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.
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.
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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)
(b)
(c)
(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.
2.2.2 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
2.3.2 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.
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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.
(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
Optional
nipples/SSD
Figure 1
Options for 2 Zone Flow
without Comingling
2 Zone 2 String
(Optional nipples/SSD
installation introduces
additional selectivity)
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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.
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.
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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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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
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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1
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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