INTEGRATED

PROJECT
MANAGEMENT

Well Control for Well Intervention

Section 2:
Completion Pressure Control Equipment

Maria Rivero Tasso Magalhaes

IPM-WIA Instructor + Knowledge Delivery Manager
European Learning Centre
Agenda
Completion Well Control Equipment
1. Blow Out preventers (BOP)
2. Completion Equipment
1. Xmas tree
2. Tubing Hanger
3. SSSV
4. Landing Nipples
5. Tubing movement
6. Circulating devices
7. Packers
8. Plugs
9. Re-entry tools
3. Completing the Well

Section 2 - 2
Blow Out Preventers (BOP)

Section 2 - 3
BOP Stack Configuration
Normally contains at least a pipe ram, a
shear/blind ram and an annular
preventor along with a spool to connect
both, the kill and choke lines.

No hard rules are given regarding the

BOP stack arrangement (relative
position of the different elements).

All stack arrangements have pros and

cons, and it is the project responsibility
to decide which arrangement best suits
the project requirements.

Refer to API STD 53 for some

recommended arrangements.
Section 2 - 4
BOP Stack Test

Pipe ram and Annular Preventor

Cup tester:
Cup tester is RIH with pipe across BOP.
Cup tester seals on the casing
Annular or pipe ram are activated
independently.
Pressure is applied from tubing and
communicated across cup tester port (above cup
seal).
Test is between cup, pipe and ram.
Positive test in direction of the flow to verify
sealing capacity
Section 2 - 5
BOP Stack Test
Blind/Shear Ram
Plug in the well:
Shear/blind ram is activated.
Pressure is applied from side port (in ram body below ram)
Test is between plug in the well and closed ram.
Positive pressure test in flow direction to verify sealing capacity.

Section 2 - 6
BOP Stack Test
Function Test

At least once a week per piece of

equipment

To verify correct functioning of

equipment.

Section 2 - 7
BOP Stack: Possible operation

Section 2 - 8
BOP Stack: Possible operation

Section 2 - 9
Equipment Rating Example

The barrier envelope working pressure:

Is chosen
Thetobarrier
withstand the maximum
envelope anticipated surface
working pressure
pressure
is as high as the lowest working pressure component
Is as high as the lowest working pressure component
The wellhead working pressure is 10,000 psi.
The slickline lubricator is rated to 5000 psi.
What is the working pressure pressure for the current rig up?
o 10,000 psi
o 7500 psi
o 5000 psi
Section 2 - 10
Pipe Ram Preventer

Section 2 - 11
Different ram types

Pipe Ram
Variable Bore Ram
Shear/Blind Ram
Blind Ram

Section 2 - 12
Pipe Ram Selection

Pipe rams close around a drill pipe, restricting flow in the annulus, but do not
obstruct flow within the drill pipe.

The pipe ram shall be selected according to pipe size that will be used (2-7/8, 3-
1/2, 4-1/2, variable size).

During workover operations it may be required to frequently change (and test) pipe
rams.

If a dual completion will be run in hole, a dual pipe ram with appropiate sizing must
be used.

The pipe ram rating shall be at least the minimum surface pressure expected.

Section 2 - 13
Ram Features

Main advantages of ram BOP compared with annular preventor.

1. Better resistance to high pressure values
2. Less control fluid volume required, which implies shorter closing time
3. They can support the drill string weight (during hang-off)
4. They allow stripping in case of very high pressure values (ram to ram)
5. Once they are closed they prevent the drill string from being expelled

Section 2 - 14
Ram Closing/Opening System

Section 2 - 15
Ram preventer main features

Section 2 - 16
Pipe ram assembly seals

Sealing off between

ram and BOP body

Sealing off around

tubing

On closure, rams are assisted by well pressure, which energises the top seal
Section 2 - 17
Ram Secondary Seal
If a primary seal leak is detected, two procedures can be adopted:
during BOP pressure tests: replace faulty primary packing unit
during blow-out control: energize secondary sealing

Section 2 - 18
Changing Rams

Unscrew the bonnet and move 4 way valve to close position. This will push the bonnet out.
Section 2 - 19
Hydraulic circuit for ram replacement

Section 2 - 20
Variable Ram
Top Seal
Packer

Body
Variable-bore pipe rams can accommodate
tubing in a wider range of outside diameters than
standard pipe rams.
Typically with some loss of pressure capacity
and longevity.
This is very easy to damage.
More expensive.
Section 2 - 21
Full Opening Safety Valve
Must install the valve in open position when you get an influx while tripping,
and then close.

Upper seat

Ball
Crank
Lower Seat

Body

Section 2 - 22
Blind/Shear Ram Preventer

Section 2 - 23
Blind Ram

1. Also known as sealing rams, which have no

openings for tubing

2. They can only be used without pipes in the

wellbore (they do not seal around pipe).

3. Close off the well and seal it.

4. During BHA M/U they can be closed to prevent

objects from falling inside the well.
Section 2 - 24
Blind/Shear Ram
Shearing pipe is considered
the tertiary barrier.

They are mainly adopted in offshore operations to allow emergency

abandoning.

They can be used on land to face particularly serious emergency

situations which cannot be solved by adopting standard procedures.

They can cut drill pipes/tubing only.

Section 2 - 25
Shear Ram Closing Sequence

Section 2 - 26
Shear Rams

Section 2 - 27
Annular Preventer

Section 2 - 28
Annular Preventer

They are designed to:

1. Close on an open well

(nevertheless this should be avoided)
1. Reciprocate or rotate the string while maintaining a seal against
the well bore (need approval during WC situation)
2. Pass the tool joints through while stripping.
3. Seal around a square or hexagonal Kelly.
4. They can be operated with a variable Operating Hydraulic
pressure.
Section 2 - 29
Annular BOP principles
Hydraulic fluid (light petroleum
hydraulic oil, or a mix of water/water
soluble oil).

seals

The piston is raised by hydraulic

pressure.
seals

The rubber packing unit is squeezed

inward to a sealing engagement with
seals
anything suspended in the wellbore.

Section 2 - 30
Annular BOP principles

CLOSURE SEQUENCE (OPEN) CLOSURE SEQUENCE (PART CLOSED)

CLOSURE SEQUENCE (SEALED OFF)

Section 2 - 31
Opening and Closing Pressure
1. Adequate opening/closing pressure values inside the chambers allow the
piston to move and vary according to BOP typology. In most cases it ranges
between 700 and 1500 psi.

2. The larger the tubing diameter, the lower the initial closing pressure.

3. In case of closing of an empty well, the BOP shall be closed with the maximum
allowable pressure (1,500 psi for all types except Cameron D which in case of
emergency can be closed at 3,000 psi.)

4. Annular BOPs closure can be:

1. well pressure assisted (The closing pressure must therefore be reduced
when the BOP is kept closed, to limit rubber wear)
2. non well pressure assisted (Usually to be preferred in case of stripping
operations).
Section 2 - 32
Flanges & Ring Gaskets

Section 2 - 33
Side Outlets Connection

Studded

Clamp Hub

Flanged

Section 2 - 34
Flange size and working pressure

The flange has a disc which is the sealing element between two flanges

The flanges have a groove for the fitting of the ring gasket.

Ring gaskets are made of a softer material than the flange body;
therefore, they deform during sealing and must be used only once.

The gasket it is identified by its ID and working pressure:

What does this mean a 7 1/16 , 15M flange?
Working pressure of 15,000 psi and 7 1/16 ID/bore

There are different types of grooves and gaskets depending on the

pressure rating and size of the flange: 6B (R and RX) and 6BX.

Section 2 - 35
API Flanges
TYPE 6B FLANGES (R or RX)
Working Pressure (psi) Size Range
2000 2 1/16 to 21 (except 18 and 20 )
3000 2 1/16 to 20 ( except 18 )
5000 2 1/16 to 11

TYPE 6BX FLANGE

Working Pressure (psi ) Size Range
2000 and 3000 26 and 30
5000 13 5/8, 16 , 18 and 21
10000 1 13/16 to 21 ( except 20 )
15000 1 13/16 to 18 ( except 16 )
20,000 Section 2 - 36
1 13/16 to 13 5/8
Ring Gaskets Sealing

Stand-off Closed Face

gives gives
instability stability

BX
R or RX Ring Gaskets
Ring Gaskets

API 6B Flange API 6BX Flange

Bigger standoff (than 6BX) Smaller standoff (than 6B)
Sealing takes place through the ring gasket Contact between flange ends prevents
only (not between the flange ends). vibrations acting on the ring gasket affecting
sealing, but the bolts loosening is more
difficult.
Section 2 - 37
Ring Gaskets Geometry
FLANGES RING GASKETS

Type R
(oval or octagon)
TYPE API 6B
2,000; 3,000; 5,000 psi

Type RX BX and RX rings are

(octagon pressure energized,
asymmetrical )
meaning that in case of
leaking, pressure helps to
Type BX
improve the sealing.
TYPE API 6BX
2,000 to 20,000 psi (square cross section RX rings from sizes 82
with tapered edges) through 91have pressure
Section 2 - 38
equalizing hole.
Choke Manifold

Section 2 - 39
Choke Manifold Schematic

Section 2 - 40
Choke Manifolds & Kill Lines working pressure

Manifold equipment subject to well

pressure (up-stream including the
choke) should have a minimum working
pressure at least equal to the rated
working pressure of the ram BOP in use.
All choke manifold valves should be full
bore.
Function Tests: at least once a week.

Section 2 - 41
Manual and Hydraulic chokes

Ajustable Chokes

Section 2 - 42
Completion Equipment

Section 2 - 43
Typical Completion for a Flowing Well

Section 2 - 44
X-mas Tree

Section 2 - 45
X-mas Tree

Section 2 - 46
X-mas Tree Valves

SWAB VALVE:
Operated only for rigless intervention.
To give pass for S/L, W/L, C/T tools and
cable/pipe.

MASTER VALVES:
To open/close in the well for production.
Normally UMV is operated, thus it has a
hydraulic operator for remote operation
LWV is closed only to replace/repair UMV
Some master valves have cutting cable
capabilities
Section 2 - 47
Flow Line

CHOKE: To regulate flow

FAIL SAFE VALVE (Surface

Safety Valve):
To shut-in the well on emergency
Thus it has hydraulic actuator for
remote operation.

FLOW WING VALVE:

Always upstream (inside) the FSV
to allow replace/reparation of it.
Section 2 - 48
X-mas Tree Valves

They are normally gate valves

Turns must be counted when opening

and closing to guarantee that the gate
travels full drift and free of any
obstructions

After closing or opening the valve it

must be back up of a turn to avoid
damage

Section 2 - 49
X-mas Tree Valves

Must be pressure tested or inflow

tested prior rigging up
intervention equipment.

Are the primary and secondary

barriers on production operations.

Some master valves have cutting

cable capabilities (tertiary barrier)

Section 2 - 50
Tubing Hangers - Functions
It isolates the completion from the annulus.
It supports the weight and load of the top of
the completion from surface to packer.
(tubing is threaded to bottom connection)
It places a plug/check valve inside the hanger
body.
(BPV/TWCV is rod conveyed and
threaded/locked on top side with or without
tubing or landing joints installed).
It connects to landing joint to land/retrieve
completion.
(landing joint is threaded on top connection)
Section 2 - 51
Tubing Hangers
Primary functions:
Isolates annulus pressure from surface
(control line of SCSSSV, control line of vent valve or ESP cable are
fedthrough across hanger body and sealed with fittings on top and
bottom connection of the body).

Section 2 - 52
Tubing Hangers Plugs

BPV is used for X-mas

tree/BOP removal

The BPV still allows fluid to

be pumped in the tubing string

The Two-ways check valve

(TWCV) is used for pressure
testing the BOP blind rams

Section 2 - 53
Sub Surface Safety Valves (SSSV)

Are installed to protect personnel, property and environment

from uncontrolled flow in the event of collision, equipment
failure, human error or sabotage.

Should be installed below the depth where well can be

damaged by impact or explosion.

They prevent flow from below only.

Section 2 - 54
Sub Surface Safety Valves (SSSV)
SUB SURFACE CONTROLLED (SSC-SSSV):
Set and retrieved by wireline.
Pressure Differential
Ambient or Pressure Operated
Injection valves

SURFACE CONTROLLED (SC-SSSV):

Surface controlled
Tubing
Wireline
Annular safety valves

Section 2 - 55
Pressure Differential Safety Valves

Pressure Differential or Velocity Safety Valves.

P. Loss in the valve leads to closure.
Return spring keeps the valve open, but whenever
a excessive velocity or flow rate is achieved, a P. loss
creates a force greater than the return spring and
valve closes.
This type of valve is also known as storm chokes.
Closing Mechanism:
Ball. Flapper. Poppet.
It cant tolerate high variation of flow.
It suits wells produced at low flow rate
Section 2 - 56
Pressure Differential Safety Valves

Section 2 - 57
Ambient Safety Valves
Pressure Operated or Ambient Valves.
Closing mechanism is controlled by a return spring and a gas chamber
(charged to a specific pressure).
It is normally closed and pressure in the well will keep it open.
Pressure = > than operating pressure (set point) from above will open
it. Whenever the ambient (tubing) pressure drops, the valve will abruptly
close.
As the differential pressure valve, this type of valve is also known as
storm chokes.
Closing Mechanism:
Ball
Flapper
Poppet
Very sensitive to pressure variation.

Section 2 - 58
Injection Valves

Acts as a check valve allowing injection, but preventing back-

flow.

Flapper type valve is the most common as its operation is

simpler and less prone to damage.

Section 2 - 59
SC-SSSV
It is a fail-safe close device (normally closed), it opens only
when sufficient hydrostatic pressure is hold on the control line.
The flapper type, opens-down, thus when closed, the
higher the well pressure, the more it closes.
Cant open with differential pressure above 100 psi. To
open the valve increase control line pressure or pressure up
above tbg.
Must be run in the hole in the open position.
By using the control line pressure (above of that tubing
pressure)
By stinging in a straddle tool which is later retrieved by s/l.
Section 2 - 60
Surface Controlled Sub Surface Safety Valves
Tubing retrieveable/conveyed
RIH along the tubing and is part of the completion string.

Wireline conveyed
RIH on slickline and installed in a landing profile installed the
completion string along the tubing.

Closing Mechanisms (for both):

Ball
Flapper (Preferred nowadays due to simplicity, roughness and
robust)
Section 2 - 61
Tubing Retrieveable SCSSSV
It has been replacing the Wireline Retrieveable valve
because:
It is highly reliable
It has a bigger ID for the same tubing size
Does not require s/l runs to retrieve and reinstall for every well
intervention.

In case of failure:
The tubing must be pulled out of the hole for replacement
or
RIH a lock open device on slickline. Then install an insert valve
that operates similar to a Wireline retrievable valve.
Section 2 - 62
Tubing Retrieveable Flapper SCSSSV

Animation

Section 2 - 63
Wireline Retrieveable SCSSSV

It is a fail-safe close device, that is kept open by the pressure

applied by the control line
Must always have the pressure equalized before opening
It is set in a dedicated safety valve landing nipple (SVLN)

Must be run in the hole open

By running tool and the prong when run with wireline
By a flow tube or a straddle when run as part of the completion

In case of failure, the valve can be retrieved by wireline

The nipple port must stay in between the two DHSV packing
stacks
Section 2 - 64
Wireline SCSSSV

Section 2 - 65
Annular Safety Valve

It seals the annulus between the tubing and the casing

It is operated by a control line.

Is mainly used for gas-lift wells to prevent the gas in the annulus
to flow back to the surface

Normally is set just below the DHSV

Ideally should be set as shallow as possible to minimize the

amount of gas flowing back

Section 2 - 66
Landing Nipples

Short section of thick walled tubular

machined to provide a locking profile:
No-go (XN)
Selective (X)

Its primary function is to receive mainly

flow control devices
Lock + blanking plug
Lock + memory gauge
Lock + isolation tool

Section 2 - 67
Locking Devices: The lock mandrel
Is RIH on slickline
It has locking dogs (X or XN) that
match (and lock) on the recess
profile of the nipple
The lock mandrel elastomeric
packing will seal on the nipple
polished bore

Any flow control or measuring

device is installed on bottom of lock
mandrel

Section 2 - 68
Flow Control Devices

Section 2 - 69
Landing Nipples
The no-go shoulder primary function is to locate the correct lock mandrel,
providing a positive indication of the nipple position.
Normally installed at the bottom of the completion string

Note: All Camco SSDs do have an X

landing profile integral to the tool.
Section 2 - 70
Wireline Retrieveable Plugs
Some plugs are designed to be installed temporarily in the well
(retrievable) by means of wireline/slickline.

The wireline retrieveable plugs may hold and seal in a landing nipple
altough there are plugs designed for installation in the tubing space instead.

Plugs may fail to hold pressure by mechanical failure or also when set in
front of a collar, scale, other obstructions or debris.

When this occurs, the first plug must be retrieved and a back up plug
must be set (at different depth to prevent similar problem). Alternatively, a
back up plug can be installed above the first one.
Section 2 - 71
Tubing Movement
Depth Depth

Why? ft THF ft THF

Changes on profile along the completion.

Pressure, Temperature, Fluid Density acting on 4,781

plugs or tubing cross-sectional sections

4,801
4,945

When?
During Tubing integrity test
\ \

5,485

During inflow test

6,042

Setting the packer

During production/injection
\ \

During hydraulic fracture 6,373

Section 2 - 72
Tubing Movement
Depth Depth

Mitigate tubing
ft THF ft THF

movement:
4,781

Use PBR/ELTSR of good

length for seals.
4,801
4,945

Use expansion joints.

Spacing out appropriately

\ \

5,485 (tension, compression, neutral)

6,042

\ \

6,373

Section 2 - 73
Circulating Devices
SSDs
SPMs
Ported Nipples

Intended circulation between tubing and annulus space above the

production packer.

Pressure consideration before opening a valve must be done for

effects of pumping rates, effect of surge pressure downstream the
valve.

Section 2 - 74
U-Tube Effect
The U tube effect studied applies across circulating devices
The pressures must be equalized before opening
For well control purpose, after circulating observe the fluid below SSD
(inside) and below packer and predict effect on column when unsetting
pkr.

Section 2 - 75
Circulating Devices - Sliding Sleeve Door (SSD)
Provides a method of circulating between the tubing
and annulus:
For selectively producing a zone
Well kill or contingency
Must be equalized before opening!!!
Operated by slickline/coiled tubing, using a shifting
tool
Concern is longer term reliability, particularly with
respect to scale, corrosion and long term seal integrity
For circulation purposes must be placed above
production packer!!!
Animation
Section 2 - 76
Circulating Devices - Sliding Sleeve Door (SSD)
Depth Depth
ft THF ft THF

For circulation purposes must be

placed above production packer!!!
4,781

For zonal isolation it must be placed 4,801

one SSD for producing zone and isolated

4,945

by additional packer. \ \

5,485

It is necessary to report the intended 6,042

direction to open and close the SSD \

(open up or open down).

\

6,373

Section 2 - 77
Circulating Devices - Ported Nipples

Provides a method of circulating between

the tubing and annulus:

It is open by applying pressure. (ball drop

and hydraulic pressure) or mechanically (bar
drop)
Cannot be closed after opened.

Section 2 - 78
Circulating Devices - Side Pocket Mandrel (SPM)
The main intention and design is not to
circulate, nevertheless provides a method of
circulating between the tubing and annulus:

For circulation purposes must be placed

above production packer!!!

It was normally used to receive gas-lift

valves (unloading, dummy/(blind), orifice)

It can be used to receive:

chemical injection valves
Gauges
Section 2 - 79
Packers
Packers functions:
To isolate annulus from pressure
To isolate the wellhead from high pressure
Corrosion protection of annulus (casing and outside of tubing
above packer)
To stop the flow of fluids (along with SSSV) if tree damaged
To allow multiple zone.

Packers elements:
Slips to hold in position (fixed depth).
Elastomers to seal annulus Section
space.
2 - 80
Packers Retrieveability

Retrievable:
Intended to be retrieved.
Production packer, GP packer, zonal isolation.
Normally by P/U in tension.
Some have retrieving tool conveyed by pipe.
Lower Volume Production Smaller Bores.

Permanent:
Intended for life span of the well
Sump packer bottom most.
Requires milling
Lower Volume Production Larger Bores
Section 2 - 81
Permanent Packers

Section 2 - 82
Packer Setting Mechanisms
Mechanical setting
Typically it requires rotation (1/2 turn at tool) and tubing slack off. The
string weight above the packer helps to seal and anchor.

Compression & tension setting

Using a slip, cone arrangement and drag blocks that engages the
casing and holds the slip stationary.
This setting uses weight of the string to expand the packing element.

Hydraulic setting
The rotation is not required.
Pressure through the string has to be applied (+/- 3500 psi).
It is required to set a plug on a landing nipple below the packer or to
drop specific setting ball in order to build hydraulic pressure.
Section 2 - 83
Setting Mechanisms - Hydraulic

Land tubing on hanger

Install plug on landing nipple using
slickline
Or alternatively drop ball (quantum)
Pressure up to test tubing integrity
(below packer setting initiation
value)
If ok, close SSSV. Bleed pressure
and inflow test SSSV. (the lowest
the tubing pressure the better).
Equalize pressure and open SSSV.
Section 2 - 84
Setting Mechanisms - Hydraulic

Pressure the string to full packer

setting value.
Bleed Off Pressure.
Perform P/U and S/L test to check
slips.
Test the seal:
If formation has pressure, perform
inflow test observing returns and
pressure in annulus.
Otherwise, pressure test the annulus
and observe zero leak.
Retrieve the plug on slickline.
Section 2 - 85
Setting Mechanisms Plug Selection

Note that the type of plug depends on

barriers required for the well.
For well suspension a barrier is required.
Plug:
It is designed to hold pressure from
below.
It requires 2 runs for setting and 2 runs for
retrieving.
Test Tool:
Can be used to save time, only 1 run
required.
Can apply pressure with S/L connected to
surface.
Pressure equalization is critical.
Section 2 - 86
Re-entry guides

Tubing end
Mule shoe
Bell guide

1. Selection depends on intended future interventions, being

the most critical S/L and W/L.
2. The tools may hang up when POOH and passing from
casing to tubing space leading to parted wire and tool LIH.
3. Consider extending the EOF to closest device.
4. Observe well deviation and clearance casing/tubing.

Section 2 - 87
Completing the Well

Section 2 - 88
Equipment Preparation

All equipment must be verified for

intended use.
The following checks are critical:
Sealing surfaces are in good shape
Seals/Elastomers without worn/broken
parts.
No missing o-rings
Ring gaskets have not been used

Section 2 - 89
Equipment Preparation

Equipment is complete and enough back up equipment.

Equipment is compatible (threads/connections must be
checked physically)
Equipment is pressure rated accordingly.
Material is correct.
All handling lifting equipment is properly sized.

Section 2 - 90
Equipment Preparation

Leaking connections may lead to well control situations.

Verify that:
Equipment has been stored, transported and handled so
connections are preserved.
Connections must have protectors.
All crossover must be physically inspected and tested with
intended connections.
Have thread inspector to brief the crew on pipe dope
application.
Have inspector to verify connections and use torque monitor
tool/software and provide torque chart.
Verify minimum-optimum-maximum threads for all equipment.
Section 2 - 91
Planning for RIH non shearable

Sand screen
Have well control crossover connected to safety joint ready on rig floor with safety valve.
Exercise well control drill to respond during emergency (connecting safety joint with
crossover and safety valve, RIH, closing on safety joint)
Ensure everyone is aware of his/her responsibilities:
Preventing (monitoring the well and ensuring correct displacement volume)
Reacting to connect safety BHA and close in the well.

ESP cables/ Control lines

Have hydraulic cutters tested and ready on rig floor.
Exercise well control drill to respond during emergency.
Ensure everyone is aware of his/her responsibilities:
Preventing (monitoring the well and ensuring correct displacement volume)
Reacting to cut and close in the well.Section 2 - 92
Confirming well integrity
Recent Casing integrity
Verification of plugs/packers installed and tested method.
Select pressures to TCP and test packer (below casing integrity value).
Weight and homogeneous completion fluid in the well
Stability of LCM, hole filling or static fluid level or means to measure fluid
level
Verify the balance condition during the job and anticipate influx (open hole,
horizontal)
Right rams to avoid crisis in situation of well control.
All crossovers for screens, washpipe, concentric pipe are on rig floor.
Verify cement job reports and analyze cement logs.
Section 2 - 93
Verifying well clean-up. Prior to RIH completion
Completion Fluid clean up (filtration)

To ensure homogeneous fluid density

To reduce formation damage:
Optimum pipe dope application
Filtration and NTU monitoring

Section 2 - 94