight pull shear
release
Production packer - 7" retrievable

Flow coupling
Seating nipple

Wireline entry guide

a. cased hole (Toni subsea)

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HP/HT Single Completion: Bouri

Field
Tubing Hanger
7" OD Casing 29 lbs/ft ( Drift = 6.059" )
SM - 2535 Size 3 1/2" pup joint
SM - 2535 Size 3 1/2" OD 9.20 lbs/ft tubing joint
SM - 2535 Size 3 1/2" pup joint
Flow coupling
Wire line Ret. Safety Valve SCSSV
Flow coupling
SM - 2535 Size 3 1/2" pup joint
SM - 2535 Size 3 1/2" OD 9.20 lbs/ft tubing joint
SM - 2535 Size 3 1/2" pup joint
CB1 Sleeding Sleeve
SM - 2535 Size 3 1/2" pup joint
SM - 2535 Size 3 1/2" pup joint

Polished Bore Receptacle

SM - 2535 Size 3 1/2" pup joint

N22 - S Anchor Seal Assembly
Retainer Hydr. Packer
Mill Out Extension
SM - 2535 Size 3 1/2" pup joint
Seating nipple
Size 3 1/2" Perforated Spacer Tube
Bottom NO-GO Seating Nipple
SM - 2535 Size 3 1/2" pup joint
Wireline entry guide

b.

HP/HT Well: Bouri Field

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SINGLE SELECTIVE COMPLETION

a. open hole (Horizontal)
b. cased hole W/Wout Gravel Pack

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Tubing Hanger 9" Monel K con 2 control line Metal Seal

Control line 1/4" SS incapsulata

Flow Coupling 4 1/2"

SCSSV 4 1/2"

MONTE ALPI 5 FIELD:

Open Hole

Tubing 4 1/2" 12.75 lb/ft 11500 lbs Dplex 25% Cr

Clampe per doppia control line incapsulata
Tubing 4 1/2" 12.75 lb/ft T95 rivestiti int. con resine epossidiche TK236
Cross Over 4 1/2" PJD-CB box up x 4 1/2" PJD-CB pin down
Side Pocket Mandrel Completo di injection valve H2S service
4 1/2" New Vam PJD-CB box up x 4 1/2" PJD-CB pin down

Hydraulic Set Retrievable Packer - H2S Service 5"

Vam thread pin down

Millout Extension 5" Vam pin x box

Cross Over 5" box up x 4 1/2" PJD-CB pin down

AR Landing Nipple H2S ser. - Utilizzabile come Equalizing Check Valve per
fissaggio packer e Lock Mandrel per sospendere Tubing perf. e 2 Memory Gauges
Tbg. Perf. 2 3/8" con fil. cilindrica per conn. a Lock Mandrel e chiuso sotto
con attacco a Memory Gauges
N 2 Memory Gauges

Tubing 4 1/2" 12.75 lb/ft T95 rivestiti int. con resine epossidiche TK236

Horizontal Section

Liner Hanger Hydraulic flex lock 5"

Liner 4 1/2" C75 12.6 lb/ft fil. Vam con finestratura a slot sotto
scarpa da 7" e con un tubo blank sopra sotto ECP per
fissaggio Inflatable Packer in caso di stimolazione selettiva

a. Open Hole: Monte Alpi 5 Field

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Gravel Pack Packer

Screen

Gravel Pack Packer

Screen

Sump Packer

b. Cased Hole With Gravel Pack

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DUAL COMPLETION
a. selective Without Gravel Pack (Monte Stillo 23)
b. selective With Gravel Pack (Zatchi Field)
c. selective Without Gravel Pack (Zatchi Field)
d. single string completion with chemical injection (BRN)
e. dual string completion with chemical injection (BRN)
f. HP/HT (Villafortuna)

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Tubing Hanger 2 3/8" EU up 2 3/8" down - BPV 2" TSB

Nipples 2 3/8 "
Flow Coupling 2 3/8" ipj P105 Box*Pin
TRSSSV - Flapper type IPJ
Flow Coupling 2 3/8" ipj P105 Box*Pin

Nipples 2 3/8 "

Flow Coupling 2 3/8" ipj P105 Box*Pin
TRSSSV - Flapper type IPJ
Flow Coupling 2 3/8" ipj P105 Box*Pin
Tubing 2 3/8" AMS N80 4.6 lbs/ft

Flow Coupling 2 3/8" ipj P105 Box*Pin

Landing Nipples X 1.875 2 3/8" AMS P105

Flow Coupling 2 3/8" IPJ P105 Box*Pin

Landing Nipples X 1.875 2 3/8" AMS P105
TBG/Sub size 2" 68 Fil. 2 3/8" AMS box
Packer "RDH" 7" 23/29 # pin down 2 3/8" AMS
Telescopic Joint
SSD 1.875" AMS P105
Blast Joint 2 3/8" IPJ P105
Landing Nipples X 1.875 2 3/8" AMS P105
T/Sub W/Shear out 2" 3/8 A. box

Packer "RDH" 7" 23/29 # pin down 2 3/8" AMS

Telescopic Joint
SSD 1.875" AMS P105
Blast Joint 2 3/8" IPJ P105

T/Sub W/Shear out 2" 3/8 A. box

Packer "RDH" 7" 23/29 # pin down 2 3/8" AMS

Landing Nipple F AMS P105 N80 4.6 #

Tubing perforated 2 3/8" AMS N80 4.6 #

Production Tube 2 3/8" AMS N80 W/L Mule/Shoe

a. Selective Without Gravel Pack (Montestillo 23)

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b. selective With Gravel Pack (Zatchi Field)

1-water injection wells dual string and dual stage gravel pack

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Zatchi Field water injection dual string completion

c. selective Without Gravel Pack (Zatchi Field)

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Single string Completion 3" 1/2 with 1.315" injection line

Bir Rebaa Nord

Control Line

Tubing 3" 1/2 13% Cr

SCSSV - Surface Controlled Subsurface Safety Valve

Water injection line size 1.315"

Casing 9" 5/8

Side pocket mandrel with injection safety valve

7" retrievable dual packer

Casing 7"

Perforated Tube
Seating nipple

d. single string completion with chemical injection (BRN )

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Tbg Retrievable
SV

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Tbg 3 1/2"

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Adjustable Union
Tbg Retrievable
SV
Tbg 7/8"
Tripple string ret. packer

Side Pocket MAndrel with Inj.

Safety VAlve

7" retrievable Dual Packer

Water Inj. Line 1.135"

e. dual string completion with chemical injection (BRN)

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Tbg 2 3/8"
Tbg 2 3/8"
Model "FVHDM" TRSCCCCV
Model "FVHDM" TRSCCCCV

Parralel Flow Head

Sab Packer

Production Port Mechanism

Blast Joint

Sab Packer

f. HP/HT (Villafortuna)
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ESP COMPLETION
a. with Gas Venting, without Gas Venting, packerless
b. proposed completion for Zatchi
Connector

Splice

Connector

Connector

Splice

Splice

Packer with
vent valve

Penetrator

Splice

Splice

Round to Flat
Splice

Round to Flat
Splice

Packer

ESP

ESP

ESP

VENTED

VENTED

UNVENTED

a. Gas Venting, Packer less, without Gas Venting,

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Tbg 2 7/8"

Packer with
gas venting

Nipple

DPPT
Circ. Valve

ESP with rotary

gas separator

b. proposed completion for Zatchi

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GAS LIFT COMPLETION

Tubing Hanger

adjustable spacer sub 2 3/8"

rotational alignment sub 5 1/2"

TRSSSV

TRSSSV

Parallel Flowhead

Gas Lift Mandrel

Gas Lift Mandrel

Gas Lift Mandrel

Gas Lift Mandrel

Tie Back Packer
Chemical Inj. Nipple

Sliding Sleeve

Production Packer

a. Tiffany
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BEAN PUMP COMPLETION

a. Torrente Tona
well head (1)
completion design (1)

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Polisched Rod

Polisched Rod

BOP for Polisched

Rod

Riser Pup Joint

BOP for Polisched

Rod

Top Adapter
Top Adapter

Torrente Tona - well head (1)

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Dual Completion selective:
Torrente Tona 17
Nipples 2 3/8 "

Tubing Hanger 3 1/2" EU Up*IPJ Down - BPV 3" TSB

Nipples 3 1/2" Up*M 2 7/8" IPJ Down
Tubing 2 7/8" IPJ J55 6.5 lb/ft
Flow Coupling

Flow Coupling
Injection Ava
Injection Ava

Landning Nipple S2
Landning Nipple S2

Special Packer Anchor

Packer A5 51B 9 5/8"

Telescopic Joint
Tubing 2 7/8" IPJ J55 6.5 lb/ft
Circulating valve XA

Shear Out S.J.

Shear Out Safety Joint

Packer A5 51B 9 5/8"

Blast Joint
Circulating valve XA

Landing Nipple F
Tubing perforated
Production Tube 2 7/8" NU

Packer FH 51A4 9 5/8"

Circulating valve XA

Packer FH 51A4 9 5/8"

CSG 9 5/8" 40 lb/ft J55

Landing Nipple F
Production Tube 2 7/8" NU

Bean Pump Completion - Torrente Tona - completion design (1)

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1. .7

SLIMHOLE
Coil Tubing single completion

CT - Single Completion

Casing 5"

Tbg 1.9"

Control Line 1/4"

Safety nipple 5"x 3.81"

with SCSSV

Coiled Tbg 2"

Landing Nipple
Casing 3 1/5"
a.

It shall not be shown to third parties nor shall it be used for reasons different from those owing to which it was given

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(FUTURE) INTELLIGENT COMPLETION

a. Aquila

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