Completion Engineer

Introduction

Once an oil or gas well is drilled, the work is far from over. While drilling engineers perform the monumental task of boring miles into the earth to tap underground reservoirs, completion engineers take over to prepare the well for safe, efficient production. Their specialized expertise in well completion transforms newly drilled holes in the ground into functioning producers of oil and gas.

Completion engineers develop comprehensive plans for “completing” wells after the initial drilling process. This involves designing and installing equipment like casing, tubing, valves, and pumps to control reservoir flow. Completion engineers oversee the logistics of transporting this intricate equipment to remote well sites. They then supervise and inspect completion operations on location to ensure everything is assembled properly. Their goal is optimizing each well for maximum productivity.

The completion process requires in-depth technical knowledge, flawless coordination, and strict adherence to safety protocols. Completion engineers collaborate extensively with geologists, drilling engineers, and field staff to bring oil and gas reservoirs online safely and efficiently. The specialized skills of completion engineers make it possible to harness underground resources. Their work is absolutely vital for converting drilled wells into functioning, producing assets.

Well Completion Planning

The first responsibility of a completion engineer is developing comprehensive plans for “completing” wells after initial drilling reaches the reservoir.

Thorough completion planning includes:

• Designing optimal well casing and tubing to control oil or gas flow. This involves selecting the proper diameter and depth for casing.
• Specifying special equipment like packers, downhole valves, and artificial lift systems to maximize production.
• Determining the precise perforation strategy. Perforations are small holes exploded in the casing so resources can enter.
• Calculating required quantities of equipment and materials like casing, tubing, cement, and chemicals. This enables accurate supply logistics.
• Planning the optimal schedule and process for installing completion equipment efficiently.
• Estimating costs for the completion phase and proposing a budget.
• Ensuring completion design meets environmental regulations and company best practices.
• Describing the step-by-step completion procedures field engineers should follow.

The completion plan provides a blueprint for transforming a drilled well into a producing asset. Every detail must be engineered to enable safe, efficient oil or gas production.

Overseeing Well Completion Operations

Once the well completion plan is finalized, the completion engineer oversees and directs execution at the drilling site. This hands-on phase is crucial to properly implementing the engineered design.

Typical completion operations the engineer supervises include:

• Running casings down the wellbore and cementing them in place. Cement provides zonal isolation and prevents leaks. The engineer ensures casing reaches the proper depths.
• Monitoring pressure tests on installed casings to verify integrity. Test results are evaluated.
• Supervising the perforation process. Explosive charges perforate the casing at precise locations and depths.
• Coordinating installation of equipment like tubing, packers, valves, and artificial lift systems. Proper placement is confirmed.
• Inspecting all equipment for defects and monitoring tests. Equipment must function per specifications.
• Making any adjustments to the completion program as needed. Real-world challenges may arise.
• Ensuring all operations adhere to company safety policies and environmental regulations.
• Directing the well clean-up process to remove excess fluid and debris. This prepares for handover.

Close supervision in the field allows the completion plan to be executed as designed. The engineer’s oversight ensures efficient, safe start-up of production.

Optimizing Well Production

A key duty of the completion engineer is selecting the best technologies and equipment to maximize oil or gas production from the well. This optimization starts during the design phase.

To optimize production, the engineer:

• Chooses casing sizes and landing depths to enable unrestricted reservoir flow. Larger diameters usually increase output.
• Designs perforation patterns that expose more hydrocarbon-bearing rock to the wellbore. More perforations equal higher inflow.
• Specifies artificial lift systems like gas lift or pumps to lift fluids to the surface. This maintains adequate pressure drawdown.
• Incorporates downhole flow control valves to regulate production from different zones. This prevents water encroachment.
• Models different completion scenarios to compare productivity and economics. The optimal design is chosen.
• Considers future operations like well stimulation or workovers that can further increase flow.
• Conducts cost-benefit analyses on different technologies, weighing productivity gains versus expense.

The completion engineer applies expertise and creativity to squeeze every barrel of oil or cubic foot of gas out of the reservoir sustainably. Their completion design has a major impact on well performance and economics.

Finalizing Well Completion

The last task of the completion engineer is overseeing the final steps to conclude the well completion process and hand over the well to production operations.

Final completion steps directed by the engineer include:

• Performing well clean-up to remove excess treatment fluids and debris that accumulated during completion. This ensures unobstructed flow.
• Confirming all equipment is installed per the completion program and properly functioning.
• Isolating zones as needed and performing any remaining perforations.
• Running production tubing and installing the production Christmas tree at the wellhead. This controls flow from the reservoir.
• Securing the wellhead and verifying its integrity to contain pressure.
• Removing completion equipment like workover rigs from the location.
• Documenting as-built completion information like equipment data sheets, drawings, and procedures. This is archived for reference.
• Officially handing over the completed well to the production engineering team. Relevant data and documentation are transferred.

The completion engineer sees the job through to the final step of transforming the drilled well into a fully functioning producer, ready to be operated and managed by the production team. Their completion work is complete.

Required Skills and Experience

Completion engineers need a diverse blend of technical and soft skills to succeed. Required expertise and experience includes:

• Degree in petroleum engineering or a related discipline like mechanical engineering. This provides fundamental engineering knowledge.
• Strong grasp of subsurface geology, reservoir behavior, drilling methods, and oilfield equipment. This comes from work experience.
• Math and science skills for analyzing technical data and making calculations.
• Attention to detail to design fully-specified completion plans and procedures.
• Communication skills to collaborate with other professionals and lead field crews.
• Problem-solving ability to assess situations and make quick decisions.
• Leadership to coordinate logistics and supervise operations.
• Knowledge of regulations and industry best practices related to well integrity and safety.
• Computer skills to model scenarios and assess data.

Most completion engineers have at least 2-5 years of experience working in production or drilling roles before moving into completions. A curious, analytical mind combined with oilfield exposure produces skilled completion engineers.

Importance of Completion Engineering

While less renowned than drilling, completion engineering is absolutely crucial for transforming drilled wells into safe, productive assets. Completion is a vital phase between drilling and production.

The importance of completion engineers includes:

• Enabling well production – Their work allows reservoirs to be produced. Without proper completion, oil and gas cannot flow.
• Optimizing well output – Their completion designs maximize oil and gas recovery over the life of wells.
• Ensuring safe operations – They implement casing, cementing, and other measures to contain pressure and prevent accidents.
• Providing cost-efficient production – Their economic analyses weigh productivity gains versus completion costs.
• Bringing wells online – Completion is the final step before wells start generating revenue from production.
• Collaborating with other experts – Completions rely on teamwork between engineers, geologists, field staff, and more.
• Supplying the world’s oil and gas – Global production depends on competent completion engineering at every well.

Completion engineering is an under-sung profession, but their work is indispensable. These technical experts make oil and gas production possible.

Conclusion

While drilling engineers perform the herculean task of boring miles into the earth to tap oil and gas reservoirs, completion engineers take over to transform these holes in the ground into functioning producers.

Completion engineers develop comprehensive plans for “completing” newly drilled wells through installing specialized equipment. At the well site, they oversee critical operations like casing, cementing, and perforating the wellbore to enable flow. Their optimization of well designs enables maximum oil and gas recovery at efficient cost.

Completion engineering requires extensive technical expertise, project management skills, and leadership ability. But the reward is seeing their well completion plans executed in the field, culminating in a producing well. Without the vital work of completion engineers, oil and gas would remain trapped underground.

The world depends on these little-known experts to safely and efficiently bring drilled wells into production. Completion engineering is the indispensable link between drilling success and oil and gas supply. Their specialized skills make the difference between dormant holes in the ground and functioning, productive wells.