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Multiple Zone Completions

CONTENTS
1 DEFINITION
2 MULTIPLE ZONE DEPLETION CONCEPTS
2.1
Co-mingled Flow
2.1.1 Advantages
2.1.2 Disadvantages
2.2
Segregated - Multiple Zone Depletion
2.2.1 Advantages
2.2.2 Disadvantages
2.3
Alternate Zone Well Completion Strategy
2.3.1 Advantages
2.3.2 Disadvantages
2.4
Selection of Development Strategy
3 MULTIPLE ZONE COMPLETION
CONFIGURATIONS
3.1
Dual Zone Completion
3.2
Completions for 3 or More Zones
4 MULTIPLE COMPLETION EQUIPMENT
4.1
Tubing Hanger Systems
4.2
Multiple Tubing Packer Systems.
5 AUXILIARY EQUIPMENT FOR MULTIPLE
COMPLETIONS
SUMMARY

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Learning Objectives:
Having worked through this chapter the Student will be able to:
Describe the options, and their inherent constraints / advantages, for producing
multiple reservoir units.
Propose general completion schematic options for producing two, three
or more zones simultaneously.
Define the equipment requirements in terms of packers, tubing hangers and Xmas
trees for multiple completion strings.

Multiple Zone Completions

1 DEFINITION
Multiple zone completions are employed on reservoirs where more than one distinct
reservoir layer is to be intersected by a single well and for which the intention or
requirement is to produce/induce these layers separately. Normally the reservoirs are
sequentially encountered as the depth increases. The concept of a homogeneous
reservoir rarely, if ever, exists in reality. However, producing formations can often
be considered stratified, and their producability depends upon the extent to which
vertical flow occurs. Stratified reservoirs are created by changes in depositional
conditions but the layers have different rock properties and hence flow characteristics
e.g. permeability. The layers can have a variable degree of vertical communication.
Alternatively, if the layers deposited by changes in depositional conditions are
separated by deposited layers having very low or non-existent vertical permeability,
each of the producing layers is a non-communicating reservoir layer.

2 MULTIPLE-ZONE DEPLETION CONCEPTS

The depletion of multiple zone reservoirs can be accomplished by one of the
following:(a) Comingling the Flow from Various Zones:
In this approach, more than one zone flows into the tubing string, e.g. two zones
producing up a single tubing string.
(b) Segregated Multi Zone Depletion:
With this approach the concept is to use multiple production conduits within
the same wellbore, where each tubing is utilised for the production of one zone.
(c) Alternate Zone Well Completion Strategy:
Here the idea is to complete each well on one specific reservoir.
The advantages and disadvantages of each of the above techniques is discussed below.

2.1 Co-mingled Flow

2.1.1 Advantages
(1) Since each well provides a drainage point in each reservoir unit, the total
number of wells is a and the capital investment, is therefore minimised.
(2) Since the amount of drilling is minimised, the production plateaux for all the
reservoirs should be reached as quickly as possible. i.e. production should be
accelerated compared to the other optional strategies

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2.1.2 Disadvantages
(1) The mixing of produced fluids in the wellbore can be disadvantageous if one
or more fluids have any of the following characteristics:
(a)

Corrosive or potentially corrosive materials e.g. acids, H2S, CO2.

(b)

Produced sand and a potential erosive effect. The implementation of

sand control procedures may be more complicated.

(c)

Fluids having different Hydrocarbon compositions and hence economic

value.

(d)

Different WOR and GOR as this would influence the vertical lift
performance of the total well system.

(2) Variation in individual zone pressures and permeability can lead to a back
pressure effect on the less productive or lower pressure reservoirs.
(3) The use of co-mingling removes the capability for continuous control of the
production process, i.e. closure of one individual zone cannot necessarily be
effected unless a relative configuration is used.
(4) Injection of fluids, e.g. stimulation fluids cannot easily be diverted into
individual layers without temporary isolation using sealants (diverters) or
bridge plugs.
(5) A change in the production characteristics of one zone e.g. water coning and a
consequent increase in WOR, will influence the total production from the well
but may be difficult to remedy without closing in the well.

2.2 Segregated - Multiple Zone Depletion

2.2.1 Advantages
(1) The production rate and duration of flow on each zone can be independently
controlled.
(2) Changes in the production characteristics of one zone will not influence the
others.
(3) Some remedial work on individual zones can be accomplished without always
affecting production on other zones, e.g. cement squeeze, reperforating,
perforation washes.
(4) Stimulation on each zone can be applied.
(5) Continuous monitoring of the depletion of each zone can be achieved, which
assists in material balance or reservoir simulation studies for reservoir
management.
4

Multiple Zone Completions

2.2.2 Disadvantages
(1) Since each zone has a tubing string the amount of production tubing and other
completion equipment required is considerable. This requires additional capital and
installation time.
(2) The mechanical complexity of the completion is increased and hence the
possibility of equipment malfunction is also increased.
(3) The amount of completion equipment is increased and hence the statistical
possibility of component failure is also increased.
(4) The retention of tubing sizes may reduce the total flow capacity of the well

2.3 Alternate Zone Well Completion Strategy

2.3.1 Advantages
(1) Effective control of all aspects of reservoir depletion and well control is
provided.
(2) Changes are easily introduced to adapt to variations in the depletion strategy,
e.g. changing a well from production to injection.
(3) Problems encountered on one well does not necessarily influence the continuity
of the production of fluid from other zones/wells.
(4) Each well is relatively simple mechanically and the risk of failure due to
complexity is minimised.

2.3.2 Disadvantages
(1) To achieve the same degree of depletion control by having good reservoir
drainage, the number of wells to be drilled and completed must increase in total.
Thus, the total cost of such a development will be substantially increased to achieve
the same drainage effiency in the reservoir.
(2) Unless the number of wells is increased, the difference of production on some
zones will defer, reduce and extend the field of life thus increasing unit production
costs.

2.4 Selection of Development Strategy

The chosen strategy for the completion and development of a reservoir drainage
system, will depend very largely on the following:

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(1) Offshore or Onshore Development
In an offshore development, the cost per well is so large that the planned number of
wells is usually minimised. This limitation will not be as significant in an onshore
development.
(2) Areal Size and Number of Reservoir Zones
The drilling of a large number of wells can be more easily accomplished with or
without directional drilling on land. Offshore, however, if the structure covers a very
large area, the use of very high angle wells will be necessary. To run very complex
multiple completions in high angle wells can lead to significant difficulties being
encountered.
(3) Variation in the Reservoir Rock and Fluid Characteristics
The degree to which corrosion or erosion is likely to occur will influence the type of
completion. In addition the degree to which drawdown on one zone might suppress
production from other zones may be important.
The flow potential of each zone might be impaired if too small a tubing size is used,
because of the lack of space within the wellbore for a multiple tubing completion.

3 MULTIPLE ZONE COMPLETION CONFIGURATIONS

Wells can be completed on any number of zones within the same well by simply
increasing the amount of completion equipment installed to provide isolation and flow
control capability. The benefits of using the same wellbore for multizone production
are significant, but as the number of zones increases, the complexity and potential for
malfunction can negate the inherent advantage of the single wellbore completion. The
optimum number of zones to be produced into any wellbore will depend on the
reservoir, e.g. in high rate, highly deviated completions, perhaps even two tubing
strings might not be desirable. In other cases three tubing strings in each wellbore
might be used to deplete a number of zones.

3.1 Dual Zone Completion

There are a number of ways in which completions can be designed to produce two
zones. Besides co-mingled flow and individual well/zone completion there are:
(1) Casing/Tubing Flow
In this case a single tubing string is run with a single packer installed to provide
isolation between zones. One zone will produce up the tubing, whilst the other will
produce up the casing-tubing annulus.
The difficulty with this type of completion is that under natural flow conditions it will
have a live annulus perhaps necessitating an annular safety valve. Also the produced
fluid is in contact with the casing and it may thus cause damage by corrosion or
abrasion. In addition, pressure limitations on the annulus with respect to casing burst
may preclude stimulation of the zone which produces via the annulus.
Two alternative completion types exist:

Multiple Zone Completions

(a) Upper zone annular flow - applied where the upper zone fluid is non-corrosive,
non-abrasive and where pressure limitations of the casing would not preclude
stimulation.
(b) In situations where the upper zone would not be suitable for annular flow, then
a lower zone annular flow system could be used requiring one tubing string, two
packers and a crossover tool. This design however, severely precludes mechanical
areas to both zones for logging, perforating etc..

Cross over

Upper Zone/ Annular Flow

Lower Zone / Annular Flow

Optional
nipples/SSD

Figure 1
Options for 2 Zone Flow
without Comingling

Single String Selective

2 Zone 2 String
(Optional nipples/SSD
installation introduces
additional selectivity)

(2) Dual Tubing Flow

In this type of completion a separate tubing string for each zone is provided with two
packers, one to isolate between zones and the other to isolate the upper zone from the
upper casing annulus. Here the depletion of each zone can be accurately monitored
and controlled. In addition, the injection of fluids into each zone is limited only by
the tubing design criteria. Also, the completion is more suited to the effective
production of problem well fluids.
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(3) Single String Selective Producer
In this completion, the well is completed over two zones, utilising one tubing string
designed to selectively allow the production of either or both of the zones. The
completion requires two packers, one to isolate between zones and the other to isolate
the annulus. In addition, an entry point for fluid from the upper zone to enter the string
must be provided which can be opened and closed as desired, e.g. a sliding side door.
Finally, when producing the upper zone into the tubing, closure of the lower zone may
be accomplished by setting a plug in a nipple at the base of the tailpipe.

3.2 Completions for 3 or More Zones

The available options discussed in section 3.1 for dual completions can be extended
for wells to be completed on three or more zones with or without some degree of zonal
co-mingling.
(1) Triple Zone Completions
This can be accomplished with either:
(i)

A completion utilising separate zonal flow into one of three tubing strings and
having three packers for isolation.

(ii) A two string completion, whereby flow from two zones is co-mingled into one
of the tubing strings.
(iii) Single zone annular flow and two tubing strings producing separately from two
zones.
(iv) Two string completion where either or both of the strings are completed to
allow selectively production from two of the zones. This requires two tubing
strings and three packers.
(v) Single string, triple zone selective completion.
(2) Four or More Producing Zones
Normally no more than three strings are run into the wellbore, but a large number of
options exist.
(1) Single string selective producer.
(2) Dual string selective producer.
(3) Dual string/selective with annular production.
(4) Triple string with annular production.
(5) Triple string with selective production.
It is clear that when four or more zones exist, the completion strings can become
complex, costly, difficult to run and retrieve, and more likely to produce mechanical
failure. The considerations can severely impact on the life of the well.

Multiple Zone Completions

4 MULTIPLE COMPLETION EQUIPMENT

In general terms, equipment requirements for multiple completions are largely based
upon the equipment available for single string completions with the following exceptions:
(a) tubing hanger systems
(b) tubing packer systems
(c) specialised installation equipment.
Obviously the number of tubing strings will affect the completion procedure.
However, since the sizes of the tubing and hence ancillary equipment are dictated by
the limitations imposed by the casing inside diameter, tensile load and torque
capabilities will not normally be a significant problem for a completion rig.

4.1 Tubing Hanger Systems

Here the difficulty is one of landing off the tubing in the landing seat in the tubing head
spool. The simplest way of achieving this is to use a segmented hanger. For each
tubing string a hanger segment is produced. Upon landing off all the tubing strings,
the hangers should form a composite circular hanger which also seals the annular
space in the landing seat within the tubing head spool. Normally each hanger segment
is made up with a tubing pup joint above and below which is attached to the rest of the
string. The tubing strings are either run independently or simultaneously.
When using a surface controlled sub-surface safety valve, provision must be made for
the control lines for each tubing string and valve system.

4.2 Multiple Tubing Packer Systems.

In a multiple tubing systems, the number of packers will normally equal the number
of zones to be produced. For a dual zone, dual tubing completion, two packers will
be required, the lower being a single packer whilst the upper will be a dual packer.
Similarly for a three zone, triple tubing completion, three packers will be required,
comprising a single, dual and a triple packer.
Multiple string packers are available to similar specifications as single string packers,
i.e. they can be either permanent or retrievable. In addition, they can be set using a
hydraulic or a mechanical setting procedure. The wireline setting procedure, although
frequently used to set the lower single string packer, would find little application for
the upper packer(s) because of the cable weight limitations.
All multiple string packers must offer a means of connecting tubing above and below
the packer for each string. In some cases mechanical attachment exists e.g. tubing
screwed onto the base of the packer whilst, in other cases, the packer offers a seal bore.
In any completion involving multiple strings, the tubing strings will have different
lengths and are denoted as the long string, intermediate string and short string. This
terminology is crucial to the running procedures for the completion, e.g. a packer may
be run into the well on the long string which is landed off, and may be set using
hydraulic pressure either by the long string or by the short string after it has been run,
located into the packer seal bore and landed off in the THS.
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Although in most cases it is preferable to run retrievable multi-string packers since it
leads to easier retrieval in an already more complex workover operation, permanent
packers are available and may be required in high pressure wells, or where significant
tubing movement and stress is anticipated. One example of such a packer in the Baker
model DE available for either hydraulic setting DEH, or for setting on tubing or
wireline the model DE-1. This packer is based on the model D packer having the same
design principle of full circular slips and metallic back up rings. The packer offers two
seal bores whose length can be extended up to 20 ft. If the packer is set on wireline,
then the long string would be run through the upper seal bore and down into the seal
bore or latched into the lower packer. The long string can then be pressure tested prior
to running the short string. With the hydraulic version, the packer with the long string
tailpipe is made up and run on both the long and short tubing strings. After landing
off, a ball is dropped down onto an expendable seat in the base of the packers and
pressure of for example, 3000 psi seats the packer and 4000 psi shears out the ball and
seat.
A dual version of the A-5 packer is available from Baker, which is set by pressure
created in the short string. A modified version termed the AL-5 is the same packer,
but can be set by pressure in the long string. To allow pressure testing of the tubing
without premature setting of the packer, a modified ALS-5 packer is available from
Baker.
Halliburton have a range of hydraulically set, retrievable packers, termed the RH
range. The RH packer has been discussed previously, but Halliburton also offer the
RDH and RTH for dual and triple completions respectively. The packers can be set
by hydraulic pressure in either the long or short string

Figures 2
Dual Completion-split
hanger

Figure 3
Dual tubing hanger integral

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Multiple Zone Completions

Figure 4
Hydraulic Set Packers; dual
and triple configuration

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Primary-Threaded
Secondary-Collet

Primary-Threaded
Secondary-J-Slot

Primary-J-Slot
Secondary-Collet

Primary-Threaded
Secondary-J-Slot

Primary-J-Slot
Secondary-Collet/
Sleeve Latch

Primary-Threaded
Secondary-Threaded

J-Slot Latch

Collet Latch

Collet/Sleeve
Latch

Since the packer is normally run on the long string, it is possible to set the packer
with the long string in tension, but the short string can be set in either tension or
compression.
Once the packer has been run to the desired depth and the long string landed off,
the short string is run and landed off within the second seal bore of the packer. A
ball dropped down the desired setting string, lands in an expendable seat (1).
Internal hydraulic pressure from the tubing shears the pins (2) by the downwards
movement of the setting piston. The downwards movement of the setting mandrel
expands the lower element and sets the slips. Upon releasing the tubing pressure,
the packer is held in the set position by internal slips (3). Differential pressure
from below the packer sets the hydraulic hold down buttons. To retrieve the
packer, the short string is first retrieved, and upwards tension will shear the pins
(5) and allow retrieval.

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Figure 5
Seal Assemblies for
Hydraulic Set Packers

Multiple Zone Completions

Hold Down
Buttons
Shear Pins

Shear Pins

(2)

(2)

Catcher Sub

Releasing
Pins

Internal Slips

(3)

Figure 6
Running, Setting and
Retrieval Operations for
typical dual hydraulic set
packer

(4)

Catcher Sub

(1)
Schematic 1
Running In

Schematic 2
Setting

Schematic 3
Retrieving

Mechanical set dual or triple packers are also available. The packer utilises a weight
set concept (3000 - 5000 lbs) and can be set by either the long or short string. In
addition, if a J latch system is used for both strings, each string can be retrieved
independently for workover without unseating the packer. The packer is available as
either short string or long string, set with or without hydraulic holdown, e.g. SH/SA
and LH/LA. The setting concept is useful since no tubing rotation is required.
Four different connecting systems are available for engaging the short and long string
into the packer:
(1) Threaded connection - this could be used for two strings if both strings were to
be run and pulled together. Normally, it is simpler to pull the strings individually.
(2) J-slot connector - requires 1/3 right hand turn at the packer for release.
(3) Collet connector - requires no rotation.
(4) Collet-sliding sleeve latch - this is an adaption of the collet connector where
an inner sleeve is fitted and this has to be shifted to lock and unlock the collet.

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5 AUXILIARY EQUIPMENT FOR MULTIPLE COMPLETIONS
(1) Circulation sleeves
A useful item for dual completions in a pressure operated sliding sleeve which allows
easy circulation of fluids between long and short strings or between the long string and
the annulus. This facility removes the necessity to remove the tree in order to
disconnect the string latches prior to circulating the well to kill or initiate production.
The tubing can, in fact, be landed off and the well circulated prior to setting the packer.
The opening of the sleeve requires about 600 - 800 psi differential pressure in the long
string. It may be necessary to have a ball and expendable seat below the packer in the
long string to protect the lower formation against the pressure generated in the tubing.
After circulation, a ball dropped down the short string lands in the expendable seat,
and pressure applied to set the packer also closes the circulation sleeve.
An alternative pressure operated circulation sleeve uses internal pressure to open the
sleeve but after use, a ball is dropped down the tubing and lands in a recess. With the
application of tubing pressure the inner sleeve is moved downwards and the device
closes. In operation it requires about 650 psi internal pressure to shear the screws on
the lower sleeve and this allows the spring to push the lower sleeve down and exposes
the ports. After circulation, the ball is dropped down and once in position a pressure
of 2900 psi will be required to shift the upper sleeve down and close off the ports.
(2) Blast Joints
The long string in a multiple completion is located in the casing opposite the perforated
sections of upper producing zones and as such they are present in the section of the
wellbore where fluid entry occurs. The direction of fluid low through the perforations
into the wellbore is normally perpendicular to the well axis and the fluid flowstream
must quickly change through 90 to flow up the tubing. The fluid entering the wellbore
may have a significant impact force on the tubing wall of the long string and will lead
to hydraulic erosion. If sand or solid fines are being produced, they will drastically
increase the erosion rate.
Accordingly, to compensate for the increased erosion, a thick walled tubing section
known as a blast point is normally included in the string opposite the perforated
intervals of the upper production zones.

SUMMARY
In this section we have discussed the options and equipment requirements for
completing multiple zone reservoirs. In most cases we must balance the reservoir
management requirements in terms of flow control, regulation and isolation as again
the additional complexity and its inherent costs - both capital and intervention, as well
as operational constituents.
In some situations the complexity can also limit production rates due to the number
of tubings within a fixed size of casing and the consequent need to use smaller tubing
diameters.

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