WELL COMPLETION

AND
WORK OVER

OIL INDIA LTD.

(A Public Sector Enterprise)

--

SCHEMATIC OF WELL COMPLETION

CHRISTMAS TREE : The X-Mas tree is a valve assembly installed immediately above the tubing
head spool to control the flow from the well. The X-Mas tree usually consists of one top valve,
one master valve two side ,valves two arm valves , Cross piece and bean body. The bean body
accommodates bean housing and beans of various sizes can be installed in the bean housing.
The X-Mas trees used by OIL INDIA LTD are of the ratings of 3000 psi, 50000 psi and 10,000 psi.
Usually two master valves are installed where the pressure expected to be encountered are in
the range 5000 psi or [Link] X-Mas tree also provides means for wire line operations.

5000 PSIG X-MAS TREE / TUBING HEAD SPOOL

S/NO

NOMINAL
DIA
( INCHES )

STUD DIA &

LENGTH
(INCHES)

NO OF
STUDS

API RATING OF
RING JOINT
GASKET

2 1/16

/8 X 6

RX-24

2 9/16

1 X 6 1/2

RX-27

3 1/8

1 1/8 X 7 1/4

RX-35

7 1/16

1 3/8 X 10 3/4

12

RX-46

11

1 7/8 X 13 3/4

12

RX-54

13 5/8

1 5/8 X 12 3/4

12

RX-57

10000 PSIG X-MAS TREE / TUBING HEAD SPOOL

S/NO

NOMINAL
DIA
( INCHES )

STUD DIA &

LENGTH
(INCHES)

NO OF
STUDS

API RATING OF
RING JOINT
GASKET

2 1/16

/4 X 5 1/4

BX-152

2 9/16

/8 1 X 6

BX-153

3 1/ 8

1 X 6 3 /4

12

BX-154

7 1/16

1 1/2 X 11 1/4

16

BX-156

11

1 3/4 X 15

16

BX-158

13 5/8

1 7/8 X 17 1/4

20

BX-159

CONVENTIONAL WELL
HEAD

TUBING HEAD SPOOL : The Tubing Head Spool is installed over the Casing
Head Housing/ Spool. It acts as a base for the X-Mas tree and also as support
for the tubings in the well as it accommodates the Tubing Hanger where the
tubings are hanged. The Tubing Head Spool is equipped with Bit Pilot to guide
the Tubings as it is lowered and also has assembly of secondary seals which
when energised acts as a seal between 5 Casing and 9 5/8 casing. The two
casing valves provides access to the tubing casing annulus.

SPOOL TESTING :
Spool testing means hydraulic testing of the space between Casing Head Housing and
Tbg Head Spool, enclosed by Primary Seal, Secondary Seal, and the Ring Joint Gasket.
NECESSASITY OF SPOOL TESTING:
a)

The Primary seal prevents casing fluid/ gas from entering 5 1/2 & 9 5/8 casing annulus. It
is not desirable to subject the 9 5/8 Casing to high pressure as the pressure rating of
the 9 5/8 casing is not high. Moreover, the cementing failure of 9 5/8 casing will
aggravate the problem by contaminating ground water.

b)

The Ring joint Gasket prevents escape of casing fluid/ gas to atmosphere through the
joint between Casing Head Housing & tubing Head Spool.

c)

The secondary seal works as back up to both of the above sealing components. If
secondary seal holds, primary seal and reing joint gasket are not exposed to casing fluid/
gas.

STEPS FOLLOWED FOR SPOOL TESTING :

Step 1 : The 5 Casing is given the final cut of 4
filed and smoothened.

or 3 as required. The cut portion

Step 2 : The tubing Head Spool is installed and tightened over the Casing Head Spool.
Step 3 : The 5 casing and the annulus between 5 and 9 5/8 casing are topped up with
the available fluid.
Step 4 : Bleed off port is opened by removing the plug.
Step 5 : The packing gun is screwed at injection port. Plastic packing are inserted in the
packing gun and injected is started. When the plastic packing starts coming out from
the bleed off port, the plug of the bleed off port is installed. Injection of plastic packing
is continued to energise the secondary seal.
Step 6 : The manifold is screwed at the test port. Hydraulic pump and pressure recorder is
attached to the manifold. Water or hydraulic fluid is pumped through the test port upto
desired pressure.
Step 7 : Pressure is monitored for a duration of at least half an hour. If pressure is holding
spool testing is completed.
SPOOL NOT HOLDING PRESSURE
1)

Leaky Ring joint

Liquid seen to come out between the flanges of Tubing Head Spool and Casing Head
Spool
Retighten the studs.

2)

Secondary seal leak

Liquid seen to come out from the casing/ spool
Insert mort plastic packing.

3)

Primary seal Leak

Liquid seen coming out through the Annulus Valve
Drilling to reinstall / replace primary seal.

TYPES OF WELL COMPLETION

(A) OPEN COMPLETION
NO PACKER , NO STANDING VALVE
ADVANTAGES
1.0 Suspended tubing can be used as a
kill string. It is easier and less damaging
to reservoir to kill by circulation.
2.0 Tubing can be used to inject corrosion
inhibitor.
3.0 Easy Hook up
LIMITATIONS
1.0 Casing is exposed to corrosive fluid
2.0 The production casing is not
protected against pressure effects during
normal operations

GAS LIFT
VALVE
PERFORATION (OPEN)
BRIDGE PLUG
PERFORATION (P/B)
FLOAT COLLAR
CASING SHOE

TYPES OF WELL COMPLETION

(B) SEMI CLOSED COMPLETION
WITH PACKER , NO STANDING VALVE
ADVANTAGES
1.0 Isolation of casing from well bore
pressure and temperature.
2.0 Quick enlivening of well by restricting
volume to be removed for enlivening the well
to tubing volume only.
3.0 Suitable for artificial lift.
4.0 The high gas pressure in case of gas lift
completion does not act on the reservoir.
4.0 Stable flow.
LIMITATIONS
1.0 Work over may be required in case of
packer leak and the packer may not get
unset.
2.0 SSD ( Sliding Slide Door) is required to
permit circulation between tubing and casing
and this necessitates wire line operation.

GAS LIFT
VALVE

PACKER
PERFORATION (OPEN)
BRIDGE PLUG
PERFORATION (P/B)
FLOAT COLLAR
CASING SHOE

TYPES OF WELL COMPLETION

(C) CLOSED COMPLETION
WITH PACKER , WITH STANDING VALVE
ADVANTAGES
1.0 ALL the advantages as in semi
closed completion.
2.0 Suitable for very low BHP wells as
the standing valve does not allow the
well fluid from tubing to fall back to the
formation.
LIMITATIONS
1.0 Same as in semi closed completion
2.0 The standing valve is to be removed
every time any job in perforations are
done.

GAS LIFT VALVE

STANDING VALVE
PACKER
PERFORATION (OPEN)
BRIDGE PLUG
PERFORATION (P/B)
FLOAT COLLAR
CASING SHOE

TALLY FOR GAS LIFT VALVE

2763 M
GLV
1

687 M

GLV
2

1318 M

GLV
3

1880 M

GLV
4

2380 M

2132 M

1570 M

1071 M

5 F/B HOOK WALL PACKER Baker R3

to be set at 3450 m

Perforation 3547.4- 3549.7 m

Float collar at

3582.4 ( m)

WORK OVER OPERATION

The work over is the oil field term for any work that attempts to increase
production from old well. A Work-Over rig is scaled down drilling Rig with
which the operations can be carried out at a sick well. The work over rig is
equipped to perform operations of pulling out and running in pipe strings,
turning the pipe string while it is in the hole, to circulate fluids in a well
and to carry out fishing operations.
NEED FOR WORK-OVER :

During the course of the life of a well drilled for the purpose of
production of oil/gas, water injection and water disposal get sick
resulting in decline in production of oil/gas or decrease in injection of
water in water disposal well / water injection well. The various types of
jobs that are required to be carried be carried out are listed below
TYPES OF WORK-OVER :
1) SERVICING OF WELLS SAND CLEANING
2) PUTTING ON ARTIFICIAL LIFT
3) ABANDONONG THE WELL
4) PREPARATION OF WELL FOR GRAVEL PACK.
5) WATER DISPOSAL / WATER INJECTION CONVERSION
6) CASING REPAIR JOB
7) ISOLATION REPAIR
8) PRODUCTION FROM NEW ZONE
9) WATER SHUT OFF JOB
10) RECOVERY OF PRODUCTION FISH

PACKER
DEFINITION : It is a downhole equipment used to seal off the
annulus between tubing and casing.
FUNCTIONS :
1)

To protect casing from high pressure during production e.g.

gas well

2)

To prevent charging effect in low pressure wells

3)

To protect casing from high pressure during injection, e.g.

hydraulic fracturing, gravel packing etc.

4)

To isolate casing leaks

5)

To protect casing during acid jobs

6)

To isolate higher up perforations

7)

To increase efficiency of gas lifting

8)

For use in multi zone production e.g. dual string, commingling

production etc.

9)

For use in conjunction with sub-surface safety valve, standing

valve, jet pump, down hole heater etc.

10) To hold kill fluid in casing tubing annulous

11)

To anchor tubing in rod pump wells

12) To prevent build up of gas in annulous due to miscreant

activities

CLASSIFICATION OF PACKER BASED ON

CONSTRUCTION
PERMANENT

WIRELINE
SET

RETRIEVABLE

PERMANENTRETREIVABLE

TUBING SET

MECHANICAL

COMPRESSION
SET

HYDRAULIC SET

TENSION
SET

INFLATABLE

ROTATION SET

CLASSIFICATION OF PACKER BASED ON FUNCTION

TESTING

PRODUCTION

INJECTION

STRADDLE

GRAVEL PACKING
CEMENT RETAINER

COMPONENTS OF A PACKER :
SEALING ELEMENTS Most packers use multiple seal
with a softer middle seal and harder outer
seals. The soft center element serves to seal off
at lower pressure differential, harder end
elements are used as back up seals to prevent
extrusion and effect of high temperature and
pressure.
SLIPS To hold the packer in position. Opposed slips
are provided in permanent packers
CIRCULATING PORTS OR VALVES To circulate or
equalize pressure.
FRICTION BLOCKS To provide drag and to prevent
rotation of packers . Needed for mechanical
packers only.
SAFETY JOINT To guard against stuck packer,
HYDRAULIC HOLD DOWN To provide extra grip if
the differential from below is more. Zone
pressure activates them.

A) MECHANICAL COMPRESSION SET

PACKER ( HOOK WALL PACKER)
The HOOK wall packer consists of slip and cone
arrangement as shown. The slips are attached to
friction block. There is a J slot in the inside
surface of the friction block assembly along with
the friction block slides and the friction block has
to be engaged in the J hook for the packer getting
engaged.
Calculation for weight released on hook
wall packer
Hooks Law :
Stress Strain
Stress/ Strain = Constant (Modulus of
Elasticity )

E = F/A
L/L
Here in the above equation
E : 3 X107 lbs/ sq inch
F : Weight desired to be loosened on packer in
lbs
L : Length of the Tubing in inch
A : Cross section area of the tubing in sq inch
L : Elongation in inch.

B) HYDRAULIC PACKER : This type of packers

are set by hydraulic pressure. The pack off is
mechanical and loss of pressure does not
affect it. The actual setting is actuated by
trigger movement of piston which energizes
the sealing element to seal off and the slips to
hold on to the casing. The setting of the
packer is accomplished with the help of
screws as shown which are to be sheared off
for it to accomplish the desired purpose.
The packer is provided with the following shear
pins
a)

Setting b) Pump out c) Release.

Settings shear : The setting pressure is
adjusted generally to around 1000 psi to 1200
psi
Pump Out : The pump out is set to around
2400psi to 2600 psi
Release : The release is adjusted to around
25,000 lbs to 30,000 lbs pull.
All the above three settings are dependent on
the STATIC BOTTOM HOLE PRESSURE of
the well. The setting pressure and the Pump
out of the plug are kept high in case of low
BHP wells and are kept low in case of wells
with high BHP.

SETTING PROCEDURE :
1.0 The packer is run on tubing to the desired
depth.
2.0 The CHRISTMAS TREE is rigged up and the
change over to water is done if required

4.0 The packer actuating ball needs

about 2 to 3 hours to reach the
desired depth. The traveling time is
dependent on the depth and
deviation.
5.0 The tubing is slowly topped up with
the fluid and the casing is kept open
to confirm the ball being set in the
Pump Out Plug. If there is no return
through the casing the ball has
occupied its position in the Pump Out
Pug.

6.0 The tubing is pressurized

hydraulically very slowly
considering the detrimental affect
of the hammering action which may
result in shearing of the pins
without any surface indication and
also without actualizing the trigger
movement of the piston. There is
slight drop in pressure after the
setting pins are sheared.
7.0 The pressure has to be retained for
few minutes for the seals and the
slips to engage in the casing.
8.0 The pressure is further increased
till the ball shears off the pump out
plug and the pump out plug along
with the ball falls to the sump. No
return of fluid from the casing
confirms the setting of the packer.

C) PERMANENT PACKER / RETAINER

PACKER
These type of packers incorporate design
and construction features which give them
long life and improved performance under
high pressure and temperature. These are
heavy duty packers equipped with two way
slips for permanent installation. These are
generally wire line set . The main features of
these packers are as under
1.0
in

These can be used as temporary or

permanent bridge plugs by running
a retrieval or Expandable plug in
tubing and setting it in the packer.

2.0

They can withstand high differential

pressures and high temperatures.

3.0

Tubing can be pulled without

unsetting the packer.

4.0
The tubing may be landed in
tension, suspension or compression. These
can be removed economically by
milling or drilling.

D) STRADDLE PACKER : These packers are

used for zone isolation and are run in

conjunction with either Hook Wall packer or
Hydraulic packer. After the Hook wall or the
hydraulic packer are set the compression of the
tubing shears of the screws on to the body of
the straddle packer and with the movement of
the cone the sealing elements expand and the
packer sets

FACTORS TO BE CONSIDERED WHILE CHOOSING

PACKER :
1.0

CASING SIZE AND WEIGHT/FEET

2.0

TUBING SIZE

3.0

NATURE OF FLUID IN HOLES

4.0

SETTING LOCATIONS AND METHOD AVAILABLE

5.0

SETTING DEPTH

6.0
PRESSURE AND TEMPERATURE TO BE
ENCOUNTERED
7.0

NATURE OF THE HOLE DEVIATED OR STRAIGHT

GAS WELL KILLING SET UP

TANKS
KILL
FLUID
KILL
PUMP

X-MASS
TREE

FLARE

ANCHOR
FLARE PIT
CHECK VALVE
GAS
RETURN
FLUID /
GAS

SEPARATOR
STEAM
JACKET

GROUND
XMT

ANCHOR

OIL

PILOT PIT

TANKS

KILLING A WELL : Killing of a well is a operation to increase the

hydrostatic head of the fluid column in the well bore above
the formation pressure, so that no formation fluid can enter
the well bore, In other words the process of deactivating the
well so that the well cannot displace any fluid on its own.
NEED FOR KILLING :
1.0 For the work-over of the well if the well falls sick
2.0 On safety consideration, due to damage of well head by
miscreants.
3.0 For abandonment of the well.
TYPES OF KILLING OPERATIONS :
1.0 Killing of Gas/Oil wells with Open completion
2.0 Killing of Gas /Oil wells with Closed/ Semi-closed completion
KILLING OF A GAS WELL WITH OPEN COMPLETION :
a)

Requirements

1)

High pressure kill pump depending on the expected pressure

to be encountered.

2)

Stand by Fire tender to cater for any emergency.

3)

Boiler facilities for steam jacket to avoid freezing of the line

4)

A Non return valve in the kill line to avoid back flow of fluids
from the well.

5)

Flare to be placed at least 90m from the well head, separator

and tanks.

6)

Kill pump at a distance of at least 45m from well head.

7)

Separators and tanks to be placed at least 45m from well

head.

STEPS TO BE FOLLOWED IN GAS WELL KILLING

1)

Check for all the necessary equipments, connections

required and the safety distances along with the pressure
ratings as shown.

2)

Ensure check valve in the kill line and stand by fire tender.

3)

Calculate the hole volume and check the availability of the

required amount of kill fluid with proper weight. The kill fluid
available should be at least 10% percentage more than the
hole volume, to take care for any fluid loss during the
operation.

4)

Check tubing and casing pressure.

5)

Test the kill line for a pressure above the expected pressure
to be encountered.

6)

Pressurize the kill line with water by above 200 300 psi
above the tubing pressure open the master valve of the XMas tree. As the pumping of the water is carried on the
tubing pressure initially drops as the gas gets compressed
and after it is compressed the tubing pressure starts to
increase. At this stage the casing valve is
to be opened
through a suitable choke in the ground X-Mas tree. This
choke is gradually increased as the fluid starts entering the
casing. The back pressure is required to be applied to
arrest the entry of fluid from the formation to the well bore.

7)

After the complete change over to water the tubing and

casing pressure drops and the well fluid is changed over
completely to kill fluid.

8)

Keep the well opened to pit and observe for any

displacement. If no displacement is observed the well is
killed.

KILLING OF A OIL/GAS WELL WITH SEMI-CLOSED /

CLOSED COMPLETION

The killing of a well with semi closed or closed completion can

be carried out simply by circulation as explained earlier if
the well is equipped with Sliding Slide Door above the
packer. The standing valve has to be removed in case of
the closed completion

Steps :
1)

Check all the the fittings for the suitable pressure ratings.

2)

Ensure availability of fire service.

3)

Check for the proper availability of the kill fluid in volume

and weight.

4)

Check and bleed tubing and casing pressure till it

becomes zero or liquid appears.

5)

Top up tubing and casing with kill fluid.

6)

Open well to pit and observe for any displacement.

7)

In case of no displacement Rig down X-Mas tree. Rig up

BOP.

ARTIFICIAL LIFT :

TYPES OF ARTIFICIAL LIFT

SUCKER ROD
PUMP

JET PUMP

GAS LIFT

ELECTRICAL
HYDRAULI
The
SUBMERSIBLE
C PUMP
need for Artificial
Lift in a well arises, if the Reservoir
Pressure of
the PerforatedPUMP
Formation is sufficient to make the reservoir fluid

flow from the reservoir to the well bore up to a certain height, but
the Bottom Hole Pressure is not sufficient to overcome the
Hydrostatic Head exerted by the fluid column of the well and thus
the well can not flow on its own .
The purpose of artificial lift is to lift out the well fluid by various
methods available. This also helps by maintaining a reduced
Flowing Bottom Hole Pressure so that Reservoir Fluids can flow
into the Wellbore.
CONTINUOUS
GAS (Low BHP Low PI)
INTERMITTENT GAS
LIFT

LIFT

A) GAS LIFT : Compressed Natural Gas at high pressure

(1500 psig) from Gas Compressor Station is supplied to a
number of wells through a set of Gas Lift Valves run on the
tubings. The gas either mechanically lifts the well fluid as in
intermittent flow or aerates the well fluid so that the well
can flow more or less naturally, as in continuous flow.
i) CONTINUOUS LIFT : The basic principle of continuous
lift is to inject the gas into the tubing at some
predetermined depth at a controlled rate. This aerates and
thus reduce the density the well fluid column above it, to a
point where the flowing BHP for a desired rate of
production is sufficient to lift the well fluid to surface. Thus
the well fluid is produced continuously from the well.
In continuous gas lift, only one valve will accomplish the
gas injection work, and this valve should be as deep as
possible as per available normal gas injection pressure.
This valve is termed as operating valve.
ii) INTERMITTENT LIFT : In intermittent lift, sufficient
volume of gas is injected as quickly as possible into the
tubing under a liquid column and then gas injection is
stopped. The volume of injected gas expands and in the
process displaces the slug of well fluid to surface.
Intermittent Lift does not require assistance of flowing BHP.
In this system, a pause or idle period is provided, when no
gas injection takes place. In this period the well is allowed
to build up the level of liquid, which depends on Reservoir
Pressure and PI of the well. Then again the next gas
injection cycle is initiated. In this manner, as the name
suggests, intermittent gas lift works on the principle of
intermittent injection in a regular cycle.

B) ROD PUMP : They consist of of the simple combination of a

cylinder and piston or plunger with suitable intakes and

discharge valves. The production rate will depend on
Deliverability and can be varied by varying stroke length
For scrapping purpose, scrappers are provided at the
parafinated zone.
C) ELECTRICAL SUBMERSIBLE PUMP : These are
essentially large and fixed volume multistage centrifugal
pumps and are run on the end of the tubing. The pump is
driven by submersible electrical motors, powered through
cable run along with tubing.
D) PRGRESSIVE CAVITY PUMP : This essentially is
submersible screw pump. It consist of a stator, having inside
spirals, run on tubing, and a rotor, having surface spirals,
hanged and run with rods coupled to a electric motor at
surface. The cavity formed between spiral surface of rotor and
stator moves up progressively on relative rotation between
them, carrying and pushing up the well fluid to surface.
E) HYDRAULIC PUMP : It essentially consists of a hydraulic
pumping system to run a subsurface production unit actuated
by hydraulic pressure. The produced fluid itself is used as
power fluid.
F) JET PUMP : It is a submersible pump, where power fluid
enter through tubing into a nozzle, which converts the
pressure head of the power fluid into velocity head (a jet). This
low pressure jet enters a inlet chamber, where it entrains the
formation fluid. The combined fluid enters a throat area where
complete mixing takes place, transferring momentum and
energy from power fluid to produced fluid. The resultant fluid
then enters a diffuser, where velocity head is converted to
pressure head allowing flow to surface through casing.

GAS LIFT VALVE SCHEMATIC

Nitroge
n Gas
Lifter
Well Fluid
GAS LIFT VALVE
BELLOW
Pd
Ab
STEM
Pc
SEAT
Pt

Ap

GAS LIFT
MANDREL
CASING

FORCE BALANCE EQUATIONS OF A GAS LIFT

VALVE
OPENING PRESSURE OF VALVE UNDER OPERATION CONDITIONS
FORCES TRYING TO HOLD THE VALVE CLOSED

Fc = PdAb
FORCES TRYING TO OPEN THE VALVE

Fo = Pc(Ab_Ap) + PtAp ( A )
The valve at closed position at the instant before opening, The
forces trying to open the valve are equal to the forces trying to
hold it closed.
Solving the equations
Pc(Ab Ap) + PtAp = PdAb
Pc = (Pd Pt R) / ( 1-R) ,

Where R = Ap / Ab

Pc Casing pressure at depth required to open the valve

CLOSING PRESSURE OF VALVE UNDER OPERATION CONDITIONS
FORCES TRYING TO CLOSE THE VALVE

Fc = PdAb
FORCES TRYING TO HOLD THE VALVE OPEN

Fo = Pc (Ab Ap) + PcAp

Fo = Fc
Pc (Ab Ap) + PcAp = PdAb
Pc = Pd
Therefore the casing pressure at valve must be reduced to dome
pressure at valve depth for the valve to close.
The difference between the opening and closing pressure at valve
depth is called spread. The spread controls the amount of gas that
passes through the valve

COMPARISION OF DIFFERENT ARTIFICIAL

LIFT METHODS
ROD PUMP

Simple design

HYDRAULIC
PUMP

SUBMERSIBL
E PUMP

GAS LIFT

Complex
design

complicated
design

simple design

Cannot be used
in deviated hole

Can be used in
deviated hole

Can be used in
deviated hole

Can be used in
deviated hole

Volume and
depth
limitations

Clean power
fluid imperative

Needs high
fluid level

Needs high
pressure gas
source.

Can handle
some sand and
waxy crude

Can handle
waxy crude but
sand and water
create problem
of providing
clean power
fluid.
Suitable for
high volume
production.

Can handle
waxy crude and
some sand

Can handle
some sand

Suitable for
high volume
production.

Suitable for
variable flow.

Suitable for low

volume
production