Workover & Completion Operations Training Course

1. Introduction to Workover and Completion Operations

1.1 Fundamentals of Well Interventions

• Types of well interventions including (workover operations, well servicing, and remedial treatments)

• Workover objectives including (production restoration, zone isolation, and well conversion)

• Intervention selection criteria including (technical requirements, economic justification, and risk assessment)

• Key operational considerations including (well control, equipment selection, and procedural planning)

• Introduction to API RP 90 and API RP 92L standards for workover and completion operations

1.2 Completion Fundamentals

• Completion types including (open hole, cased hole, and multi-zone completions)

• Completion objectives including (zonal isolation, flow control, and well integrity)

• Completion selection criteria including (reservoir characteristics, production requirements, and operational constraints)

• Key design considerations including (reservoir characteristics, production goals, and operational limitations)

• Completion equipment including (tubulars, packers, and flow control devices)

2. Workover Planning and Preparation

2.1 Workover Candidate Selection

• Production performance analysis including (decline curve analysis, problem well identification, and optimization potential)

• Diagnostic methods including (production logging, pressure transient testing, and fluid analysis)

• Economic screening including (cost-benefit analysis, incremental recovery assessment, and investment ranking)

• Risk assessment including (technical feasibility, operational hazards, and mitigation strategies)

• Candidate prioritization including (value ranking, resource allocation, and scheduling optimization)

2.2 Workover Program Development

• Program objectives including (technical goals, success criteria, and performance metrics)

• Well status evaluation including (barrier verification, pressure conditions, and fluid contents)

• Equipment selection including (rig specifications, tooling requirements, and specialty tools)

• Procedural planning including (operational sequence, contingency plans, and critical path identification)

• Technical specifications including (fluid design, pressure limitations, and equipment ratings)

2.3 Operational Preparation

• Site preparation including (location requirements, equipment positioning, and environmental considerations)

• Personnel requirements including (crew composition, specialized expertise, and supervision levels)

• Material logistics including (inventory planning, critical spares, and delivery scheduling)

• Regulatory compliance including (permitting requirements, notification procedures, and approval timelines)

• Risk management including (HAZID/HAZOP, job safety analysis, and emergency response planning)

3. Workover Equipment and Operations

3.1 Workover Rigs and Equipment

• Workover rig types including (conventional, hydraulic, and coiled tubing units)

• Rig selection criteria including (well depth, load capacity, and operational requirements)

• Surface equipment including (BOPs, wellhead adaptors, and pressure control systems)

• Downhole tools including (packers, fishing tools, and specialized equipment)

• Ancillary equipment including (fluid handling systems, pressure testing units, and monitoring systems)

3.2 Well Control for Workover Operations

• Well control principles including (barrier philosophy, pressure management, and kill methods)

• BOP equipment including (ram configurations, annular preventers, and control systems)

• Well control procedures including (kick detection, shut-in procedures, and kill methods)

• Special considerations including (bullheading, lubrication, and stripping operations)

• Testing and verification including (pressure testing, function testing, and documentation)

3.3 Common Workover Operations

• Tubing replacement including (pulling procedures, inspection criteria, and redeployment techniques)

• Artificial lift repair including (pump replacement, gas lift valve servicing, and system optimization)

• Zonal isolation including (plug setting, squeezing techniques, and barrier verification)

• Stimulation operations including (acidizing, fracturing, and chemical treatments)

• Sand control remediation including (screen replacement, gravel pack repair, and frac-pack operations)

3.4 Fishing Operations

• Fish identification including (obstruction characterization, dimensional assessment, and location determination)

• Fishing tool selection including (overshots, spears, and specialty tools)

• Operational procedures including (engagement techniques, retrieval methods, and jarring operations)

• Milling operations including (mill types, operational parameters, and debris management)

• Contingency planning including (sidetracking considerations, well abandonment options, and alternative strategies)

4. Completion Design and Equipment

4.1 Casing and Liner Systems

• Casing design including (size selection, grade determination, and connection specifications)

• Liner systems including (conventional liners, expandable liners, and tieback systems)

• Running procedures including (makeup practices, flotation techniques, and centralization methods)

• Cementing considerations including (slurry design, placement techniques, and evaluation methods)

• Special applications including (multilateral junctions, open hole packers, and expandable systems)

4.2 Tubing and Downhole Equipment

• Tubing design including (size selection, grade determination, and connection specifications)

• Packer selection including (permanent packers, retrievable packers, and specialty isolation devices)

• Flow control equipment including (safety valves, sliding sleeves, and inflow control devices)

• Specialty components including (blast joints, polished bore receptacles, and seal assemblies)

• Tubing accessories including (landing nipples, no-go profiles, and circulation devices)

4.3 Completion Fluids

• Fluid selection criteria including (compatibility requirements, density control, and formation protection)

• Clear brines including (monovalent brines, divalent brines, and blended systems)

• Solids-laden fluids including (calcium carbonate systems, sized salt systems, and specialty weighting agents)

• Fluid properties including (density, rheology, filtration characteristics, and stability)

• Fluid handling including (mixing procedures, filtration systems, and quality control)

4.4 Sand Control Completions

• Sand production mechanisms including (mechanical failure, reservoir conditions, and production effects)

• Gravel pack systems including (conventional packs, high-rate water packs, and alternate path techniques)

• Screen selection including (wire wrap screens, premium screens, and expandable screens)

• Frac-pack operations including (design considerations, execution procedures, and evaluation methods)

• Stand-alone screen applications including (selection criteria, deployment techniques, and operational limitations)

5. Completion Installation Operations

5.1 Lower Completion Operations

• Wellbore preparation including (cleaning techniques, drift verification, and debris removal)

• Liner running including (operational procedures, centralization strategies, and hanger setting)

• Primary cementing including (placement techniques, displacement efficiency, and quality verification)

• Perforation operations including (gun selection, underbalance strategies, and execution procedures)

• Open hole completions including (isolation techniques, inflow control, and deployment methods)

5.2 Upper Completion Operations

• Tubing installation including (running procedures, space-out determination, and pressure testing)

• Packer setting including (mechanical setting, hydraulic setting, and verification methods)

• Completion fluid displacement including (wellbore cleaning, filtration control, and fluid properties)

• Wellhead completion including (tubing hanger installation, tree mounting, and pressure testing)

• System integrity verification including (pressure testing, barrier verification, and function testing)

5.3 Multi-Zone Completion Techniques

• Stacked completions including (packer spacing, selective access methods, and flow path design)

• Commingle completion considerations including (zonal contribution, compatibility issues, and regulatory requirements)

• Intelligent completions including (control line deployment, downhole monitoring, and flow control systems)

• Dual string completions including (parallel tubing, concentric arrangements, and production allocation)

• Multi-lateral completions including (junction types, access methods, and isolation techniques)

5.4 Speciality Completion Techniques

• High-temperature completions including (material selection, elastomer limitations, and design considerations)

• High-pressure completions including (pressure containment, barrier philosophy, and equipment ratings)

• Corrosive environment completions including (material selection, inhibition strategies, and monitoring systems)

• Horizontal well completions including (tool orientation, deployment methods, and zonal isolation)

• Extended reach completions including (friction reduction, weight transfer, and deployment techniques)

6. Well Intervention Techniques

6.1 Slickline Operations

• Slickline equipment including (units, tools, and pressure control)

• Common operations including (fishing, shifting, and setting plugs)

• Operational procedures including (tool deployment, depth control, and recovery)

• Advanced applications including (memory gauges, sampling tools, and perforating systems)

• Operational challenges including (depth correlation, jarring operations, and tool recovery)

6.2 Wireline Operations

• Electric line equipment including (units, tools, and pressure control)

• Common operations including (perforating, logging, and setting plugs)

• Operational procedures including (tool deployment, depth control, and recovery)

• Advanced applications including (formation sampling, mechanical services, and remedial operations)

• Operational challenges including (well conditions, depth limitations, and tool deployment)

6.3 Coiled Tubing Operations

• Coiled tubing equipment including (units, BHA components, and pressure control)

• Common operations including (cleanouts, stimulation, and fishing)

• Operational procedures including (tool deployment, circulation techniques, and recovery)

• Advanced applications including (milling, perforation, and completion installation)

• Operational challenges including (reach limitations, buckling, and fatigue management)

6.4 Snubbing and Hydraulic Workover

• Hydraulic workover equipment including (units, BOPs, and workstrings)

• Snubbing operations including (pipe handling, force calculations, and pressure control)

• Operational procedures including (stripping, tool deployment, and recovery)

• Advanced applications including (completions, sidetracking, and plug-and-abandon)

• Operational challenges including (wellbore conditions, pipe management, and well control)

7. Specialized Workover and Completion Operations

7.1 Re-completion Operations

• Candidate selection including (production potential, mechanical integrity, and economic justification)

• Zonal isolation including (abandonment techniques, plugging materials, and verification methods)

• Wellbore preparation including (cleanout techniques, casing repair, and reentry preparation)

• New zone completion including (perforation strategies, stimulation techniques, and production optimization)

• Production monitoring including (performance verification, intervention effectiveness, and optimization opportunities)

7.2 Sidetrack Operations

• Sidetrack candidate selection including (mechanical limitations, geological targets, and economic justification)

• Window milling including (whipstock setting, milling assembly, and operational procedures)

• Directional drilling including (trajectory planning, orientation control, and survey techniques)

• Re-completion methods including (casing design, cementing considerations, and completion selection)

• Special considerations including (well control, formation evaluation, and production tie-in)

7.3 Thru-Tubing Operations

• Tool selection including (delivery systems, operational tools, and size limitations)

• Common operations including (perforating, plugging, and stimulation)

• Operational procedures including (deployment techniques, depth control, and tool recovery)

• Advanced applications including (logging, drilling, and completion)

• Operational challenges including (access limitations, pressure control, and tool functionality)

7.4 Plug and Abandonment Operations

• Regulatory requirements including (barrier specifications, verification methods, and documentation)

• Surface abandonment including (wellhead removal, site restoration, and environmental considerations)

• Downhole abandonment including (zonal isolation, cement placement, and mechanical plugs)

• Special considerations including (sustained pressure, multiple casing strings, and damaged wells)

• Verification methods including (pressure testing, tagging, and logging techniques)

8. Completion and Workover Fluids

8.1 Fluid Selection and Design

• Selection criteria including (well conditions, operational requirements, and completion compatibility)

• Clear brine systems including (density ranges, inhibition properties, and handling considerations)

• Oil-based systems including (formulation, properties control, and environmental considerations)

• Specialty fluids including (solids-free systems, low-damage formulations, and foam applications)

• Fluid testing including (property verification, compatibility testing, and quality control)

8.2 Fluid Management

• Surface equipment including (tanks, mixing systems, and filtration units)

• Fluid handling including (transfer procedures, mixing techniques, and contamination prevention)

• Filtration and solids control including (equipment selection, filtration standards, and monitoring techniques)

• Fluid treatment including (oxygen scavenging, biocides, and specialty additives)

• Waste management including (disposal options, treatment requirements, and environmental compliance)

8.3 Fluid-Related Challenges

• Formation damage mechanisms including (fluid invasion, particle bridging, and chemical interactions)

• Fluid compatibility issues including (precipitation reactions, emulsion formation, and elastomer effects)

• Well control considerations including (density control, circulation techniques, and kill procedures)

• Environmental considerations including (spill prevention, waste minimization, and regulatory compliance)

• Remediation techniques including (cleanup treatments, filtercake removal, and damage reversal)

9. HSE in Workover and Completion Operations

9.1 Operational Safety

• Hazard identification including (job safety analysis, risk assessment, and mitigation planning)

• Pressure control including (barrier philosophy, equipment testing, and operating procedures)

• Personnel safety including (PPE requirements, work practices, and safety supervision)

• Equipment safety including (certification requirements, inspection protocols, and operational limitations)

• Emergency response including (well control events, personnel injuries, and environmental incidents)

9.2 Well Control Considerations

• Barrier management including (barrier definition, verification methods, and regulatory requirements)

• Pressure monitoring including (surface gauges, downhole measurements, and abnormal pressure recognition)

• Kill procedures including (bullheading, circulation methods, and lubrication techniques)

• Special situations including (gas migration, underground blowouts, and surface equipment failures)

• Crew training including (certification requirements, drills, and competency verification)

9.3 Environmental Protection

• Spill prevention including (containment systems, operational procedures, and preventive measures)

• Waste management including (drilling waste, completion fluids, and hydrocarbon containment)

• Emissions control including (venting limitations, gas handling, and regulatory compliance)

• Site management including (location design, drainage control, and restoration requirements)

• Regulatory compliance including (permitting, reporting requirements, and documentation)

10. Operational Efficiency and Continuous Improvement

10.1 Performance Optimization

• Operation planning including (critical path analysis, resource allocation, and schedule optimization)

• Non-productive time reduction including (failure prevention, contingency planning, and equipment reliability)

• Cost management including (AFE control, vendor management, and resource optimization)

• Technical limits including (operational boundaries, optimization techniques, and performance enhancement)

• Continuous improvement including (lessons learned, best practice development, and knowledge sharing)

10.2 Quality Assurance

• Quality management system including (procedures, verification methods, and documentation)

• Equipment certification including (inspection requirements, testing protocols, and acceptance criteria)

• Operational standards including (API recommended practices, company standards, and industry guidelines)

• Competency assurance including (personnel qualification, skill verification, and training requirements)

• Documentation including (work records, certification documents, and regulatory reporting)

10.3 Technology Integration

• Equipment advancement including (tool development, material improvements, and technology application)

• Digital technologies including (real-time monitoring, data analytics, and remote operations)

• Automation opportunities including (rig floor automation, pipe handling systems, and process control)

• Integration techniques including (cross-discipline collaboration, technology selection, and implementation planning)

• Value assessment including (technology evaluation, cost-benefit analysis, and implementation justification)

11. Case Studies & Group Discussions

• Regional case studies from Middle East operations including (challenging well conditions, complex interventions, and innovative solutions)

• Workover success stories including (production enhancement, technical innovations, and cost optimization)

• Problem-solving exercises including (operational challenges, diagnostic approaches, and solution development)

• Equipment selection scenarios including (application-specific analysis, technology evaluation, and decision justification)

• The importance of proper training in successful workover and completion operations