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3.

3 Completion Equipment

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Tubing String
Tubing string is the normal flow conduit used to transport produced
fluids to the surface or to inject fluids to the formation. Production tubing
is assembled with other completion components to make up the
production string, which should be compatible with the wellbore
geometry, reservoir production characteristics and the reservoir fluids.

The proper selection, design, and installation of tubing string are critical
parts of any well completion. sub-surface safety valve, side pocket
mandrels, artificial lift equipment, landing nipples, sliding sleeves and
production packers are the most common completion components.

Sizing is also important, a tubing string that is too small causes large
friction losses and limits production. It also may severely restrict the type
and size of artificial lift equipment. A tubing string that is too large may
cause heading and unstable flow, which results in loading up of the well
and can complicate workovers.

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Example of Tubing Strings

https://www
.youtube.co
m/watch?v=
TKHfDSnjb
XE&t=3s

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Packers

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What is a Packer?
A Packer is a sub-surface tool used to provide a seal between the Tubing and Casing (or
wall) of a well, thus preventing the movement of fluids past this sealing point.

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Why run a packer?

• Production control
• Well testing
• Equipment protection
• Well repair and stimulation
• Safety

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Why run a packer?

It is required for Production Control!


In a Gaslift well
• To keep pressurized the tubing-casing annulus.

• To facilitate kick-off.

• To prevent produced (abrasive?) fluids from


passing through the Gaslift-Valves.

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Why run a packer?

It is required for Production Control!


In multiple zone completions
• Incompatibility of pressures from different zones
• Separate production from different zones
• Control of an individual layer for HGOR or High
Water cut

In Steam Injection Wells


• To provide/maintain the annulus for heat loss control

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Why run a packer?

It is required for Well Testing!


In Exploration Well Testing
• Because of unknown properties of formation fluids
and gases

In Production Well Testing


• To locate entry point of water or gas (if PLT is not
available)

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Why run a packer?

It is required for protection of equipment!


• To protect the casing from corrosive fluids /
gasses
• To keep-off high formation pressures off the
casing and wellhead

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Why run a packer?

It is required for well repair & stimulation!


• Pressure testing of the casing
• Detection of a casing leak
• To shut-off gas or water entry
• During squeeze cementation
• During fracturing, to keep high pressures off
the casing
• During acidizing, as a diversion tool
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Why run a packer?

It is required for HSE reasons!


• In Marine environment, to protect against the
effects of surface hazards (collision)

• To reduce the effects of wellhead leaks

• To provide environmental protection from


potential failures of high pressure wells near
populated areas

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Packers

Two main types and typical


application

Permanent Packers
• production phase (long term)

Retrievable Packers
• multiple completions
• production phase (short term)
• tool for production / pressure testing

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Packers - generic mechanism
To perform two things must happen.

• Firstly a cone must be driven behind tapered


slips to force the slip out and into the casing
wall.
• Secondly a sealing element must be
compressed to effect a seal against the
casing wall.
• The two most important basic components
are therefore the slips and sealing element.
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Packers - generic mechanism

• Packer slips can be unidirectional or may be


designed to resist force from either direction

• Sealing elements may be one piece


construction or composed of multiple
elements of different degrees of hardness

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Packer classification

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Permanent packers

Packer becomes an integral part of the


casing
• Tubing ran in / pulled separately
• Tail assembly remains in the hole
• Retrieved by milling and picking
• Leaving casing wall ‘suspect’

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Setting permanent packer

Outer Sleeve
drive downwards

Inner Body
pull upwards

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Permanent packers

Advantages
• Tubing can be pulled out leaving packer + tail
assy in hole
• Tubing can be re-run and connected to the
packer
• Cheaper than retrievable packers

Disadvantages
• Destructive removal (milling)
• Milling > casing damage
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Method of Setting Permanent Packers

• Electric wireline
• Hydraulic pressure

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Wireline (Electric) setting tool
ELECTRIC CABLE

Casing

CROSS LINK

FORCES DOWN THE


CROSS LINK SLEEVE
Packer inside
casing
DOWNWARD THRUST ON
TOP OF PACKER

UPWARD PULL

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Hydraulic Setting Tool

SUPPORT SLEEVE
SUPPORT SLEEVE

(a) (a) (a) (a)


SHEAR SCREWS
SHEAR SCREWS
CONTROL LATCH
CONTROL LATCH
CONTROL PLUG
CONTROL PLUG
UPPER PISTON
UPPER PISTON

(b) (b) (b) (b)


UPPER PISTON
UPPER
RODPISTON ROD

LOWER PISTON
LOWER PISTON
LOWER PISTON
LOWER
RODPISTON ROD
(b) (b) (b) (b)

CROSS LINKCROSS LINK


CROSS LINKCROSS
SLEEVELINK SLEEVE

SETTING MANDREL
SETTING MANDREL

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Methods of Retrieving Permanent Packers

• Milling
• Milling and retrieving with a
packer milling assembly
• Retrieving with the tubing
string

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Packer milling assembly
Packer milling and retrieving tools are designed to mill and retrieve production packers in a single run. The packer mill
consists of a mill body and a replaceable mill or long rotary shoe dressed with crushed carbide.

• Milling assembly

• Packer

• Spear (packer picker)


engages for retrieval

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Packer Retrieving with Tubing String

The polished nipple also has a


landing nipple profile in its ID. The
housing also has an internal j-
profile that engages the lugs of the
nipple and anchors the tubing
On the top of the packer is located string to the packer.
a special nipple. The nipple has a
polished seal surface on its OD The packer can be released
and has j-lugs that are used to mechanically and retrieved from
anchor a seal housing in place. the wellbore with the tubing string.

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Seal assemblies for permanent
packers
The tubing locator seal assembly does not lock into The anchor tubing seal assembly is latched to the packer.
the packer. The tubing string can't be landed in The string can be landed in tension to take up expansion
tension except that of its own weight, however, the during production. Helical buckling is prevented if
tubing can be landed with setdown weight. sufficient tension is pulled. The risk of leakage is reduced.

Locator Seal Anchor Seal


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Types of Seal Assemblies
When tubing expansion is required

Half mule
Seals shoe guide

PERMANENT LOCATOR SEAL


PACKER ASSEMBLY

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Types of Seal Assemblies
To hang-off tubing in tension

Threaded
Latch

Seals

PERMANENT ANCHOR LATCH


PACKER ASSEMBLY

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PBR and Seal Assemblies
PBR: Polished Bore Receptacle

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Permanent packers - application

• High pressure and temperature


• Exact location correlated by wireline (Casing
Collar Locator)
• Deeper setting depths
• Trip times are faster, tubing run separately
• Deviated and extended reach wells
• Maximum dependability
• Gravel pack packer - can hang off long screen-
liner assy.
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Retrievable packers (1)

•Run and set on tubing (or drill pipe in case of


well repair)

•Integral part of the tubing

•Retrieved by pulling the tubing.

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Retrievable Packers (2)

•Advantages
• Saves rig time (easy pull-out)
• No milling necessary

•Disadvantages
• May swab-in well
• Sand, wax may make it un-retrievable
• Tubing - without the Packer can only be pulled out by:
• flash-cutting
• safety point is included
• detachable packer head is included
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Retrievable Packers - Application

Retrievable packers preferred


where:
• Completion life is relatively short
• Wellbore conditions are non-hostile
• e.g., temperature, pressure, H2S
• Setting depth shallow to medium
• Low to moderate differential pressures
• Straight wellbore or moderate
deviation
• Multiple zones are to be produced
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Method of Setting - Retrievable Packers

•Hydraulically Set
• Typical application as a production packer
– Mechanically set
• Typically used during well repair
• Application: tool for pressure and production
testing
• Tension-set
• Rotational-set (outdated)

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Method of setting – hydraulic –
set retrievable packers

•Setting
• Pressurizing the tubing
• A means of temporarily plugging the tubing is
incorporated in the bottom of the packer or in
the tubing below the packer
• Once set, they remain set by mechanical lock
or entrapped pressure

•Retrieving
• Straight pull on the tubing

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Hydraulic - Set Retrievable Packer -
Simplified Cross Section

hold-down buttons

Inner cylinder
Internal Slips

Seal element
Cone
Slips

Shear Pins
for release
Shear pins
to drop Ball
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Selection considerations – hydraulic set
retrievable packers

• Medium to high pressure


• Single and dual completions
• Deviated holes
• Can be set after tubing and Xmas tree has
been installed

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Dual packer systems - hydraulic
set retrievable packer
• Dual packer systems:
• Generally require one
dual packer and one
single (conventional)
packer
• Allow production through
two tubing strings from
the same wellbore
• Enable production from
adjacent high and low
pressure zones
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Retrievable dual packer

Long String
Short String
Stab-in bowl
Snap latch

Receptacle for
Short String

Sleeve

Bottom Connector

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Method of setting – compression – set packers

•Setting
• Slip and cone arrangement for setting
• Tubing weight is used to compress and
expand the sealing element
• Cannot be unseated by downward force (annular
pressure above packer or extra tubing weight)
• Hence holds pressure differentials from above

•Retrieving
• By simple up - pull on tubing
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Mechanically set compression packer

Simplified Cross Section


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Selection considerations - compression - set
packers

Straight and relatively shallow wells


• To hold pressure differentials from above,
(pressure testing casing above packer)

• To hold pressure from below, a hydraulic


hold-down system has to be incorporated in
the Packer Assembly

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Hydraulic Hold Down

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Mechanically set Tension Packer

Slips
Cone

Shear Pin

44 Simplified Cross Section


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Tension-set Packers

Setting
• By pulling tension in the Tubing
• Cannot be unseated by upward force
• Holds pressure differentials from below

Retrieving
• By simple slack-off on the tubing

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Selection considerations tension –
set packers

• Straight and relatively shallow wells


• Selected to hold pressure differentials from below,
(pressure testing below packer, i.e. casing and
liner or to frac formation)
• Pressure from below helps to increase the setting
force
• If dirt settles on top of slips can make it
unretrievable
• Overpull may shear the release pin
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Inflatable Packer

Expandable
Expandable
seal
seal
element
element

Pump-out
Pump-out
ball
ball
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Inflatable Packer

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Inflatable Packer

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Running the completion string,
retrievable packers
• Be careful not to swab in the well when pulling
out packer.

• Straight pull release packers may prematurely


shear and release due to tubing contraction.

• Pressure test may set packer

• Deposits may render packer non-retrievable

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Completion Equipment &
Components

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Completion equipment

Tubing accessories

• Landing nipples
• Locking mandrels
• Flow couplings
• Blast joints
• Expansion nipple

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Completion equipment (2)

•Communication equipment
• Sliding Sleeve (Sliding Side Door)

• Side Pocket Mandrel

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Completion equipment
Landing nipples
There is a need to install or to hang-off
in the tubing:
• A plug to pressure test the tubing
• A plug in the tubing below packer to safe-
guard the well
• A standing valve or plug during workover
• Gauges to measure bottom hole pressures
and / or temperatures

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Plugs
Solid Plug Standing valve

ball
seat

flow
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Completion equipment

Landing Nipples
- Is a short pipe, part of tubing string

- Has a recess to lock or hang-off a Locking Mandr

- Has a polished bore to receive a seal

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Completion equipment
No - Go landing nipple

• Nipple installed at bottom of tubing


• Same recess as the normal landing nipple but with
a reduced bore

• Stops locking mandrels leaving the tubing

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Landing Nipple
normal No-Go

No-Go

Installed at bottom of tubing

Like the normal landing nipple,


but with a reduced bore

Stops locking mandrels leaving


the tubing

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Completion Equipment
Landing nipple Locking mandrel
fishing neck

recess

locking dogs
polished
bore

packing

59
Connection for plug etc.
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Camco DB-6 lock mandrel

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The lower part of a completion string
for pressure gauge installation

Landing Nipple
Pup Joint

Packer

Cross Over

Landing Nipple
Perforated Joint

No-Go, hang-off press gauge

Pup Joint
Wireline Re-entry Guide
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6
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Tubing ID (Slip-type) Lock

- 3 slips mounted on a tapered body Fishing Neck

which wedges the slips outward to


effect a lock against the tubing wall
Locking Slips
- Designed to hold pressure from one
direction

- Can hold only limited pressure


differential
Sealing Cups

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Flow couplings
A tubular manufactured in 2 to 4 ft lengths with
tubing threads at the ends.
• Installed at points in the tubing string where excessive
turbulence is expected
 above and below cross-overs,
 above and below a landing nipple, SSSV nipple, etc

• Thick wall tubular with full tubing ID

• Thick wall provides protection against internal erosion

• Made of high-grade alloy steel


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Flow couplings
Tubing

Flowing Coupling

Landing Nipple
or other component

Flowing Coupling

64 Tubing
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Blast joints

A tubular manufactured in 10 or 20 ft lengths


with tubing threads at the ends.
• Thick walled tubular
• Part of the tubing and positioned opposite the
perforations a dual or multiple completion

• It’s thick wall gives added protection against


erosion from the jetting action of the producing
perforations

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Expansion joint

In expanded position the lock keys


will engage and torque can
transmitted to the tubing joints
underneath to unscrew Anchor Latch
lock key

housing

TO BE USED WHEN EXTREME


EXPANSION IS EXPECTED
lock key
i.e. STEAM INJECTION WELLS
seal

inner sleeve
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Communication equipment –
Sliding side door (SSD)

Sliding (inner)
Sleeve

Seals

OPEN Ports CLOSED


Seals

Inner Ports

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Sliding Side Door

Sliding
Inner Sleeve

Sliding
Inner Sleeve

PORTS
OPEN
PORTS
CLOSED

Network of Excellence in Training


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Communication equipment SSD
combined with landing nipple

Landing Nipple
Profile

SSD (sliding side door)

Sleeve

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Communication equipment SSD

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Side pocket mandrel (SPM)

1
1 Orientation guide to orientate wireline tool,
• kick-over tool

• 2 Side pocket for gas lift valve

• 3 Upper seal bore 2

• 4 Ports (communication to annulus) 3

4
• 5 Lower seal bore 5
6
6 Recess for latching gas lift valve in place

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and flow path

Fishing neck

Bellows
Lock

Injection gas enters ports


Upper seal and acts against the belows
to unseat the ball seal

Port
Gas passes through the
check valve which prevents
Lower seal reverse flow to annulus

73 Bottom latch
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Communication equipment running
GLV inside pocket mandrel (1)

Kick-over tool to run gas lift valve assembly

Side Pocket Mandrel

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Communication equipment running
GLV inside pocket mandrel (2)

GLV passing through (by-passing mandrel)

Kick-over tool oriented and tripped

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Communication Equipment running
GLV inside pocket mandrel (3)

GLV latched in valve pocket

Kick-over tool retrieved

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Safety Valves in Well
Completions

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Safety Valves

Surface safety valve - SSV

• Automatic fail-safe close valve installed at


the Upper Master Valve of the x-mas tree

• A positive shut-off flow in case of


- Line leaks
- Process upsets in the surface facility
- Emergency shutdown.

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Safety Valves

•Subsurface safety valve - SSSV


• A valve installed in the tubing down the well.
• When activated it stops well flow.
• Valve usually activated in combination with
Surface Safety Valve

NOT AN OPERATIONAL VALVE


USED FOR SAFE GUARDING AND
IN EMERGENCY ONLY
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Subsurface Safety Valves

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Subsurface Safety Valves –
SSSV application (1)
Why Install?
• Protect people, property and the environment
in case of blowout from sabotage or human
error, collision, equipment failure, fire or leaks
Factors determining whether to install?
• Location and types of wells
• Government legislation
• Effect of blowout on people and the
environment
• Damage to the producing reservoir

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Subsurface safety valves –
SSSV application (2)
•Which type of wells require SSSV?
• Offshore flowing oil and gas production wells
• Offshore wells gas injection wells capable of
flow
• Onshore gas producing and injection wells
• Onshore flowing sour (H2S) oil / gas wells
• Wells in earthquake-prone zones
• Certain onshore oil wells
o Near major roads and/or near populated areas
o Near environmental sensitive areas
o Near security sensitive areas

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Tubing safety valves, functional
requirements
• Flow barrier in the tubing when required.

• Fail-safe closing at a pre-determined condition or


command

• To withstand the maximum reservoir pressure in


closed position

• Minimum pressure drop in during production

• In closed-position, pump through capability

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Subsurface safety valves –
SSSV application (3)
Tubing Safety Valves
SC-SSSV - Surface Controlled Subsurface safety valve:
• Controlled from the surface
• Installed and retrievable by wireline WR SC-SSSV
• Installed as an integral part of the tubing TR SC-SSSV

SSC-SSSV - Subsurface controlled subsurface safety


valve
(Storm Choke)
• Actuated by the flow characteristics of the well
• Installed by wireline

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SSSV Selection Process
(TR-SSSV or WR-SSSV?)
Will time to first No Is wireline access No Will limited bore of Use wireline retrievable
workover exceed difficult or expensive? WR-SSSV pose problems? subsurface safety valve
10 years? • Erosion - corrosion No (WR-SSSV)
Yes Yes • Scale precipitation
• Sulphur plugging • Install (5 to 15 ft) flow
Would use of a TR-SSSV • Hydrates couplings above SSV
pose a major casing Yes • Pressure losses nipple
design or clearance Yes • Install (3 ft) flow coupling
problem? below nipple in gas wells
Evaluate options and high GLR oil wells
No • TR-SSSV • Evaluate elastomer
• Oversized upper tubing selection and test
Does economic analysis justify use of No compatibility with
TR-SSSVs? and larger WR-SSSV
hydrocarbon
• Include higher capital cost and • Use of exotic materials
service life of TR-SSSV to minimize corrosion
• Consider production deferment and • Chemical inhibition
SSV service costs associated with all Yes
wireline and through tubing Use tubing retrievable subsurface safety
operations on a well with WR-SSSV valve (TR-SSSV)
• Consider use of WR-SSSV insert • Review stability and cleanliness of control line
valve in TRSSV that fails to test, or
fluid
fails to open
• Review ability to withstand bending loads and
• Check SINTEF study to determine select position in straight section of hole
reliability
• Check flow by clearance for gas lift and kill fluids
• Select lockout and WR-SSSV back-up features
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Landing nipple for WR-SC-SSSV
Control line

Lock profile

Honed bore

Non welded shoulder to


protect C/L while RIH

Honed bore

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SC-SSSV wireline retrievable
type

Control line

WR SC-SSSV

Seals

Landing nipple

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SC-SSSV tubing retrievable type

Flapper open Flapper closed

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Tubing retrievable SC-SSSV

FEATURERS
• Integral part of tubing
• No restriction in flow path ID
• Flapper shut off
• Robust design
• Equalizing while opening
• Lock open option
• WR-SC-SSSV can be installed as backup
NOTE: valve sensitive for tubing loads

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Running Tubing and Control Lines

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Control line feed through hanger
Side out let control line

Hole drilled through hanger


Tubing hanger
Hanger shoulder

Control line connector to hanger

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SSSV setting depth (1)
Depends on several factors:
• Government legislation
• Company policies
• Give maximum depth protection against leakage from
• tubing to annulus
• Give maximum protection for abnormal situations where
– both tubing and casing could be seriously damaged (e.g.
– earthquake areas)
• Set valve below cratering depth (blowouts)
• Minimise accumulation of hydrate, wax and scales

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SSSV setting depth (2)

Other factors for consideration


• Below the mudline
• Provides protection in case wellbore is intersected
by during
• drilling
• Close to the reservoir as possible to provide down-
hole shut-in.
• Additional barrier below the lowest gas-lift valve
where there
• is no annulus safety valve installed.
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SSSV setting depth (3)

Recommended minimum setting depth

Offshore
• 50 meter below the deepest pile
penetration
Onshore
• 100 meter below ground level

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SSSV setting depth (4)
•Some proposed definitions
• Shallow set -- SSSV set between surface and 1000 ft

• Medium set -- SSSV set between 1000-2000 ft below surface

• Deep set -- SSSV set more that 2000 ft below surface

• Packer set -- SSSV set at production packer

• Below packer -- SSSV set below production packer or below


artificial lifting equipment

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SSSV setting depth (4)

•Deep-set SSSV - Disadvantages???


• Installation difficult and time consuming
• Larger volume of hydrocarbon will flow to
surface

• Higher downhole temperature affects reliability


and life-span of non-metal valve parts
• The hydrostatic head generated by the hydraulic
control-line column will generate excessive
forces at the valve mechanisms
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Subsurface safety valves –
SSSV application (3)
Annulus Safety Valve (ASV)
• Provides a flow barrier in the casing-tubing
annulus
• Consists of an annular safety valve packer
with a by-pass.
‐ The by-pass opening is controlled by a safety
valve
‐ The safety valve is either WR type or an
integral part of the packer (TR type)
‐ The safety valve is a surface controlled fail-safe
close
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Integral annulus Safety Valve

Casing Casing
Tubing valve control line Tubing valve control line

TR-SCSSV TR-SCSSV

Annulus valve control line Annulus valve control line


Tubing
Wireline Retrievable
Annulus Safety Valve Annulus Safety Valve
Concentric Tubing Anchor
Concentric tubing anchor

Pack-off tubing hanger Pack-off tubing hanger

Wire line retrievable annulus


safety valve

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Annulus safety valves
Functional requirements
• A controlled barrier in the casing-tubing annulus
• Fail-safe closing
• Controlled from surface and separately from the
Tubing SSSV
• To withstand the maximum reservoir and or injection
pressure in closed position
• Minimal pressure drop in the gas injection path
• Pump through of kill fluids in closed position

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Reliability aspect of SC-SSSV
Type Years
• TR ball (obsolete) 11.3
• TR flapper 55.4
• WR ball eq. (obsolete) 14.9
• WR flapper eq. 21.3
• WR flapper non eq. 16.6
• All valves 19.4

Ref. Sintef phase III report


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Reliability aspects of SC-SSSV

Typical failure modes


• Nipple/lock: Erosion, corrosion, vibration

• Control line: Corrosion/vibration, mechanical damage,


Advice: Encapsulate control line (flat-pack)
• Installation: Failed: to open and to set in nipple
corrosion and packing failure
• Equalizing: Leaking in closed position by flappers

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SC-SSSV calculations

• Safety device: to-close-on-failure

• Opened by hydraulic pressure from


surface

• Closed by spring force

Risk: If the valve is set too deep in the well, the hydraulic pressure in the
control mechanism may be too high and prevent the valve from
closing

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SC SSSV setting depth
calculations

Valve fully open Valve fully closed


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SC-SSSV calculations
To control (keep) the valve open

Pc = Pvo + Pt + Pm - Ph

where:
Pc = control pressure at surface [psig]
Pvo = pressure valve fully open [psig]
Pt = tubing pressure acting on piston [psig]
Pm = pressure safety margin [psig]
Ph = hydrostatic pressure of control line fluid on top of piston [psig]

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SC-SSSV calculations
To start opening the valve, i.e. Equalising

Pc.eq = Pvc +Pt- Ph

Where:
Pc.eq = control pressure at surface at which valve starts equalising [psig]
Pvc = pressure at which the valve is fully closed [psig]
Pt = tubing pressure acting at piston [psig]
Ph = hydrostatic pressure of control line fluid [psig]

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SC-SSSV calculations
Setting depth

Dm = (Pvc - Pm) / G

Where:
Dm = Maximum depth (TVD) of SC-SSSV [ft]
Pvc = Pressure at which valve is fully closed [psig]
Pm = Pressure safety margin [psig]
G = Gradient of the control line fluid [psig/ft]

108 Copyright ©2012 NExT. All rights reserved

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