Completion Engineering

As Completion Engineers, we leverage advanced engineering software and modeling tools to design, optimize, and execute well completions that maximize production, ensure long-term integrity, and minimize operational risks.

How We Apply Technologies to Deliver the Best Solutions

We use casing and tubing stress analysis tools to ensure mechanical integrity under downhole conditions. Nodal analysis and well performance modeling help us evaluate different completion scenarios, optimizing production rates before implementation.

For unconventional reservoirs, we employ fracture propagation modeling to optimize cluster spacing, proppant placement, and fluid systems. Pressure-matching techniques validate fracture geometry, while reservoir simulators predict long-term production impacts.

In sand-prone wells, we apply gravel pack and screen modeling tools to prevent sand ingress while maintaining flow efficiency. Cementing and zonal isolation simulations ensure proper barrier placement to avoid fluid migration.

We optimize perforation density, phasing, and charge selection using advanced gun design software, enhancing connectivity between the wellbore and reservoir while minimizing near-wellbore damage.

We model ESP, gas lift, and rod pump systems to select the most efficient artificial lift method. Flow assurance analysis helps mitigate issues like slugging and liquid loading, sustaining long-term production.

Through finite element analysis (FEA), we assess casing and completion durability under extreme loads. Tubing movement simulations in HPHT wells prevent costly failures, ensuring long-term reliability.

We use production analytics platforms to identify underperforming wells for re-stimulation. Execution tracking tools improve operational efficiency, while cloud-based collaboration systems enable real-time decision-making with clients.

Stress regime analysis ensures fractures stay within target zones, preventing unwanted height growth. Discrete fracture network modeling helps optimize stimulation designs for better recovery.

Post-completion, cleanup efficiency modeling ensures effective stimulation, while flowback diagnostics validate fracture performance and guide future designs.

By combining geological and well log data with completion designs, we ensure perforations and fractures target the most productive zones, maximizing reservoir contact.

Why Clients Trust Our Engineering Solutions

  • Precision Design –Eliminating guesswork with advanced simulations.
  • Risk Reduction – Validating designs before execution to prevent failures.
  • Cost Efficiency – Optimizing completions for maximum ROI.
  • Data-Backed Decisions – Using real-time analytics to refine strategies.

Whether for unconventional shale, offshore deepwater, or complex sand control completions, our expertise ensures safe, efficient, and high-performing wells tailored to each client’s needs.

Case Study: Mitigating Tubing Failure & Sustained Annulus Pressure in a High-Pressure Gas Well Challenges

Here is a case study demonstrating how these approaches have delivered results in a specific field:

A client encountered repeated tubing leaks in a high-pressure gas well, along with uncontrolled annulus pressure buildup in the A-annulus (tubing-casing). These issues risked well integrity, compliance violations, and potential blowouts.

Tubing Stress Analysis

  • Conducted finite element analysis (FEA) to model tubing movement under thermal cycling (shut-in vs. flowing conditions).
  • Identified excessive compression buckling near the packer due to temperature-induced elongation.
  • Redesigned the tension/compression packer system and adjusted the tubing taper to mitigate stress concentrations.

Annulus Pressure Management

  • Diagnosed the source of A-annulus pressure (trapped gas migration vs. micro-annulus leakage).
  • Used thermal and pressure transient modeling to simulate fluid expansion and leakage paths.
  • Recommended a dual-action solution:
    • Installed an annulus pressure relief valve (APRV) for controlled bleed-off.
    • Applied nanopolymer sealant during cement remediation to eliminate micro-annuli.

Real-Time Monitoring & Verification

  • Deployed downhole gauges to track annulus pressure trends post-intervention.
  • Validated tubing integrity with multi-arm caliper logs after 6 months of production.

Results

Key Result Details
Zero tubing failures Over 2+ years of production.
Annulus pressure stabilized Within safe operating limits.
$8M saved By avoiding workovers and non-productive time (NPT).

Key Takeaways for Clients

  • Proactive modeling of tubing stresses prevents costly failures in thermal cycling wells.
  • Annulus pressure diagnostics must distinguish between thermal effects vs. true leaks.
  • Combining hardware + monitoring ensures long-term integrity.
Takeaway Image 2

Copyright © Benorch Energy Service LTD, All Right Reserved.