Mechanical Engineer's Continuing Professional Development

Continuing Professional Development
Throughout my career as a mechanical engineer/project engineer over the past 4 years, I

have managed to improve my technical knowledge and management skills by attending
several courses demonstrated below:
1) Halliburton Completions 101 at Halliburton Training Centre, University

Technology Petronas, Malaysia:- 22nd October 2012
This course gives an overview of the role of production packers in well
completions. In addition to learning design overviews, application and
installations procedure, hands on lab activities will be conducted using the major
types of completions packers and equipment to reinforce the participants
understanding.
2) Halliburton Completions 2 at Halliburton Headquarters, Kuala Lumpur,
Malaysia:- 17th April 2014
This course addresses advanced well completions and equipment, metallurgy and
elastomers, advanced calculations and completion designs.
3) Halliburton Subsurface Safety Valves and Systems at Halliburton Training
Centre, University Technology Petronas, Malaysia:-22nd May 2014
This course addresses Subsurface Safety Valves and Systems selection based on
the design of the valves, the operating environment and recommended practices
provided in API RP 14B, to provide a functional Subsurface Safety System.
4) Halliburton My Competencies Employee's Training at Halliburton
th
Headquarters, Kuala Lumpur, Malaysia:- 27 November 2012
This training session provides an overview of the Halliburton Competency
program. The course introduces employees to the principals and concepts of the
Competency Fundamentals; Development, Assessment and Documentation of a
competency; and the Rater Qualification.
5) Loss Prevention System with SSHE Induction at Terengganu Safety Training
Centre Sdn Bhd, Terengganu, Malaysia:- 26th May 2013
This course includes develop and use Job Safety Analysis for all work tasks or
procedures, perform safe performance self-assessment throughout the task at
hand, conduct incident prevention observations on a planned and regular basis,
report and investigate all near misses, incidents and injuries, communicate the
lessons learned from all investigations and to further improve loss prevention
measures, perform quality assessments of loss prevention system tools and
procedures and accountability in incident prevention.
COMPETENCY DEMONSTRATION REPORT (CDR)
Duration: October 2010 – June 2012
Employer: Fraser & Neave Beverages Manufacturing Sdn Bhd, MALAYSIA
Designation: Process Improvement Engineer
CE1.1 Introduction
Fraser & Neave Beverages Manufacturing Sdn Bhd is the biggest local soft drinks bottling company in
Malaysia. The company is listed in the Kuala Lumpur Stock Exchange and is rated as one of the most
highly sought after company to work with in Malaysia. Fraser & Neave Beverages Manufacturing core
business involves carbonated soft drinks, fruit juices as well as dairy products. Apart from manufacturing
beverages, Fraser & Neave is also involved in the confectionary business which involves their sister
company, Cocoaland Sdn Bhd.
CE1.2 Background
I had the opportunity to join Fraser & Neave Beverages Manufacturing Sdn Bhd as a process
improvement engineer under the engineering department. I joined the company after 3 months of my
graduation with a Bachelor Degree in Mechanical Engineering from the University of Sheffield, United
Kingdom. Whilst working with the engineering department in the company, I was tasked from
understanding the basic process of mixing, bottling/canning beverages, packaging and shipping out the
finished products throughout the country. Besides that, I was also tasked in understanding the functions
of the machines involved such as the fillers, mixing tanks, heat exchangers and CO2 injectors and basic
operating and maintenance procedures.
The opportunity given to me to learn was invaluable and upon my 6th month of my employment, I was
given the chance to be involved with a team in setting up a 2nd sugar silo for the factory.
CAREER EPISODE 1 (CE1): 100 TONNE SUGAR SILO HOPPER SYSTEM
CE1.3 Personal Engineering Activity

My role as a process improvement engineer is task to enhance and implement new production systems
for the manufacturing plant. This enables me to:
CE1.3.1 Experience firsthand by working with a team in solving engineering challenges as well as
the local law in establishing new architecture “Street, Drainage and Building Act 1974”
CE1.3.2 Learn and get involve in a different scope of engineering especially electrical and
electronics.
CE1.3.3 Implementing the project to meet the company’s dead line and to ensure all operations
with regards to establishing the structure are not experiencing any down time.
CE1.3.4 In line with continuous improvement for the project, whereby I took into consideration
the options for future extension of the sugar injection line.
CE1.4 Problem Statement

The climate of my country often poses a problem in keeping dry goods in optimum conditions. This is
due to the extreme humidity of the weather which will cause sugar to deteriorate.
In the event of such humidity, the sugar supplied will not be able to last long, hence resulting in incurred
cost to the company’s operations.
Considering that the amount of sugar required to keep manufacturing beverages for the entire country,
it was my role to work with the team on the design aspects of sugar silo dehumidifier system as well as
to manage the pre-implementation process.
CE1.5 Engineering Application Demonstration

CE1.5.1 Engineering Considerations
Before starting out the project, my team and I had to consider various engineering challenges to
reduce the risk of a potential hazard or engineering flaw in the design. These factors consists:
 Physical Size of the Silo

The sugar silo is planned to be placed right outside of the factory warehouse where it needs to
convey sugar to the production line within the factory. The silo must be located in an area
where by sugar trucks has enough space to park and connect the hose to pump sugar into the
silo.
 Health, Safety, Environment (HSE)

Dust explosion from sugar is a major concern when establishing a sugar silo structure. The cause
of the hazard often happens when all these contributing factors are in place:
o Oxygen
o High concentration of dust suspended in midair.
o Ignition Source.
Therefore the objective is to prevent any potential of ignition (electrical charges, static
electricity etc.) and reduce the concentration of suspended particles in a confined space.
 Reliability of Conveyer Unit
The conveyer unit must be working constantly without fail in order to keep up with our
production lines. Since production is happening 24 hours a day, the conveyer unit must require
a backup power supply in case of any failures from occurring.
 Minimal Maintenance
With high volume of production comes high operating expenses. The sugar silo must be
susceptible to harsh environments and vigorous operating hours therefore a robust system must
be selected in order to minimize maintenance cost.
CE1.5.2 Analysis
CE1.5.2.1 The team and I has hosted a round table discussion with the executives from Site
Acquisition (SA) team to understand what are the requirements set by the local
authorities in establishing a high rise structure within the area. By understanding their
requirements, we are able to propose a design which falls into the boundaries set by the
local authorities in terms of height of the structure, the area required and noise
production.
CE1.5.2.2 I also went to consult our in house QAQC executives for the conditions required to keep
sugar in optimum condition. This allows us to set a benchmark of the dehumidifier
which we will install to keep humidity at minimal level.
CE1.5.2.3 The wear and tear, replacement of parts and consumables required in case of a
breakdown must be constantly available especially for major parts like the dehumidifier
and the conveyer system.
CE1.5.3 Solution
With all the different factors taken into consideration during the analysis stage, I had consolidated all
the inputs with the team and proposed the most optimal solution for the Sugar Silo.
CE1.5.3.1 We opted for a dehumidifier system which is able to link itself to the top of the silo to
keep humidity at bay. The dehumidifier specifications were made in conjunction to the
proposed humidity level at bay. A hygrometer was used to constantly monitor the
amount of moisture present.
CE1.5.3.2 Pinch valves and rotary air locks were incorporated as mechanical isolation barriers to
prevent a dust explosion from amplifying to a hazardous level.
CE1.5.3.3 Spark detection system was also implemented to detect any thermal particles in the air
flow or conveyer belt before it reaches any source of ignition.
CE1.5.3.4 Ventilation to discharge potential products of combustion into the atmosphere in case
of a dust explosion. This will allow us to safely contain the pressure generated inside the
silo below the safety design threshold.
CE1.5.3.5 Backup power source was linked to our secondary transformer which is capable to keep
the conveyer unit in operation while maintenance works are carried out to the primary
transformer.
CE1.5.3.4 Standard operating procedures was produced in order to make the operator aware of
the potential hazards present and procedures to follow to prevent any catastrophe from
occurring
CE1.6 Summary
The sugar silo was successfully erected in the year 2013. Post analysis shows us the that the safety
systems implemented were effective and sugar conditions were at optimum level and suitable for
consumption.
The need for maintenance were only required twice a year by checking the pipe lines to pump sugar
from sugar trucks. Electronic devices were shielded hence it is not exposed to the surroundings which
prolongs service life.
Lessons learned throughout the implementation of the project were continuous engagement with the
related parties as there are constantly new suggestion for improvements and always maintain clear
communication with the people involved so that everyone understands their responsibilities.
Duration: August 2012 – Current
Employer: Halliburton Energy Services (M) Sdn Bhd
Company Designation: Associate Technical Professional, Well Completions
General Designation: Well Completions Engineer
CE2.1 Introduction
Halliburton is one of the biggest oil and gas Service Company in the world. The company started out as a
humble oil well cementing company in Duncan, Oklahoma by Erle P.Halliburton which has grown
successfully over the years until today. As of the current Halliburton, the company now offers services
ranging from drilling, well testing, completions, wireline, cementing and intervention. Halliburton
consists of approximately 80,000 employees and operates in 80 different countries.
After 1.5 years working with F&N Beverages Manufacturing, I have found my calling as a mechanical
engineer in the oil and gas industry by joining Halliburton in the Completions department on 6th August
2012. With my profound interest in well development and engineering, I was given the opportunity to
experience firsthand on how jobs are carried out at offshore platforms and learn the technology
involved in manufacturing down hole equipment.
CE2.2 Background
I joined the company as an associate technical professional which is a term given to all new engineers in
the company and placed under the completions department, hence my role can also be known as a
mechanical completions engineer.
CAREER EPISODE 2 (CE2): Completing Petronas Angsi A33 Work Over

Angsi A33 is a Petronas well which has been first drilled and completed in the year 2002. After 10 years
in production, Halliburton is tasked to rework the well to replace its deteriorating down hole equipment
and to work on enhancing the well production.
In December 2012, I was selected to be part of a 5 man team to complete a work over well in the South
China Sea basin. The well is name Angsi A33 which belongs to our national oil operator “Petronas
Carigali” is located approximately xx km from the Malaysian east coast. The well is designed to be a dual
completion string which is able to produce from 2 zones concurrently.
CE2.4 Scope of Responsibility

CE2.4.1 Being an engineer with 4 other field specialists, my responsibility is to gather relevant
data of the well and pertaining to the end requirements from the customer. The
information required covers the well trajectory, expected formation pressure, well
temperature, measured depth, casing / liner tallies and finally the proposed depth to
place the completion equipment.
CE2.4.2 Besides my responsibility to source these valuable information, I am also tasked to
coordinate the man power to perform equipment testing, and measuring the length of
completion tubing so that I can produce a running tally which will be a document for our
customer and rig crew to reference to when performing the job. The document will
allow us to determine the approximate depth based on the tubing or equipment
number.
CE2.4.3 In order to convey these instructions to the team, I had to gather a debrief session for
all the team members involved. The purpose of the meeting is to:
 Strategy of completion - to complete the well successfully and to achieve the

objective of a job well done without any incurred down time and most importantly
Health, Safety & Environment issues.
 Implementing the Completion System – which covers handling equipment required
(such as sizes of pickup elevators, dog collars and tubing slips), contingencies in case
of equipment failure (steps taken to troubleshoot before deciding on using the
backup).
 Health, Safety and Environment - safety measures (such as TIW safety valves are
present on the rig floor, alarm systems are all functional and linked to the rig
emergency shut down system), environment (to avoid any spills of hydraulic oil
during testing equipment such as the tubing retrievable safety valve and how to
dispose of waste), surroundings (danger zones which are exposed to high pressure
valves, traffic of heavy lifted objects and risk of working at heights)
CE2.4.4 I am also in charge of being the focal person for information on technicalities as well as
preparing technical procedures to run the job. The document is called the “Design of
Service” is compiled for offshore personnel as an official instruction manual to carry out
the job. The document consists of data such as well schematics, tool specifications and
calculations to operate down hole equipment.
CE2.4.5 The completion report (refer to Figure 1 to 3) is also part of my responsibility as this is
an important document to be provided to the customer as a reference of types of
equipment that were installed and the actual depth of the equipment in the well. Other
information such as tubing, casing grade and the completion fluid used will also be
recorded.
CE2.4.5 Calculations mainly involves down hole equipment such as packers and tubing retrieval
safety valves.
 Packers are defined as a standard component of oil or gas wells used to provide a seal
between the production zones. The sealing usually takes places outside of
the production tubing and the inside of the casing, liner, or wellbore wall.
 Tubing Retrievable Safety Valves (TRSV) are component on an oil and gas well, which
acts as a failsafe mechanism to prevent the uncontrolled release of reservoir fluids in
the event of a worst-case-scenario surface disaster. The TRSV is usually regarded as the
first barrier of defense if a disaster occurs. Typically operated hydraulically through a
control line attached to the valve all the way up to the surface.
 Sliding Side Door (SSD) is a device that allows communication between tubing and
casing annulus by shifting the internal sliding sleeve open with a 42BO shifting tool. The
tool is typically run in hole on wire line.
 Pump Out Plug (POP) is a plug run on a work string with the purpose of performing
tubing integrity test, safety valve inflow test and setting a hydraulic packer by dropping
an aluminum ball into the completion string to prevent communication between the
string and casing annulus. Upon achieving its purpose, the pump out plug can be
pumped out by shearing the ball seat which retains the ball by increasing the pressure
acting against the ball which will then allow the communication between tubing and
casing to be established.
 Blast Joints are basically tubing with a higher wall thickness. Usually placed within the
perforation zones to withstand erosion from pore pressures over time.
 X & XN Nipple Profiles provides a landing point for respective PXX and PXN profile plugs
and lock mandrels to be installed within the completion string.
Dual Completion String Schematic
COMPLETION REPORT
FIELD : Angsi A SIZE WEIGHT GRADE THREAD DEPTH (m)MDDF COMPLETION TYPE:
WELL: Angsi A33#WO CASING 9 5/8" 47 L-80 VAMTOP 2984.1 DUAL GAS PRODUCER'
DATE: 26-Dec-12 LINER
PCSB REPS : TUBING SIZE WEIGHT GRADE THREAD DEPTH (m)MDDF COMPLETION FLUID:
BILLY.T.POWELL/BILL KIRKSEY LS 3-1/2" 9.2 L-80 JFE-FOX 2816.565 8.5 PPG NaCl(D/WATER + 3% KCl) filtered to 30 NTU
GUNASEGARAN SS 3-1/2" 9.2 L-80 JFE-FOX 2347.360 JOB TICKET NO: # 3732 / 900050278
HALLIBURTON REPS : PACKERS RELEASE : 9-5/8" BHD PACKER OVERPULL 72K ON L/S TO RELEASE P/UP WT S/OFF BLOCK
RIZAFARID/BRYAN OOI 9-5/8" AHC PACKER CUT INNER MADREL TO RELEASE 120 56 HWU
AQMAL/ELIYAS/SHARIL 9-5/8" BWS PACKER MILL OUT TO RELEASE.
METER DESCRIPTION INCHES
1
ITEM DEPTH LENGTH SHORT STRING Part # Control # ID OD
2 0.000 23.100 Elevation (RKB to HOP) - -
3 13 1 23.100 Hanger-Dual 3-1/2" 9.2# JFE FOX, 13CR SOLAR HGR 543 2.992 10.850
4 14 23.100 4.203 Pup Joint- 3 1/2"-9.2 Fox 13Cr 15 ft --------------- 2.992 3.500
15 27.303 9.110 Tubing- 3 1/2"-9.2 Fox L-80-13CR --------------- 1 JT TBG 2.992 3.500
36.413 3.765 Pup Joint- 3 1/2"-9.2 Fox 13Cr 12 ft --------------- 2.992 3.500
44.553 114.680 Tubing- 3 1/2"-9.2 Fox L-80-13CR --------------- 12 JTS TBG 2.992 3.500
2 162.353 0.835 FL CPLG 36 13CR 3 1/2-9.20 FOX-K B-P 811FN28120 2.880 3.920
6 3 163.188 1.490 TRSV,NE,5.03 2.813,H2S/CO2,5K Self Equalize 781SXE28706-F TRSV-1814 2.813 5.030
7
17 165.513 3.110 Pup Joint- 3 1/2"-9.2 Fox 13Cr 10 ft --------------- 2.992 3.500
8 168.623 2015.508 Tubing- 3 1/2"-9.2 Fox L-80-13CR --------------- 211 JTS TBG 2.992 3.500
9
5 2188.801 0.370 'X' Nipple- 2.813" 3 1/2"-9.2 Fox BxP 13Cr 811X28115 X-2293 2.813 3.893
I-1 2189.171 4.645 Pup Joint- 3 1/2"-9.2 Fox 13Cr 15 ft --------------- 2.992 3.500
10
12 2216.101 0.355 Top Sub --------------- 2.926 3.521
2216.456 0.365 COE TO Top Sub --------------- 2.820 8.570
6 2216.821 Dual Pkr- 9 5/8" 40-43.5# BHD 3 1/2"-9.2 FOX-K BxP, 13Cr 812BHD90310-F BHD-748 2.820 8.570
19
2216.821 1.425 COE To Bottom --------------- 2.820 8.570
I-35U
2218.246 0.485 Bottom Sub --------------- 2.926 3.521
20 7 2220.023 1.317 Telescopic Swivel Jt- (EXTENDED) 831TO35045-F 2.880 4.240
2223.315 9.580 Tubing- 3 1/2"-9.2 Fox L-80-13CR --------------- 1 JT TBG 2.992 3.500
23
8 2239.735 1.290 SSD- XD 3 1/2"-9.2 Fox BxP 13Cr 821XD28153-F XD-2112 2.813 4.550
I-85 24 811BN28161-G
9 2244.755 35.973 Blast Jt- 20' + 10' , 3 1/2"-9.2 Fox BxP 13Cr 4 JTS BJ 2.992 3.920
811BN28162-G
I-95U
2341.272 0.355 Top Sub --------------- 2.926 3.521
2341.627 0.370 COE TO Top Sub --------------- 2.820 8.570
26 10 2341.997 Dual Pkr- 9 5/8" 40-43.5# BHD 3 1/2"-9.2 FOX-K BxP, 13Cr 812BHD90310-F BHD-746 2.820 8.570
2341.997 1.430 COE To Bottom --------------- 2.820 8.570
27 2343.427 0.490 Bottom Sub --------------- 2.926 3.521
28 11 2344.607 0.400 'XN' Nipple- 2.750" 3 1/2"-9.2 Fox 13Cr 811XN27581-F 2.690 3.893
12 2345.682 1.678 POP Assy- 3 1/2"-9.2 Fox B 13Cr c/w perf pup 812POP4008-F 2.871 3.970
29
2347.360 - End of Tubing
30
34
31
32
33
1-100
Figure 1: Short String Completion Schematic

METER DESCRIPTION INCHES
1 ITEM DEPTH LENGTH LONG STRING Part # Control # ID OD
2 0.000 23.100 Elevation (RKB to HOP) - -
3 13 23.100 Hanger-Dual 3-1/2" 9.2# JFE FOX, 13CR SOLAR HGR-542 2.992 10.850
5 16
14 172.112 1.490 TRSV,NE,5.03 2.813,H2S/CO2,5K Self Equalize 781SXE28706-F TRSV-1813 2.813 5.030
6 15 173.602 0.835 FL CPLG 36 13CR 3 1/2-9.20 FOX-K B-P 811FN28120 2.880 3.920
17
9 18
I-1 2202.661 9.570 Tubing- 3 1/2"-9.2 Fox L-80-13CR --------------- 1 JT TBG 2.992 3.500
11 2215.956 0.500 Top Sub --------------- 2.926 3.521
12
2216.456 0.365 COE TO Top Sub --------------- 2.820 8.570
6 2216.821 Dual Pkr- 9 5/8" 40-43.5# BHD 3 1/2"-9.2 FOX-K BxP, 13Cr 812BHD90310-F BHD-748 2.820 8.570
19 2216.821 1.425 COE To Bottom --------------- 2.820 8.570
I-35U 2218.246 0.710 Bottom Sub --------------- 2.926 3.521
22
811BN28161-G
I-70 18 2244.006 35.966 Blast Jt- 20' + 10' , 3 1/2"-9.2 Fox BxP 13Cr 4 JTS BJ 2.992 3.920
23 811BN28162-G
I-85 24 2341.127 0.500 Top Sub --------------- 2.926 3.521
2341.627 0.370 COE TO Top Sub --------------- 2.820 8.570
I-95U 10 2341.997 Dual Pkr- 9 5/8" 40-43.5# BHD 3 1/2"-9.2 FOX-K BxP, 13Cr 812BHD90310-F BHD-746 2.820 8.570
25 2341.997 1.430 COE To Bottom --------------- 2.820 8.570
2343.427 0.740 Bottom Sub --------------- 2.926 3.521
I-95 19 2413.105 1.290 SSD- XD 3 1/2"-9.2 Fox BxP 13Cr 821XD28153-F XD-2111 2.813 4.550
28
811BN28161-F
20 2418.120 27.100 Blast Jt- 20' + 10' , 3 1/2"-9.2 Fox BxP 13Cr 3 JTS BJ 2.992 3.920
811BN28129
29
30
31
32 2554.084 0.270 Top Sub --------------- 2.958 6.140
33 2554.354 0.550 COE TO Top Sub --------------- 2.958 8.300
1-100
21 2554.904 Packer- 9 5/8" 43.5-53.5# AHC 3 1/2" 9.2 Fox-k BxP 13Cr 812AHC98207-X AHC-344 2.958 8.300
2554.904 0.972 COE To Bottom --------------- 2.958 8.300
2555.876 0.288 Bottom Sub --------------- 2.958 6.140
22 2558.065 1.293 SSD- XD 3 1/2"-9.2 Fox BxP 13Cr 821XD28153-F 2.813 4.550
Figure 2: Long String Completion Schematic

2667.959 6.300 Blast Jt- 20' 3 1/2"-9.2 Fox BxP 13Cr 811BN28129 2.992 3.920
23 811BN28161-F
2674.259 9.050 Blast Jt- 20' + 10' , 3 1/2"-9.2 Fox BxP 13Cr 1 JT BJ 2.992 3.920
811BN28129
2 2725.245 2.990 Blast Jt- 10' 3 1/2"-9.2 Fox BxP 13Cr 811BN28161-F 2.992 3.920
3 13 24 811BN28161-F
4 14 2728.235 18.100 Blast Jt- 20' + 10' , 3 1/2"-9.2 Fox BxP 13Cr 2 JTS BJ 2.992 3.920
811BN28129
15
811BN28161-F
2784.540 9.000 Blast Jt- 20' + 10' , 3 1/2"-9.2 Fox BxP 13Cr 1 JT BJ 2.992 3.920
25 811BN28129
2793.540 2.970 Blast Jt- 10' 3 1/2"-9.2 Fox BxP 13Cr 811BN28161-F 2.992 3.920
2796.510 0.270 Top Sub --------------- 2.958 6.140
5 16 2796.780 0.550 COE TO Top Sub --------------- 2.958 6.140
6 26 2797.330 Packer- 9 5/8" 43.5-53.5# AHC 3 1/2" 9.2 Fox-k BxP 13Cr 812AHC98207-X AHC-350 2.958 8.300
2797.330 0.972 COE To Bottom --------------- 2.958 8.300
7
2798.302 0.288 Bottom Sub --------------- 2.958 6.140
17
9 18 27 2799.280 1.295 SSD- XD 3 1/2"-9.2 Fox BxP 13Cr 821XD28153-F 2.813 4.550
2800.575 2.990 Blast Jt- 10' 3 1/2"-9.2 Fox BxP 13Cr 811BN28161-F 2.992 3.920
I-1 28 811BN28161-G
2803.565 9.000 Blast Jt- 30' , 3 1/2"-9.2 Fox BxP 13Cr 1 JT BJ 2.992 3.920
10 811BN28162-G
12 29 2813.270 0.395 'XN' Nipple- 2.750" 3 1/2"-9.2 Fox 13Cr 811XN27581-F 2.750 3.893
2813.665 0.175 No Go Locator to Top --------------- 2.992 3.500
19 30 2813.840 Locator- No-Go 3 1/2"-9.2 Fox B x UN P 13Cr f/ 4.000" 812L40109-F 2.880 4.250
I-35U 2813.840 0.070 No Go Locator To Bottom 812L40109-F 2.880 4.250
31 2813.910 1.515 Seal Unit (5EA)- HSN 3 1/2"-12 UN BxP 13Cr f/ 4.000" 812MSN40051-F 2.880 4.056
20 2815.425 0.225 Adapter 892BPC33289-F 2.986 3.970
32 2815.650 0.915 Self Align MSG- 25CR 212SDG40003-F 2.595 3.970
21 33 2816.565 - End of Tubing - 0.000
22
I-70
23 LOWER COMPLETION
2814.540 0.960 COE to Top of Packer 4.000 8.120

I-85 24 34 2815.500 Packer- 9 5/8" 36-59.4# BWS 4 3/4-8UN HNBR 13CR 812BWS95405-F 4.000 8.120
2815.500 0.535 COE to Bottom Of Packer 4.000 8.120
I-95U 2816.035 - End of BWS Packer Assy
25
26
27
I-95
28
29
30
34
31
32
33
1-100
Figure 3: Long String Completion Schematic (Continuation)

Fluid Density Effect on Hydrostatic Pressure
Fluid Density Effect on Hydrostatic Pressure
Reservoir Properties Annulus Long String Short String Interpolate

RKB = 41.00 m RDH Packer
IN ANNULUS LS with SMSG SS with SMSG x1 = 3036.00
Ave downhole density String full with brine String full with brine x3 = 3046.00
ppg CaCl Brine
1 ppg CaCl Brine ppg CaCl Brine x2 = 2987.00
8.3 ppg NaCl Brine 8.3 ppg NaCl Brine 8.3 ppg NaCl Brine y1 = 1551.00
ppg HEC
2 ppg HEC ppg HEC y3 = 1552.46
Depths in TVD 3 13 Depths in TVD Depths in TVD
4 14 y2 = 1543.85
15
8.3 ppg NaCl Brine 1524 m 8.3 ppg NaCl Brine 1524 m Interpolate
Hydrostatic = 2158 psi Hydrostatic = 2158 psi SS/POP
Differential = 0 psi x1 = 3036.00
start-to-set x3 = 3046.00
Differential = 594 psi x2 = 3004.00
minimum set y1 = 1551.00
5 16 y3 = 1552.46
I7 1600 psi 8.3 ppg NaCl Brine 1549 m
Hydrostatic = 2194 psi
6 y2 = 1546.33
Differential = 594 psi
7
Interpolate
17
8 E6/E7
x1 = 2820.00 x1 = 2820.00
8.3 ppg NaCl Brine 1583 m 9 18 8.3 ppg NaCl Brine 1583 m x3 = 2850.00 x3 = 2850.00
Hydrostatic = 2242 psi Hydrostatic = 2242 psi x2 = 2840.00 x2 = 2841.00
Differential = 0 psi y1 = 1497.93 y1 = 1497.93
I-1
start-to-set y3 = 1507.06 y3 = 1507.06
10 Differential = 531 psi
11 minimum set y2 = 1504.02 y2 = 1504.32
12
35U 1800 psi 8.3 ppg NaCl Brine 1646 m Interpolate
Hydrostatic = 2331 psi 8.3 ppg NaCl Brine 1584 m E8 BHR POP
Differential = 531 psi 19 Hydrostatic = 2243 psi x1 = 3036.00 x1 = 3036.00
I-35U Differential = 597 psi x3 = 3132.00 x3 = 3132.00
when shearing POP pins x2 = 3046.00 x2 = 3063.00
8.3 ppg NaCl Brine 1727 m

20 8.3 ppg NaCl Brine 1727 m Hydrostatic Pressure Calculation
Hydrostatic = 2446 psi Hydrostatic = 2446 psi Hydrostatic = Depth(m) x 3.281 x 0.052 x Fluid Density(ppg)
21 Differential = 0 psi
start-to-set
22
minimum set
I-70
23
i95u 1770 psi 8.3 ppg NaCl Brine 1873 m
I-85 24
I-95U
25
8.3 ppg NaCl Brine 1876 m 8.3 ppg NaCl Brine 1876 m
Differential
Hydrostatic = 2657 psi Hydrostatic =
Differential =
2657 psi
0 psi
pressure acting
26 start-to-set against the shear
27 minimum set pins in the packer
i95 1770 psi 8.3 ppg NaCl Brine 1873 m
I-95
28
29
30
34
31
Differential pressure
32
between formation 33
1-100
pore pressure vs
completion fluid
density
Note: Negative Pdiff Values indicate UNDERBALANCE condition.

All calculation is based on mid perforation TVD.
Figure 4: Differential pressure experienced by each packer based on formation pore pressure
Hydrostatic pressure Temperature &
effect on the shear pins Hydrostatic pressure
effect on the shear pins
Packer Setting Pressure Calculations
Item Set Pin Piston Area Set Pressure Pressures to Activate Pressures to Activate
Overbalance = 0 psi at BHD STS (ADJUSTED FOR OVERBALANCE AND DERATED
Overbalance = 594 psi at BHD min set FOR TEMPERATURE) Tech Bulletin CPS085
TEMPERATURE FACTOR
Overbalance = 0 psi at BHD STS Temperature at BHD:260F
Overbalance = 531 psi at BHD min set Temperature at BHD:260F
Overbalance = 597 psi at SS Expand Temperature at POP SS:260F
Overbalance = 0 psi at AHC STS Temperature at AHC:260F
psi at BHD STS Overbalance = 0 psi at AHC Min Set Temperature at AHC:260F
Overbalance = 0 psi at AHC STS
Overbalance = 0 psi at AHC Min Set
9-5/8"BHD Dual Packer 12C2508 28.5 sq in pins L ( psi) O (psi) H ( psi) pins L ( psi) O (psi) H ( psi) pins L ( psi) O (psi) H ( psi)
812BHD90310-F 3900 lbs/pin 7 862 958 1054 7 862 958 1054 7 819 910 1001
2500 psi min setting press 137 psi/pin 8 985 1095 1204 8 985 1095 1204 8 936 1040 1144
0.95
5000 psi max setting press stainless steel pin 9 1108 1232 1355 9 1108 1232 1355 9 1053 1170 1287
SS set ; LS Rel 10 1232 1368 1505 10 1232 1368 1505 10 1170 1300 1430
16 (RELEASE), 12 (SETTING) 11 1355 1505 1656 11 1355 1505 1656 11 1287 1430 1573
60,000 lbs to release(12S7186:12ea) min 2500 min 1906 min 1811
9-5/8"BHD Dual Packer 12C2508 28.5 sq in pins L ( psi) O (psi) H ( psi) pins L ( psi) O (psi) H ( psi) pins L ( psi) O (psi) H ( psi)
812BHD90310-F 3900 lbs/pin 7 862 958 1054 7 862 958 1054 7 819 910 1001
0.95
SS set ; LS Rel 10 1232 1368 1505 10 1232 1368 1505 10 1170 1300 1430
16 (RELEASE), 12 (SETTING) 11 1355 1505 1656 11 1355 1505 1656 11 1287 1430 1573
60,000 lbs to release(12S7186:12ea) min 2500 min 1969 min 1871
Short String Pump Out Plug 410PD431 Steel 6.847 sq in pins L ( psi) O (psi) H ( psi) pins L ( psi) O (psi) H ( psi) pins L ( psi) O (psi) H ( psi)
0.94
812POP4008-F 3190 lbs/pin 8 3542 3936 4330 8 3005 3339 3673 8 3542 3936 4330
12Holes available 492 psi/pin 9 3985 4428 4871 9 3448 3831 4214 9 3241 3601 3961
10 4428 4920 5412 10 3891 4323 4755 10 4428 4920 5412
9-5/8" AHC Packer 12S7110 15.59 sq in pins L ( psi) O (psi) H ( psi) pins L ( psi) O (psi) H ( psi) pins L ( psi) O (psi) H ( psi)
812AHC98207-X 4500 lbs/pin 4 1039 1155 1270 4 1039 1155 1270 4 987 1097 1207
0.95
8 (SETTING) 7 1818 2021 2223 7 1818 2021 2223 7 1728 1919 2111
Cut To release 8 2078 2309 2540 8 2078 2309 2540 8 1974 2194 2413
min 4000 min 4000 min 3800
9-5/8" AHC Packer 12S7110 15.59 sq in pins L ( psi) O (psi) H ( psi) pins L ( psi) O (psi) H ( psi) pins L ( psi) O (psi) H ( psi)
812AHC98207-X 4500 lbs/pin 4 1039 1155 1270 4 1039 1155 1270 4 987 1097 1207
0.95
8 (SETTING) 7 1818 2021 2223 7 1818 2021 2223 7 1728 1919 2111
Cut To release 8 2078 2309 2540 8 2078 2309 2540 8 1974 2194 2413
min 4000 min 4000 min 3800
Figure 5: Recommended Packer Setting Pressure

Tubing Retrieval Safety Valve Pressure Calculations
Operation Description Applied Tubing Recommended Recommended Test Pressure

Pressure (psi) Control Line Hold (psi)
Open Pressure (psi) *
Tubing Integrity Test 1000 3300
Set Packer 3500 5000 7300
Expend POP 5000 7300
*Recommended Control Line Pressure = Tubing Pressure + Max Full Open (1800 for this TRSV) + 500
Control Line Fluid : Tellus 32 Hydraulic Oil
Control Line Specifications: 11x11mm PVDF encapsulation ¼” 0.049” wall thickness, WP 10,000psi
Figure 6: Recommended Applied Test Pressure for TRSV
CE2.5 Summary
The job was carried out successfully after 21 days at the site. All safety valves are operating superbly and
all the packers were successfully deployed. The production zones did not have any communication
between one another and the customer was able to produce from multiple zones at one time. They
were also very satisfied as they are able to produce from different zones selectively with the use of our
sliding side door (SSD) which can be shifted open and close depending on the customer’s requirements.
The option to comingle the production zones is another advantage which the customer is able to pursue
from this design and they were very satisfied with our team’s performance.
CAREER EPISODE 3 (CE3): Deploying Halliburton’s Single Trip Multi
Zone Sand Control System in Petronas Baram BA41SR Well
CE3.1 Introduction
CE3.1.1 Petronas Baram BA41SR is located at the waters of the Sarawak state. Baram BA41 is the first
well in Malaysia to utilize Halliburton’s Single Trip Multi Zone (STMZ) Sand Control System.
Considering Baram BA41SR is within a matured oil field, the well is managed by Enhanced Oil
Recovery Company (EORC) which is collaboration between Shell and Petronas.
CE3.1.3 Summarizing the engineering design that took place, the Single Trip Multi Zone (STMZ) Sand
Control System was proposed on the basis that the difference between pore pressure does not
exceed a differential of 300 psi, the distance between the perforation intervals is within the
acceptable range of 300ft, the bottom hole pressure and temperature were below 5000 psi and
325 degrees Fahrenheit respectively.
CE3.1.4 With all the specifications within the acceptable threshold, the STMZ is also expected to save up
to 48 hours of rig time which translates to approximately 700,000 USD.

I was part of a 4 man team to head this project and identify the limitations that we are expected to face
in order for me to optimize the proposed system to suit the well conditions whilst taking into
consideration the importance of selecting the right equipment and designing the completion string as
the well is expected to generate a large amount of oil production which worth millions of dollars per
day.
CE3.3 Background
Wells within the Baram field is expected to produce a large amount of sand which poses a challenge in
producing oil. Apart from facing a challenge in production, the customer is also faced with another
challenge which is completing the well within a tight time line. In January 2014, I was nominated to be
part of a 4 man team to develop a solution for our customer in order to overcome the challenges faced.
Our 4 man team consists of 2 advisors and 2 engineers under sand control solutions to work together
and accomplish our goals to deploy the new system safely and efficiently. This project is a major
breakthrough for the country as it’s the first system of its kind and therefore careful planning and
execution is extremely crucial to ensure the job’s success.
The treatment that is required for this well is termed Gravel Packing which means a down hole filter
designed to prevent the production of unwanted formation sand. The formation sand is held in place by
properly sized gravel pack sand that, in turn, is held in place with a properly-sized screen.
CE3.4 Problem Statement
The well is expected to produce a large amount of sand and there were 4 production zones to be tapped
in. Considering each zone is to produce sand along with oil at pore pressures of approximately 3000 to
3600 psi over an interval of 600 feet, an efficient completion design along with the appropriate service
tool is required in order for us to gravel pack each zone in the well.
CE3.5 Engineering Application Demonstration

CE3.5.1 Engineering Considerations and Analysis
To design and optimize the Single Trip Multi Zone system, there were many considerations that I had to
put in place which includes the amount of screen length coverage over the perforation intervals, the
amount of blank pipes used which contributes to the space out of the service tool, essential handling
equipment, a backup mechanism to prevent any clogging of the service tool due to sand production, the
maximum collapse pressure which the completion string can withstand and the amount of friction
produced from flowing fluid.
CE3.5.2 Screen Coverage
The concept of designing the completion string for a well that requires gravel packing heavily relies on
the amount of screen coverage over the perforation interval. I have used the rule of thumb of at least
10ft of screen coverage above and below the perforations contribute to good gravel packing operations.
Taking the bottom perforation depth as the reference point, I had to calculate the amount of 10ft and
30ft screens used to ensure sufficient coverage can be achieved.
CE3.5.2.1 STMZ Zone Q6.5/7.0 & Zone R2/R3
No Part No DESCRIPTION I.D. O.D. LENGTH (ft) DEPTH (ft)
HANDLING PUP, NC38 5.577 7702.89

MPA TOOL 2.562 7708.46
1 12VBA84-Z VBA PKR,7,26-29,3.880 3.880 6.015 6.612 7711.03
12P85535 SUB,BOT,5 1/2-10 UNS X 4-8 UN 3.375 5.820 0.490 7717.64
12P75391 HONED TUBE,CLOSING SLEEVE ASSEMBLY,4-8 UN,3.250 3.250 4.160 1.439 7718.13
12P76872 COMB CPLG,4-8 UN X 4 API-NU,4140 LAS,B- 3.305 4.798 0.743 7719.57
92PPC44312 PUP JT EXT,4-9.50 API-NU X 98.77,41XX LA 3.481 4.031 7.752 7720.31
TOP 12MUS70320-A MAKEUP SUB,4 API-NUE,B-P 3.528 5.270 2.692 7728.06
BTM 12MUS70320-A MAKEUP SUB,4 API-NUE,B-P 3.528 5.270 1.583 7730.75
892BPC44013 ADPTR,4.0 NU 4 1/2 LCT B-P,H2S 3.530 4.797 0.750 7732.34
2 PCSB PUP JT,4 1/2-11.6 API-LCT BOX x PIN, 5FT, L80 3.852 4.545 5.000 7733.09
92BPC44276 REDCG ADPTR,4 1/2 API-LC X 4-9.50 API-NU 3.528 5.050 0.969 7738.09
12P76872 COMB COUPLNG 4-8 UN X 4 API-NU BxB 3.305 4.798 0.742 7739.06
12P80394 REDCG CPLG,4-8 UN BOX X 5 API-STC BOX,4140 LAS, 3.305 5.619 0.751 7741.24
12P72158 EXTN,UPR,MFS,5-15.00 API-STC P-P,HVY WALL X 3.25
Zone Q6.5/7.0 4.368 5.530 5.542 7741.99
12P75389 MCS, HSG,CL SLV,CL SLV ASSY,5 API-LCT 4-8UN X 3.25 3.250 5.530 1.785 7747.53
12P75391 HTB, CLO SLV ASSY, 4-8 UN-2A, 3.250, 41XX LAS, P-P 3.250 4.160 1.439 7749.32
12P75388 SUB, BOT, CLO SLY ASSY, 4-8 UNS-2B X 4 1/2-API LTC, 3.250, 41XX LAS, B-B 3.305 5.020 0.738 7750.75
92PPC44034 PUP JT,4 1/2-13.50 API-LCT PIN x PIN,36.0,P-110 3.920 4.545 2.500 7751.49
12P75388 SUB,BOT,CLO SLV ASSY,4-8 UNS BOX X 4 1/2 LTC BOX 3.305 5.020 0.738 7753.99
92PPC44311 PUP JT EXT,4-9.50 API-NU X 44.0,41XX LAS, P-P 3.481 4.031 3.192 7756.91
12P76841 CPLG,IND,4 API-NU,B-B 3.250 4.798 0.368 7760.10
12P76841 CPLG,IND,4 API-NU,B-B 3.250 4.798 0.292 7760.47
92PPC44359 SWG NIP,4-9.50 API-NU X 4 1/2-11.6 API-LC PIN 3.528 5.050 0.635 7760.76
PCSB PUP JT,4 1/2-11.6 API-LCT BOX x PIN, 5FT, L80 3.852 4.545 5.000 7761.40
890370 BLANK PIPES, 4 1/2-11.6 API-LC B x P, 10ft 3.894 5.630 10.000 7771.40
890374 Zone R2/R3
30FT WWS SCREENS, 0.012 GAUGE, 4 1/2-11.6 API-LC PIN 3.894 5.630 30.000 7791.40
890374 30FT WWS SCREENS, 0.012 GAUGE, 4 1/2-11.6 API-LC PIN 3.894 5.630 30.000 7821.40
12P75391 HONED TUBE,CLOSING SLEEVE ASSEMBLY,4-8 UN PIN x PIN,3.250 3.250 4.160 1.439 7893.11
3 12OO4502 PACKER, ISOLATION, 7, 23-29, 3.250, 4-8 UN 3.290 6.000 3.026 7894.54
n/a ADPTR 4-8 UN 2B Pin x 5" API STC Box 3.310 5.563 0.537 7897.57
12P72158 EXT,UPR,MFS,5-15.00 API-STC,P-P,HVY 4.368 5.530 5.542 7898.11
12P72158 EXT,UPR,MFS,5-15.00 API-STC,P-P,HVY 4.368 5.530 5.542 7906.59
12P75389 MCS, HSG,CL SLV,CL SLV ASSY,5 API-LCT 4-8UN X 3.25 3.250 5.530 1.785 7912.13
12P75391 HTB, CLO SLV ASSY, 4-8 UN-2A, 3.250, 41XX LAS, P-P 3.250 4.160 1.439 7913.92
12P75388 SUB, BOT, CLO SLY ASSY, 4-8 UNS-2B X 4 1/2-API LTC, 3.250, 41XX LAS, B-B 3.305 5.020 0.738 7915.36
92PPC44034 PUP JT,4 1/2-13.50 API-LCT PIN x PIN,36.0,P-110 3.852 4.545 2.500 7916.09
12P75388 SUB,BOT,CLO SLV ASSY,4-8 UNS BOX X 4 1/2 LTC BOX 3.305 5.020 0.738 7918.59
12P76872 COMB CPLG,4-8 UN X 4 API-NU,4140 LAS,B- B 3.305 4.798 0.742 7920.77
92PPC44311 PUP JT EXT,4-9.50 API-NU X 44.0,41XX LAS, P-P 3.481 4.031 3.192 7921.51
12P76841 CPLG,IND,4 API-NU,B-B Top to Middle 3.250 4.798 0.368 7924.71
12P76841 CPLG,IND,4 API-NU,B-B Middle to Bottom 3.250 4.798 0.292 7925.07
92PPC44359 SWG NIP,4-9.50 API-NU X 4 1/2-11.60 3.528 5.050 0.635 7925.37
4 890373 10FT WWS SCREENS, 0.012 GAUGE, 4 1/2-11.6 API-LC PIN 3.894 5.630 10.000 7991.00
92BPC44407 COMB ADPTR,4 1/2 API-LC X 4 1/2-12.60 VAMTOP PIN 3.480 5.050 1.065 8001.00
812OO45039-A COL LCH ASSY,4.50,4 1/2-12.60 VAMTOP BOX 3.360 4.967 2.241 8002.07
Figure 7: 7in STMZ Schematic

CE3.5.2.2 Screen Coverage Calculation for Zone R2/R3
Based on the schematic above, calculations on zone coverage were referenced to the bottom zone with
additional 10ft of screen overlap and working all the way up, a total of 1ea x 30 ft screen and 3ea x 10ft
screens are required to achieve the setup below.
16.00 Top overlap

7957.00 Top Perf
7991.00 Bttm Perf
10.000 Btm Overlap
4 890373 10FT WWS SCREENS, 0.012 GAUGE, 4 1/2-11.6 API-LC PIN 3.894 5.630 10.000 7991.00
92BPC44407 COMB ADPTR,4 1/2 API-LC X 4 1/2-12.60 VAMTOP PIN 3.480 5.050 1.065 8001.00
CE3.5.2.3 Screen Coverage Calculation for Zone Q6.5/Q7.0
Similarly, the coverage for interval Q6.5/7.0 requires a total of 3ea x 30 ft screens and 2ea x 10ft screens
are required to achieve the setup below.
15.60 Top overlap

7807.00 Top Perf
7878.00 Bttm Perf
13.397 Btm Overlap
CE3.5.3 Completion String Design
In between the screens and blank pipes, main components of the completion string consists of the
following assemblies below. I have chosen these assemblies based on the well bottom hole temperature
of 200 degrees Fahrenheit and bottom hole pressure of approximately 3600 psi.
 VBA packer assembly (Rated to 5000 psi differential pressure and 325 degrees Fahrenheit)
 Isolation Packer Assembly (Rated to 5000 psi differential pressure and 325 degrees Fahrenheit
and higher start to set pressure to prevent the VBA packer and isolation packer to set at the
same time.)
 Snap Latch with Sump Packer Assembly
CE3.5.3.1 VBA Packer Assembly
The VBA packer assembly is the top most component of the completion string. It is attached directly to
the upper service tool (Refer to CE3.4.4.1) and will be run in hole along with the isolation packer
assembly and snap latch assembly hung below. The VBA packer helps to isolate the perforation zones by
sealing the annulus within the casing internal diameter and communication can only be achieved
through the MCS below the packer. The VBA packer assembly consists of the main components below:
VBA MCS Seal Bore

Packer
Figure 8: VBA Packer Assembly
CE3.5.3.2 Isolation Packer Assembly
The isolation packer assembly is the middle packer below the VBA packer assembly and its main purpose
is similar which is also to isolate the production zone. The isolation packer has its own MCS as well and is
positioned right below the isolation packer.
Isolation Packer MCS

Figure 9: Isolation Packer Assembly
CE3.5.3.3 Snap Latch and Sump Packer Assembly
The snap latch allows us to determine that we have reached the appropriate depth by latching onto the
sump packer which was lowered into the well in the earlier. The snap latch latches onto the packer by
applying a certain amount of slack off force therefore allowing the snap latch to locate the packer
groove within the packer and the bevel to prevent the snap latch from further moving downwards.
Bevel Snap Latch Sump Packer

Groove
Figure 10: Snap Latch and Sump Packer
CE3.5.4 Service tool Setup and Positions
The main component of the STMZ system is the service tool which is required to treat each zone by
pumping in retainer fluid and gravels to enhance sand filtration. The setup of the tool is really crucial to
ensure that it is capable of treating each perforation zone without interfering with the other by singling
out each zone during treatment with the help of seal mandrels. I have selected a few components which
will serve the purpose of isolating and treating based on the need to locate the position of the tool
(treating) and to close the MCS when it’s required (isolating). The component of the service tool consists
of the parts stated below:
 Upper Service Tool

 Lower Service Tool
 Shifters & Locator
 Lower Isolation Seal.
CE3.5.4.1 Upper Service Tool & VBA Packer
The upper service tool main function is to allow the VBA packer to be set by pressuring down the
hydraulic unit which is connected to drill pipes all the way up the rig floor. The lugs will help retain the
entire weight of the completion string with additional help of shear pins which will be attached to the
packer from the service tool. Finally the elastomeric seal at the bottom of the service tool allows
pressure isolation by positioning the seals in the packer seal bore.
Elastomeric Seals Connect to Wash Pipe
Connect to Drill Pipe Hydraulic Unit Lugs
Figure 11: Upper Service Tool
Seal Bore
Figure 12: VBA Packer
CE3.5.4.2 Lower Service Tool
The lower service tool will be placed below the isolation seal assembly. The main purpose of the lower
service tool is to allow communication of treatment fluid and gravel (filtration stones) from the drill pipe
into the micro annulus of the completion string and then flow out to the formation through the
mechanical closing sleeve (MCS). To enable the flow path to be achieved, the crossover port on the tool
must be positioned directly above the mechanical closing sleeve and allowing the remaining top and
bottom seal assembly to seal off in the compatible seal bore. The ball check valve will act as a barrier to
which pressure from above can be pumped against it to direct the flow of fluid out from the crossover
port as well as to ease the RIH process by releasing pressure from below the ball up the service tool
string to avoid any buoyancy effect on the tool.
Crossover Port Seal Assembly Return Port Ball Check Valve
Figure 13: Lower Service Tool

Crossover Port to be positioned at this point Seal Bore to allow the seal assembly to be
to allow flow of treatment fluid and gravel positioned at this point to prevent any flow of
into the formation. treated fluid into the micro annulus.
Figure 14: Mechanical Closing Sleeve (MCS)
CE3.5.4.3 Shifter and Locator
The shifter is a tool to shift open and close the mechanical closing sleeve hence it’s called the MCS
shifter. As for the locator tool, this tool main function is to give us an indication at the surface for the
location of our crossover port in the lower service tool. Indication in terms of an increase in weight
when the locator tool is passing through a seal bore or an indicator coupling gives us an idea of the
depth of our tool is located with reference to the running tally. An over pull of 13,000 lbs is required to
allow further pick up to the next seal bore.
Locating Profile Shifting Profile
Figure 15: Locator Collet Figure 16: Shifting Collet

CE3.5.4.3 Lower Isolation Seal
The last part of the service tool is the lower isolation seal. The lower isolation seal allows us to reverse
out fluid within the tool string to clear of excess gravel and debris through the ported mandrel. It also
has a weeping ball mechanism which allows pressure bypass to avoid any risk of pressure trapping in the
tool and resulting in a hydraulic lock. This part of the tool is really effective as the ball check is still
capable of holding pressure at the same time it provides a small leak path to clear the tool of excess
pressure. The seal mandrel throughout the tool body prevents any gravel or debris from flowing into the
annulus of the completing string.
Ported Mandrel Weeping Ball Seal Mandrel
Figure 17: Lower Isolation Seal
CE3.4.5 Packer Pinning Table and Hang Weight
Considering the upper service tool is directly linked to the VBA packer, the number of pins installed must
withstand the amount of hang weight from below. Temperature effects and material of the pins must
also be noted as it can adversely affect the performance of each pins installed. I have calculated the
amount of hang weight by using the formula below as it’s very critical to prevent the entire packer
assembly from falling into the well if the weight and amount of pins does not match.
Weight = (OD2-ID2)*2.67*Length
CE3.5.5.1 Assembly Weight
Item OD (in) ID (in) Length (ft) Weight (lbs)
VBA PKR,7,26-29,3.880 6.02 3.88 6.62 373.13

SUB,BOT ,5 1/2-10 UNS X 4-8 UN 5.82 3.38 0.75 45.17
HONED T UBE,CLOSING SLEEVE 4.16 3.25 2.03 36.53
COM B CPLG,4-8 UN X 4 API-NU,4140 4.80 3.31 0.74 24.00
PUP JT EXT ,4-9.50 API-NU X 98.77,41XX 4.03 3.48 8.23 90.80
M AKEUP SUB,4 API-NUE,B-P 5.27 3.53 2.80 114.58
M AKEUP SUB,4 API-NUE,B-P 5.27 3.53 1.41 57.62
ADPT R,4.0 NU 4 1/2 LCT B-P,H2S 4.80 3.53 1.00 28.24
PUP JT ,4 1/2-11.6 API-LCT BOX x PIN, 5FT , 4.55 3.85 5.00 77.69
REDCG ADPT R,4 1/2 API-LC X 4-9.50 API- 5.05 3.53 1.17 40.81
COM B COUPLNG 4-8 UN X 4 API-NU BxB 4.80 3.31 0.74 24.00
REDCG CPLG,4-8 UN BOX X 5 API-ST C 5.62 3.31 0.75 41.42
EXT N,UPR,M FS,5-15.00 API-ST C P-P,HVY 5.53 4.37 6.00 184.33
M CS, HSG,CL SLV,CL SLV ASSY,5 API-LCT 5.53 3.25 1.78 95.38
HT B, CLO SLV ASSY, 4-8 UN-2A, 3.250, 4.16 3.25 2.03 36.53
SUB, BOT , CLO SLY ASSY, 4-8 UNS-2B X 4 5.02 3.31 0.74 28.11
PUP JT ,4 1/2-13.50 API-LCT PIN x 4.55 3.92 3.04 42.97
SUB,BOT ,CLO SLV ASSY,4-8 UNS BOX X 4 5.02 3.31 0.74 28.11
CPLG,IND,4 API-NU,B-B 4.80 3.25 0.66 22.01
SWG NIP,4-9.50 API-NU X 4 1/2-11.6 API-LC 5.05 3.53 1.09 37.91
BLANK PIPES, 4 1/2-11.6 API-LC B x P, 10ft 5.62 3.89 10.00 436.95
BLANK PIPES, 4 1/2-11.6 API-LC B x P, 30ft 5.62 3.89 30.00 1,310.84
30FT WWS SCREENS, 0.012 GAUGE, 4 1/2- 5.98 3.89 30.00 1,653.67
10FT WWS SCREENS, 0.012 GAUGE, 4 1/2- 5.98 3.89 10.00 551.22
REDCG ADPT R,4 1/2 API-LC X 4-9.50 API- 5.05 3.53 1.17 40.81
PACKER, ISOLAT ION, 7, 23-29, 3.250, 4-8 6.00 3.29 3.03 203.40
REDCG CPLG,4-8 UN BOX X 5 API-ST C 5.62 3.31 0.75 41.42
EXT ,UPR,M FS,5-15.00 API-ST C,P-P,HVY 5.53 4.37 6.00 184.33
M CS, HSG,CL SLV,CL SLV ASSY,5 API-LCT 5.53 3.25 1.78 95.38
HT B, CLO SLV ASSY, 4-8 UN-2A, 3.250, 4.16 3.25 2.03 36.53
SUB, BOT , CLO SLY ASSY, 4-8 UNS-2B X 4 5.02 3.31 0.74 28.11
PUP JT ,4 1/2-13.50 API-LCT PIN x 4.55 3.85 3.04 47.26
SUB,BOT ,CLO SLV ASSY,4-8 UNS BOX X 4 5.02 3.31 0.74 28.11
COM B CPLG,4-8 UN X 4 API-NU,4140 4.80 3.31 0.74 24.00
CPLG,IND,4 API-NU,B-B 4.80 3.25 0.66 22.01
SWG NIP,4-9.50 API-NU X 4 1/2-11.6 API-LC 5.05 3.53 1.09 37.91
BLANK PIPES, 4 1/2-11.6 API-LC B x P, 10ft 5.62 3.89 10.00 436.95
COM B ADPT R,4 1/2 API-LC X 4 1/2-12.60 5.05 3.48 1.35 48.42
COL LCH ASSY,4.50,4 1/2-12.60 VAM T OP 4.97 3.36 2.24 80.06
Total = 26,987
Figure 18: Total Assembly Weight

CE3.5.5.2 Gravel Pack Down Hole Tool Pinning Sheet
GRAVEL PACK DOWNHOLE TOOL PINNING SHEET (7" STMZ)
Gravel Pack Tool Data - SVCE TL,UPR,STMZ,3.88 X 3.25,API-NC38 X; 12OO3312

2
Setting Piston Area (12P70113) 12.28 in Top Connection API-NC38 Box
Max. OD (Cylinder -12P71857) 5.700 in Bottom Connection 2 7/8-6.40 TSH 511 Pin
Pri. Setting Ball OD Tool Collapse Rating N/A
398 K lbs (3-1/2" 13.3# Drill Pipe)
186.6 (PORT HOLES);
Sec. Setting Ball OD (93B230) 2.125 in Tensile Rating (lbs)
110.0 (2 7/8-6.40 TSH 511);
52.5 (1.900-2.75 API-NU)
Shear Value for Specific Pin Type

1st Shear - Start-to-set Shear Screw (12S7010) @ Tool Setting Piston 6 holes at 12P75748
Shear Screw - Shear Value Shear Out Shear Pressure
Qty Installed Total Shear (lbs) Area (in2) Temp Factor
12S7010 (lbs/screw) Pressure corrected for temp
Minimum - 4,500 5 22,500 12.28 1,832 76 1,393
Nominal - 5,000 5 25,000 12.28 2,036 76 1,547
Maximum - 5,500 5 27,500 12.28 2,240 76 1,702
Amount
2nd Shear of pins to
- Driv-Lok Pinwithstand atrelease
(410PD232) -To least Tool
25,000 lbs= of
from Pkr Str.hang weight
Pull + Shear Temperature
force of applied surface pressure 12 holes at VBA packer factor
Shear Pin - Shear Value Piston Area Shear Out Shear Pressure that causes deteriorate
Qty Installed Total Shear (lbs) Temp Factor
212W7600 (lbs/pin) (in2) Pressure (psi) corrected for temp
of pin material
Minimum - 6950 10 69,500 12.28 5,660 94 5,320
Optimum - 7,600 10 76,000 12.28 6,189 94 5,818
Maximum - 7,980 10 79,800 12.28 6,498 94 6,108
Shear Force of Applied Surface Pressure Straight Pull on pipe
Total Shear Hydrostatic at Piston Area Shear Force
Shear Pin - Applied Str. pull required to release tool from
value of Pins Pkr depth (psi of applied
410PD232 Pressure (psi) (in2) pressure(lbs)
the Pkr
(lbs) overbalance)
Minimum - 69,500 4,000 0 12.28 49,120 20,380
Optimum - 76,000 4,000 0 12.28 49,120 26,880
Maximum - 79,800 4,000 0 12.28 49,120 30,680
Amount of Pressure required to set the Packer Amount of over pull required to release the tool from
packer.
Figure 19: Packer Pinning Table and Metallurgical Temperature Factors

CE3.6 Summary
The system will be deployed by the end of November and it will be the first of its kind for my country.
This project will be the pioneer for the 7 inch single trip multi zone system and to further enhance the
company’s stand point of being the best in the providing the well completion solutions and services to
our customers.
For future development, this system will also be used as a basis to further improve the tool’s efficiency
and effectiveness, modular screens will be incorporated instead of regular screens which greatly reduces
the amount of leak path resulting in better gravel packing and also reducing the amount of time
required to run the equipment into the well.
I will be working along with other engineers in proposing further improvement to the current tool and
possibly to incorporate gauges for data mining.
PROFESSIONAL ENGINEER
Summary Statement
These are the competency Units and Elements. These elements must be addressed in the Summary Statement
(see Section C). If you are applying for assessment as a Professional Engineer, you will need to download this
page, complete it and lodge it with your application.
Paragraph in the career

A brief summary of how you have
Competency Element episode(s) where the
applied the element
element is addressed
PE1 KNOWLEDGE AND SKILL BASE
 Systematic approach and design  CE 1.5

of solution to engineering
problems faced in the sugar silo
system by identifying the
problem statement and
brainstorming potential solutions
by performing in depth analysis
of the options involved and
finally producing a design
PE1.1 Comprehensive, theory-based solution.
understanding of the underpinning  Designing the well with the  CE 2.4.3
natural and physical sciences and the intention of producing from
engineering fundamentals applicable to multiple zones. The equipment
the engineering discipline involved was also suitable for
the well conditions.
 Tackling the challenges of sand  CE 3.5
production and with the
objective of saving rig time. The
Single Trip Multi Zone system
was selected as a best option to
treat sand producing zones in
one go therefore saving ample
rig time.
 Calculating pressure required to  CE 2.4.5. Figure 5

set the packers by taking into  CE 3.5.5.2 Figure
considerations the bottom hole 19
temperature and hydrostatic
PE1.2 Conceptual understanding of the
pressure affecting the
mathematics, numerical analysis,
performance of the packer
statistics and computer and information
setting pins.
sciences which underpin the
 Calculating the hold open  CE 2.4.5.Figure 6
engineering discipline
pressure of the safety to ensure
that enough pressure is applied
into the safety valve piston to
confirm the valve is in the open
position.
 Performing space out for the  CE 3.5.2 Figure 7
amount of screen coverage in the
to enable the service tool to treat
the respective production zones.
 Understanding the requirements  CE 1.5.2

and rulings of the local authority
when erecting a new
infrastructure.
 Competent in slick line tools to  CE 2.4.6.Fiigure 7
perform packer setting
PE1.3 In-depth understanding of
operations.
specialist bodies of knowledge within
the engineering discipline  Have knowledge of the sequence  CE 3.5.5.2.Figure
of pumping requirements from 20
the production enhancement
engineers in terms of what
chemicals are used to pump and
fracture the sand producing
zones.
 Conceptualizing the idea of  CE 3.5.1

producing from multiple zones
simultaneously by carefully
placing the packers at specific
depths to separate the zones and
installing the sliding side doors
PE1.4 Discernment of knowledge at strategically to allow multi
development and research directions zone comingling.
within the engineering discipline  Designed the critical Single Trip  CE 3.5.3.2
Multi Zone system with an
emergency reverse position to
allow redundant chemicals to be
pumped out from the completion
string in case the primary
reverse is not achievable.
 Identified HSE, governing  CE 1.5.1

bodies, social impacts and  CE 2.4.3
financial consideration on
proposed solution to enable a
PE1.5 Knowledge of contextual factors comprehensive proposal to be
impacting the engineering discipline designed
 Seeking the aid of field experts
to provide their inputs in the  CE 1.5.2.1
overall development of the  CE 1.5.2.2
project.  CE 3.5.2
PE1.6 Understanding of the scope,

principles, norms, accountabilities and  Consideration on HSE is highly  CE 1.5.3.4
bounds of contemporary engineering emphasized during the planning  CE 1.5.3.5
practice in the specific discipline stage of the sugar silo. For  CE 1.5.3.6
example the cause of dust
explosion could occur due to
oxygen levels, high
concentration of suspended dust
and any presence of ignition
source such as static electricity
could cause a potential hazard.
Therefore, in order to reduce the
potential of any dust explosion,
the concentration of oxygen
must be reduced and humidity
levels must be kept at an
optimum level by implementing
good ventilation system and a
dehumidifier.
 At well sites, potential blow out  CE 2.4.3
could occur due to uncontrolled  CE 2.4.5.Figure 6
well pressure. I had to ensure
that our well design met the
international safety standards to
incorporate a suitable down hole
safety valves (that is rated to the
recommended shut in pressure)
to provide temporary control
over a disaster. A well should
have at least 2 barriers available
which is the safety valve as the
first barrier and the Xmas tree as
the second barrier. During
running the completion string
into the hole, mobile safety
valves such as the TIW safety
valve must be incorporated and
all emergency shut down system
is in place.
PE2 ENGINEERING APPLICATION ABILITY
 In working on sugar silo, dual  CE 1.4, CE1.5

well completions and single trip  CE 2.4. CE2.5
multi zone sand control system,  CE 3.4, CE3.5
I demonstrated the ability to
follow proper problem solving
PE2.1 Application of established
processes by identifying the
engineering methods to complex
problem statement, compiling
engineering problem solving
engineering considerations, and
organizing discussions with
project members, performing
analysis and designing the
appropriate solution.
PE2.2 Fluent application of engineering  In designing the solution for the  CE 1.4, CE1.5
techniques, tools and resources sugar silo, I worked on an  CE 2.4. CE2.5
elimination process to ensure  CE 3.4, CE3.5
each challenges is met with a
solution.
 Usage of space out calculation  CE 1.4, CE1.5
and packer setting pressure sheet  CE 2.4. CE2.5
helps me to identify the final  CE 3.4, CE3.5
outcome of whether our
equipment is suitable for the
well conditions.
 My projects were executed the  CE 1.4, CE1.5

based on a complete design  CE 2.4. CE2.5
cycle by identifying the  CE 3.4, CE3.5
problem, the factors that
contribute to the issue, possible
PE2.3 Application of systematic solutions and elimination
engineering synthesis and design process, consideration for HSSE
processes and governing body
requirements, calculation for
proper capacity and
dimensioning for the solution
and cross-border engineering
requirements to complete the
solution

I was appointed the engineer in  CE 1.4, CE1.5
charge for leading the  CE 2.4. CE2.5
implementation of Petronas  CE 3.4, CE3.5
Angsi A33 well and designing
the Single Trip Multi Zone
system for Petronas Baram
BA41. I had to manage the
technical requirements from
Petronas to be shared with other
business units within the
PE2.4 Application of systematic company.
approaches to the conduct and  For Petronas Baram BA41  CE 1.4, CE1.5
management of engineering projects Single Trip Multi Zone well, I  CE 2.4. CE2.5
was tasked to design, plan and  CE 3.4, CE3.5
deliver the well proposal and I
engaged appropriate resources
from relevant departments,
worked with a cost effective
model in mind, and incorporated
long term sustainability features
in the well design via material
analysis that fits the well
conditions and contingencies in
case of any failures.
PE3 PROFESSIONAL AND PERSONAL ATTRIBUTES
 For the sugar silo project, I put  CE 1.4, CE1.5

PE3.1 Ethical conduct and professional
exceptional emphasis on the  CE 2.4. CE2.5
accountability
local governing requirements  CE 3.4, CE3.5
when establishing an
infrastructure.
 Discussions were made with  CE1.5.2

people from other departments
such as HSE, QA/QC, etc to
obtain resources as well as their
opinions to support the project’s
engineering design review.
 The engineers from production  CE 3.5.5.2
enhancement were consulted to
PE3.2 Effective oral and written advise on the chemical treatment
communication in professional and lay program to treat the formation in
domains Baram BA41. Setup of pumping
units, pressure gauges, valve
positioning as well as the service
tools functions are discussed as
it is very critical for us to
identify whether the treatment
for each zone is a success and
everyone is aware of the final
objective.
 In designing the new 7 inch  CE 3.5.3.2

for Baram BA41, the
conventional method of only
having 1 reverse position is not
used instead 2 reverse position is
implemented by incorporating
an additional upper extension in
PE3.3 Creative innovative and case hydraulic lock occurs
proactive demeanor within the tool string which will
disable us from reverse all
excess proppant or debris out
from the tool. This helps reduce
the risk of the tool getting stuck
in hole which can cause severe
consequences such as well
abandonment.
 Well trajectory as well as down  CE 2.4. CE2.5

hole conditions were obtained to  CE 3.4, CE3.5
help us propose a suitable
PE3.4 Professional use and system which meets all the
management of information well’s criteria.
 Running histories of the 7 in  CE 3.4, CE3.5
were obtained from Brunei for
us to capture any lessons learned
to help improve the current
system and to produce a
comprehensive completion
program for our personnel and
customer offshore.
 Formation length and depth of  CE 3.4, CE3.5
formation is required for us to
determine the screen coverage to
ensure good sand control is
established.
 My willingness to learn from  CE 1.5.2

others who are more  CE 3.5.1
experienced than me although
their paper qualifications may
PE3.5 Orderly management of self, and not be the same
professional conduct  Working on projects is not a  CE 1.5.2
one-man show therefore, I am  CE 3.5.1
open to listening to advice,
comments and feedback from
others
 For Baram BA41 Single Trip  CE 3.4, CE3.5

Multi Zone project, I engaged
engineers from Brunei who were
servicing Brunei Shell
PE3.6 Effective team membership and Petroleum for reports and case
histories of the system.  CE 3.4, CE3.5
team leadership
 Improvement to the current
system was also done by
consulting global advisors from
the United States by conducting
a conference call meeting.

Mechanical Engineer's Continuing Professional Development

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Mechanical Engineer's Continuing Professional Development

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Continuing Professional Development

Throughout my career as a mechanical engineer/project engineer over the past 4 years, I

1) Halliburton Completions 101 at Halliburton Training Centre, University

CAREER EPISODE 1 (CE1): 100 TONNE SUGAR SILO HOPPER SYSTEM

CE1.3 Personal Engineering Activity

CE1.4 Problem Statement

CE1.5 Engineering Application Demonstration

 Physical Size of the Silo

 Health, Safety, Environment (HSE)

CAREER EPISODE 2 (CE2): Completing Petronas Angsi A33 Work Over

CE2.3 Personal Engineering Activity

CE2.4 Scope of Responsibility

 Strategy of completion - to complete the well successfully and to achieve the

Figure 1: Short String Completion Schematic

Figure 2: Long String Completion Schematic

2814.540 0.960 COE to Top of Packer 4.000 8.120

Figure 3: Long String Completion Schematic (Continuation)

Reservoir Properties Annulus Long String Short String Interpolate

8.3 ppg NaCl Brine 1727 m

Note: Negative Pdiff Values indicate UNDERBALANCE condition.

Figure 5: Recommended Packer Setting Pressure

Operation Description Applied Tubing Recommended Recommended Test Pressure

Figure 6: Recommended Applied Test Pressure for TRSV

CE3.2 Personal Engineering Activity

CE3.5 Engineering Application Demonstration

CE3.5.2 Screen Coverage

No Part No DESCRIPTION I.D. O.D. LENGTH (ft) DEPTH (ft)

HANDLING PUP, NC38 5.577 7702.89

Figure 7: 7in STMZ Schematic

16.00 Top overlap

CE3.5.2.3 Screen Coverage Calculation for Zone Q6.5/Q7.0

15.60 Top overlap

CE3.5.3.1 VBA Packer Assembly

VBA MCS Seal Bore

CE3.5.3.2 Isolation Packer Assembly

Isolation Packer MCS

Bevel Snap Latch Sump Packer

Figure 10: Snap Latch and Sump Packer

CE3.5.4 Service tool Setup and Positions

 Upper Service Tool

CE3.5.4.1 Upper Service Tool & VBA Packer

Figure 11: Upper Service Tool

Figure 12: VBA Packer

CE3.5.4.2 Lower Service Tool

Crossover Port Seal Assembly Return Port Ball Check Valve

Figure 13: Lower Service Tool

CE3.5.4.3 Shifter and Locator

Locating Profile Shifting Profile

Figure 15: Locator Collet Figure 16: Shifting Collet

Ported Mandrel Weeping Ball Seal Mandrel

Figure 17: Lower Isolation Seal

CE3.4.5 Packer Pinning Table and Hang Weight

Item OD (in) ID (in) Length (ft) Weight (lbs)

VBA PKR,7,26-29,3.880 6.02 3.88 6.62 373.13

Figure 18: Total Assembly Weight

GRAVEL PACK DOWNHOLE TOOL PINNING SHEET (7" STMZ)

Gravel Pack Tool Data - SVCE TL,UPR,STMZ,3.88 X 3.25,API-NC38 X; 12OO3312

Shear Value for Specific Pin Type

Figure 19: Packer Pinning Table and Metallurgical Temperature Factors

Paragraph in the career

 Systematic approach and design  CE 1.5

 Calculating pressure required to  CE 2.4.5. Figure 5