Design Process for Workovers Core COPYRIGHTcloud1.activelearner.com/contentcloud/portals/hosted3/PetroAcademy/... · If well stable, TIH with completion string consisting of MS WL

Design Process for Completions and Workovers Core

Design Process

Learning Objectives

This section will cover the following learning objectives:

Explain the work product of a completions engineer

Describe an initial completion procedure and sketch

Translate chronological steps from a procedure to a well sketch

Recognize and describe morning reports

Recognize the engineering that is required for developing aprocedure

Design Process for Completions and Workovers Core ═════════════════════════════════════════════════════════════════════════

© PetroSkills, LLC. All rights reserved._____________________________________________________________________________________________

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Work Product of a Completions Engineer

The classic workproduct of a completion/

workover engineer

Pre-sketch

Proposed sketch

Procedure


1Engineering team develops the procedure



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Work is documented through a series of morning reports3

Operations team executes procedure in the field2




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Completions or work over engineer will review thereports and discuss work status with operations team4


Engineer uses morning reports to complete final well sketch5



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Sketches and Procedures – Initial Completion

Pre-sketch Proposed SketchProcedure

Well left with 10 ppg mud in casing

when drilling rig moved off location.

7” 32#/ft casing run to 8000’ with PBTD at 7850’

1. MIRU SL2. Hold safety meeting. Make gauge ring run to PBTD est. 7850’,

send results to Engineering.3. RDMO SL4. If approval to proceed, MIRU completion rig5. Make bit and scraper run to PBTD6. TIH with open ended workstring, displace hole with 9.8 ppg KCL

completion fluid.Note: expected reservoir pressure is 3600 psi at 7500’. 9.8 ppg fluid will provide a 222 psi OB.

7. Test casing to 5000 psi for 15 minutes8. MIRU EL unit, hold explosives safety meeting and conduct JSA.

RIH and perforate 7500-7570’ (reference OH log dated Nov 9, 2016) with 4 5/8” gun loaded 6 spf, 60 deg phasing,32 gm RDX charges

9. POOH with guns, check that all shots have fired, if not, inform Engineering

10. Monitor hole conditions for 4 hours, report any fluid loss or pressure build up

11. If well stable, TIH with completion string consisting of MS WL reentry guide, XN landing nipple, model MJG mechanical retrievable packer, sliding side door, and 2 7/8” 6.5 #/ft tubing. Set packer at 7400’.

12. MIRU SL, set plug in lower XN nipple, test tubing to 5000 psi for 15 min. RDMO SL.

13. Test backside to 5000 psi for 15 min.14. Install BPV, ND BOPs, NU 5000 psi tree and flowlines, pull BPV,

turn well over to Production15. If required, use lease gas to rock well in, open on 16/64 ck.

Model MJG packer set at 7400’

Perforations 7500’-7570’ MD. Note, top sand at 7500’, bottom sand at 7610’.

WEG at 7410’

XN at 7405’

SSD at 7390’

2 7/8” 6.5 ppf API EUE N-80 tubing



















WEG at 7410’

XN at 7405’

SSD at 7390’


The well in the current (original) condition.

For New Completion: This is generally the way the drilling rig left the well, so it is usually simple. Note that by tradition we do not show other casing strings nor the wellhead. But these can be important, so do not forget that other casing stings exist in the well and that there is something on the top.

For Workover: This sketch may be very complicated, with lots of equipment already in the well!



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WEG at 7410’

XN at 7405’

SSD at 7390’


A series of chronologically organized steps that the operations team should follow to get to the proposed sketch.

Generally involves placing items into the well or pulling them out of the well, and doing so in such a manner that the reservoir pressure is always contained – no unwanted flow of reservoir fluids to the surface!

Sketches and Procedures: Terminology

1. MIRU SL2. Hold safety meeting. Make gauge ring run to PBTD est. 7850’, send

results to Engineering.3. RDMO SL4. If approval to proceed, MIRU completion rig5. Make bit and scraper run to PBTD6. TIH with open ended workstring, displace hole with 9.8 ppg KCL


7. Test casing to 5000 psi for 15 minutes8. MIRU EL unit, hold explosives safety meeting and conduct JSA. RIH

and perforate 7500-7570’ (reference OH log dated Nov 9, 2016) with 4 5/8” gun loaded 6 spf, 60 deg phasing,32 gm RDX charges





13. Test backside to 5000 psi for 15 min.14. Install BPV, ND BOPs, NU 5000 psi tree and flowlines, pull BPV, turn

well over to Production15. If required, use lease gas to rock well in, open on 16/64 ck.

MIRU – move in and rig upSL – slick line unitEL – electric lineRDMO – rig down and move offPBTD – plug back total depthTIH – trip in hole; usually jointed pipeTOOH – trip out of hole; usually jointed

pipeRIH – run in hole, often not pipe

(e.g., wireline or coiled tubing)POOH – pull out of holeND – nipple down (unfasten bolts;

usually for a BOP or tree)NU – nipple up



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Sketches and Procedures




1. MIRU SL2. Hold safety meeting. Make gauge ring run to PBTD est. 7850’, send results

to Engineering.3. RDMO SL4. If approval to proceed, MIRU completion rig5. Make bit and scraper run to PBTD6. TIH with open ended workstring, displace hole with 9.8 ppg KCL


7. Test casing to 5000 psi for 15 minutes8. MIRU EL unit, hold explosives safety meeting and conduct JSA. RIH and

perforate 7500-7570’ (reference OH log dated Nov 9, 2016) with 4 5/8” gun loaded 6 spf, 60 deg phasing,32 gm RDX charges

9. POOH with guns, check that all shots have fired, if not, inform Engineering10. Monitor hole conditions for 4 hours, report any fluid loss or pressure build

up11. If well stable, TIH with completion string consisting of MS WL reentry

guide, XN landing nipple, model MJG mechanical retrievable packer, sliding side door, and 2 7/8” 6.5 #/ft tubing. Set packer at 7400’.


13. Test backside to 5000 psi for 15 min.14. Install BPV, ND BOPs, NU 5000 psi tree and flowlines, pull BPV, turn well

over to Production15. If required, use lease gas to rock well in, open on 16/64 ck.

Pre-sketch Proposed Sketch



WEG at 7410’

XN at 7405’

SSD at 7390’

2 7/8” 6.5 ppf API EUE N-80 tubingThis is what the completion engineer wants to

get to – the final state of the well. There is a lot of engineering that goes into this sketch; which is the overall subject of this skill module. Consider for now several questions:

Why perforate that interval? Why just perforate, and not frac or gravel

pack? Why run that packer and that size tubing? Why run tubing at all?



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Sketches and Procedures – Intervention

1. MIRU SL2. Hold safety meeting. Make

gauge ring run to PBTD est. 7850’, send results to Engineering. Note any sand or obstructions inside the tubing.

3. Make up lock mandrel with pressure gauges for XN landing nipple at 7405’.

4. Run lock mandrel and set in XN nipple, hang off gauges, pull running tool.

5. RDMO SL

Pre Sketch Proposed SketchProcedure

Sketches and Procedures – Intervention

1. MIRU SL2. Hold safety meeting. Make

gauge ring run to PBTD est. 7850’, send results to Engineering. Note any sand or obstructions inside the tubing.

3. Make up lock mandrel with pressure gauges for XN landing nipple at 7405’.

4. Run lock mandrel and set in XN nipple, hang off gauges, pull running tool.

5. RDMO SL

Pre Sketch Proposed SketchProcedure


SSD at 7390’ Model MJG packer set

at 7400’ XN at 7405’ WEG at 7410’ Perforations 7500’-

7570’ MD. Note, top sand at 7500’, bottom sand at 7610’.

2 7/8” 6.5 ppf API EUE N-80 tubingSSD at 7390’Model MJG packer set at 7400’XN at 7405’Lock mandrel with pressure gauges hung off Feb 15 ‘17WEG at 7410’Perforations 7500’-7570’ MD. Note, top sand at 7500’, bottom sand at 7610’.

What is going to be done?



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Sketches and Procedures – Workover

1. MIRU SL2. Hold safety meeting. Make gauge ring run to PBTD

est. 7850’, send results to Engineering.3. RDMO SL4. If approval to proceed, MIRU completion rig5. Install BPV, remove tree, NU BOPs6. TIH with open ended workstring, displace hole with

9.8 ppg KCL completion fluid.Note: expected reservoir pressure is 3600 psi at 7500’.

9.8 ppg fluid will provide a 222 psi OB. 7. Test casing to 5000 psi for 15 minutes8. MIRU EL unit, hold explosives safety meeting and

conduct JSA. RIH and perforate 7500-7570’ (reference OH log dated Nov 9, 2016) with 4 5/8” gun loaded 6 spf, 60 deg phasing,32 gm RDX charges





13. Test backside to 5000 psi for 15 min.14. Install BPV, ND BOPs, NU 5000 psi tree and

flowlines, pull BPV, turn well over to Production15. If required, use lease gas to rock well in, open on

16/64 ck.

Pre Sketch Proposed Sketch

Sketches and Procedures – Workover


est. 7850’, send results to Engineering.3. RDMO SL4. If approval to proceed, MIRU completion rig5. Install BPV, remove tree, NU BOPs6. TIH with open ended workstring, displace hole with

9.8 ppg KCL completion fluid.Note: expected reservoir pressure is 3600 psi at 7500’.

9.8 ppg fluid will provide a 222 psi OB. 7. Test casing to 5000 psi for 15 minutes8. MIRU EL unit, hold explosives safety meeting and

conduct JSA. RIH and perforate 7500-7570’ (reference OH log dated Nov 9, 2016) with 4 5/8” gun loaded 6 spf, 60 deg phasing,32 gm RDX charges





13. Test backside to 5000 psi for 15 min.14. Install BPV, ND BOPs, NU 5000 psi tree and

flowlines, pull BPV, turn well over to Production15. If required, use lease gas to rock well in, open on

16/64 ck.



SSD at 7390’ Model MJG packer

set at 7400’ XN at 7405’ WEG at 7410’ Perforations 7500’-

7570’ MD. Note, top sand at 7500’, bottom sand at 7610’.

2 3/8” 4.7 ppf J-55 tubing SSD at 7390’ Model XYZ packer set at 7150’ XN at 7155’ WEG at 7160’ Perforations 7200 – 7230 MD.

Note, top sand at 7200’, bottom sand at 7230’.

Cmt Retainer at 7400 Perfs squeezed with cement

through cement retainer Perforations 7500’-7570’ MD.



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Morning Reports

The work should go according to theprocedure

There may be slight or major differences

There may be significant deviations

The engineer will use the morning reportsto develop a final post well sketch

Morning ReportsFinal Post Well Sketch

Morning Reports

Morning ReportsA report that the operations team prepares daily, usually in the morning (6 AM is a typical report time).

These reports are industry standard. Globally, every company uses something similar. The format and content may vary slightly, but all contain similar information.

Reading these reports is important for most disciplines and managers involved in upstream activities.

What does your company use as a morning report tool?



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Field Execution

Coiled tubing units

Slick line

Rigs

Equipment used in well completions and workovers:• Rigs

• Coiled Tubing Units

• Snubbing, or Hydraulic Workover Units

• Electric Line

• Slick line

• Stand alone pumping operations (bull heading)

See Well Intervention Core.

Electric line

Hydraulic workover unit



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WEG at 7410’

XN at 7405’

SSD at 7390’




















WEG at 7410’

XN at 7405’

SSD at 7390’

2 7/8” 6.5 ppf API EUE N-80 tubingThis is the proposed sketch. This is what the

completion engineer wants to get to i.e., thefinal state of the well. There is a lot of engineering that goes into this sketch; which isthe overall subject of this module. Consider for now several questions: Why perforate that interval? Why run that packer and that size tubing? Why run tubing at all? Why just perforate, and not frac or gravel

pack?



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Which zone? Multiple zones?

Engineering Design Components

Completion Location

Do we need sand control or fracturing?Primary Sand Face

Completion Method

Almost always required – how?Perforating

What equipment is needed for safety and flexibility –over the well’s life

Upper Completion Selection

Based on reservoir inflow over the life of the well, rate, pressure, fluid composition

Tubing Selection

Needs to hold reservoir pressure and not damage (be compatible with) the reservoir

Completion Fluid

Consider your barriers (usually two required) at each stage of the operation

Barriers

What Engineering Went into this Procedure?

Typically, some combination of open hole well logs and core data is used to help identify the zones and determine the relevant properties.

Which zone or zones? Where are our target zones of interest? Is there just one zone of interest or are there

more? How are we going to approach this completion

from the targets initially?

Completion location



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Primary Sand face completion method

Lower Completion

Just run casing and perforate (a satisfactory option if the reservoir is consolidated and has reasonable permeability)

If the reservoir is unconsolidated, you may need to install some form of sand control

If the reservoir has very low permeability, you may need to fracture the reservoir

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In most cases, we will need to select our perforationstrategy as part of this sand face completion – guntype, shots per foot, etc.

See the Sand Control Core and Onshore Unconventional Well Completions Core

modules for more information.

Christmas tree

General requirement to have two barriers in place for any operation

A barrier is used in place for any uncontrolled lossof produced fluids leading to the environment

Barriers change throughout completion/workover operations – this is different from drilling operations where the two barriers (mud and the BOPs) are fairly constant

Barriers

Sub‐surface safety valve

Tubing

Packer

Tubing and Packer




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Includes: Selection of the flowing conduit (usually up

through tubing with a packer installed, but not always)

Type of packer Selection of other equipment (in this example

the wireline reentry guide, the XN landing nipple, and the sliding side door), and mightinclude others, including subsurface safety valves.

Upper completion selection

Selection of components

The selection of those components will be based on a range of factors including safety and long‐term flexibility

Must select tubing size, grade, andconnections Requires analysis of Darcy’s Law

Also look at pressures and the long‐term drive mechanism to determine the optimum tubing

Barrier

Barrier


Select the metals and elastomers Based on fluid components, pressure,

and temperature Select the completion fluid

Selection of completion fluid

Always a clear brine, NOT drilling mudMultiple factors: Completion fluid must have sufficient

hydrostatic head from the density to control the reservoir pressure at reservoir depth

Completion fluid must be able to controlthe reservoir pressure while in the completion phase

Completion fluid must also be compatiblewith the formation, both the rock and the reservoir fluids.

Barrier



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If your well is capable of flowingnaturally at pressure, then a treewill need to be selected.

Select a tree based on pressure, and any corrosive fluids you may have.



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Learning Objectives

This section has covered the following learning objectives:

Explain the work product of a completions engineer

Describe an initial completion procedure and sketch

Translate chronological steps from a procedure to a well sketch

Recognize and describe morning reports

Recognize the engineering that is required for developing aprocedure



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Back to Work Suggestions

Leverage the skills you’ve learned by discussing the skill module objectives with your supervisor to develop a personalized plan to implement on the job. Some suggestions are provided.

Find and review a completion procedure that has been done in the field.

Find the procedure, the pre-sketch, the proposed sketch, the final sketch and the morning reports.

Review these documents, and discuss your review with a senior completions engineer.




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Basis of Design


Learning Objectives

This section will cover the following learning objectives:

Explain and provide an example of Basis of Design (BOD)

Compare and contrast design and BOD



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Cooking Analogy – Introduce the Basis of Design

Planned outcome

List of ingredients

Basil chicken recipe

Marinate chicken for 4 hours in a blend of balsamic vinegar, juice of 2 lemons including the lemon pieces, olive oil, fresh rosemary, garlic, salt, pepper

Prepare basmati rice with sliced mushrooms

Prepare sautéed broccoli, olives, red bell peppers, and green beans, add drizzle of soy sauce and splash of sherry

Prepare salad of lettuce, fresh tomatoes, feta cheese, and salad dressing of choice

Cook chicken in cast iron skillet, with lemon pieces, turning frequently until done, season with garlic, salt, pepper

Place cast iron skillet with chicken in oven on warm with whole fresh basil leaves on top

Lightly wilt spinach in some of the juices from the cast iron skillet

Serve chicken on the wilted spinach, basil on top, with rice, vegetables, and salad

Process Recipe

You may want topause a moment to reviewPAUSE

Cooking Analogy – Introduce the Basis of Design

A lot of thinking

before cooking

Cultural preference?

Taste preference?

Chicken on sale that day?

Had pork the day before?

Health?

Taste?

Equipment?



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Basis of Design

What is a Basis of Design (BOD)?

The BOD is the “why” to the program’s“what”

BOD is all the things you (should) consider when developing the proposed sketch and the procedure/equipment selection

Many of these things you consideredhave significant uncertainty at theCompletion stage since this occurs atthe beginning of the well life

BOD is critical to document

Design vs. Basis of Design

What (Design)Why (Basis of

Design)

1. Run 3.5” tubing2. Run 13 chrome tubing3. Perforate at 8000’–8200’4. Use Service Company X

for all equipment5. Install sand monitoring on

flow line

1. Reservoir properties indicateinflow is best handled by 3.5”

2. Reservoir fluid analysisshows CO2

3. Interpreted Petrophysical logsindicate the best “pay”8000–8300’, but the reservoirdrive is expected to bewater influx

4. Procurement has a sole sourcecontract with “X”

5. Geologic work suggests potentialfor unconsolidated sandstone



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est. 7850’, send results to Engineering3. RDMO SL4. If approval to proceed, MIRU completion rig5. Make bit and scraper run to PBTD6. TIH with open ended workstring, displace hole with

9.8 ppg KCL completion fluid* Note: expected reservoir pressure is 3600 psi at 7500’. 9.8 ppg fluid will provide a 222 psi OB

7. Test casing to 5000 psi for 15 minutes8. MIRU EL unit, hold explosives safety meeting and

conduct JSA. RIH and perforate 7500–7570’ (reference OH log dated Nov 9, 2016) with 4 5/8” gun loaded 6 spf, 60 deg phasing,32 gm RDX charges


10.Monitor hole conditions for 4 hours, report any fluid loss or pressure build up

11. If well stable, TIH with completion string consisting ofMS WL reentry guide, XN landing nipple, model MJG mechanical retrievable packer, sliding side door, and 2 7/8” 6.5 #/ft tubing. Set packer at 7400’


13.Test backside to 5000 psi for 15 min.14. Install BPV, ND BOPs, NU 5000 psi tree and flowlines,

pull BPV, turn well over to Production15. If required, use lease gas to rock well

in, open on 16/64 ck.


Example BoD for our Example Well

Well left with 10 ppg mud in casing when drilling rig moved off location

2 7/8” 6.5 ppfAPI EUE N-80 tubing

SSD at 7390’ Model MJG packer set

at 7400’ XN at 7405’ Lock mandrel with pressure

gauges hung off Feb 15 ‘17 WEG at 7410’ Perforations 7500’–7570’

MD. Note: top sand at 7500’, bottom sand at 7610’


You may want to pause a moment to review the information.

PAUSE



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Find and review a Basis of Design statement used in your company for a recent completion.

Discuss your review with a senior completions engineer.

Note, not all companies have these titled documents, if not, talk with a senior completions engineer about how the elements within a typical BoD are incorporated into your company’s work process.

Find and review a Basis of Design statement used in your company for a recent completion.


Note, not all companies have these titled documents, if not, talk with a senior completions engineer about how the elements within a typical BoD are incorporated into your company’s work process.


Basis of Design



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Learning Objectives

This section has covered the following learning objective:

Explain and provide and example of Basis of Design (BOD)

Compare and contrast design and BOD



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Find and review an AFE, AAR, and CWOP.


Note, not all companies use all three of these products. You should be able to find an AFE, as these are very standard. If you do not find an AAR or CWOP, discuss the reasons why your company does not use them in your work process – who knows, maybe there is an opportunity for improvement!

Find and review an AFE, AAR, and CWOP.


Note, not all companies use all three of these products. You should be able to find an AFE, as these are very standard. If you do not find an AAR or CWOP, discuss the reasons why your company does not use them in your work process – who knows, maybe there is an opportunity for improvement!


Basis of Design



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Linkage to Management Systems

Design Process for Workover and Completions

Core

Learning Objectives

This section will cover the following learning objective:

Illustrate and explain the link between management systemsand the engineering design process



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This is usually represented as a wheel and comes from the work of Deming.

Project Management

Business Management

Safety Management

Quality Management


PLAN

Basis of Design,Proposed Sketch, and CWOP matches up with the procedure

DOOperations follows the procedure

CHECK

Daily morning reports are reviewed by the Operations and Engineering team

ACT

Immediate corrections may be made to the well completion based on new data

The AAR, morning reports, and the post sketch all feed into the next PLAN (a revised Basis of Design and Proposed Sketch).

Many companies actively follow a Project Managementapproach to well drilling and completions.

Several major service companies have divisions that offer fully integrated drilling and completion package divisions, “total” packages, and these typically are built around the project management methodology.



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Learning Objectives

This section has covered the following learning objective:

Illustrate and explain the link between management systems andthe engineering design process



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Completion Design


Learning Objectives

This section will cover the following learning objective:

Identify the objectives of a completion

Identify and describe each aspect that is to be considered toachieve the two objectives

Compare the different drive mechanisms



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Drive Mechanisms

Generally, three main types of drive mechanisms areconsidered active in the Petroleum Industry.

Solution Gas Drive

Gas Cap Drive

Water Drive

• There may be a combination ofmore than one type, and theymay have differentcontributions to the overall driveof the reservoir – weak vs.strong water drive, for example

Depletion or Gas Expansion

Water Drive

For Oil Reservoirs

For Gas Reservoirs

Solution Gas Drive

Solution gas drive

• The gas dissolved in oilcomes out of oil andexpands pushing the oil outof the reservoir

Oil Zone

Liberated Gas



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Solution Gas Drive Performance

Idealized typical solution gas drive performance behavior.

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RESERVOIR PRESSURE

DAILY OIL PRODUCTION RATE

PRODUCING GAS-OIL RATIO

Pi

Pb

Rsi

TIME

Gas Cap Drive Reservoir

Gas cap drive

• The free gas in thereservoir expands andpushes thehydrocarbons out

Original GOC

Liberated Gas



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Gas Cap Drive Performance

Idealized, typical gas cap drive performance behavior.

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RESERVOIR PRESSURE



TIME

Pi

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Water Drive Reservoir

Water (aquifer) drive

• The underlying aquiferpushes thehydrocarbons to thesurface

Oil Zone

Water-Invaded Zone

Original WOC

Water



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Strong Water Drive Performance

Idealized, typical strong water drive performance behavior.

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Pi

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RESERVOIR PRESSURE



DAILY WATER PRODUCTION RATE



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Mudlogdata

Coredata

Open hole logs: Resistivity Nuclear Acoustic Other

Cased hole logs: Nuclear Production logs Other

Formation Evaluation

While Drilling Wireline

Corrections:- invasion- layering- deviation

Reservoir Monitoring

Interpretation modelsincl. QC and Uncertainty

The Petrophysical Scene



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Essential Equip.Ancillary Equip.Sandface Completion• Sand Control• Frac• AcidPerforating MethodCompletion Fluid

Completion/ Workover Design

Equipment Design and SelectionEquipment Design and Selection

Wireline nipplesCirculating devicesChemical injectionmandrelsArtificial lift

Flow couplingsTubing sealsBlast jointsSand Control Equip

Tubing/ connectionWellhead/ treeSubsurface safety systemsPacker

Program Design and Selection

Program Design and Selection

1. Flexibility

2. Durability

See Design Fundamentals for more information the design phase.



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Learning Objectives

This section has covered the following learning objectives:

Identify the objectives of a completion

Identify and describe each aspect that is to be considered to achieve the two objectives

Compare the different drive mechanisms

PetroAcademyTM Completions and Workovers

Onshore Conventional Well Completion Core


Perforating Core

Onshore Unconventional Well Completion Core

Sand Control Core

Hydraulic Fracturing

Design Fundamentals

Well Completion Fundamentals

Formation Damage and Matrix Stimulation Core

Flow Assurance and Production Chemistry Core

Production Problem Diagnosis Core

Well Intervention Core

Workover Fundamentals



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Documents

Design Process for Workovers Core COPYRIGHTcloud1.activelearner.com/contentcloud/portals/hosted3/PetroAcademy/... · If well stable, TIH with completion string consisting of MS WL