Comprehensive Recompletion Design for Sour Gas Well X: Production Performance, Corrosion Damage Prediction, and Tubing Stress Analysis BACHELOR THESIS Ida Ayu Laksmi Kusuma Wardhani 12219048 Submitted as partial fulfillment of the requirements for the degree of BACHELOR OF ENGINEERING in Petroleum Engineering study program PETROLEUM ENGINEERING STUDY PROGRAM FACULTY OF MINING AND PETROLEUM ENGINEERING INSTITUT TEKNOLOGI BANDUNG 2023 COMPREHENSIVE RECOMPLETION DESIGN FOR SOUR GAS WELL X: PRODUCTION PERFORMANCE, CORRO SION DAMAGE PREDICTION, AND TUBING STRESS ANALYSIS BACHELOR THESIS Ida Ayu Laksmi Kusuma Wardhani 12219048 Submitted as partial fulfillment of the requirements for the degree of BACHELOR OF ENGINEERING in Petroleum Engineering study program Approved by: Thesis Adviser, Ardhi Hakim Lumban Gaol, S.T., M.T NIP 198706302012121001 Wijoyo Niti Daton, S.T., M.T. NIP 198209272015041001 1 Comprehensive Recompletion Design for Sour Gas Well X: Production Performance, Corrosion Damage Prediction, and Tubing Stress Analysis Ida Ayu Laksmi Kusuma Wardhani*, Ardhi Hakim Lumban Gaol, S.T., M.T., M.Si., and Wijoyo Niti Daton, S.T., M.T.** Copyright 2023, Institut Teknologi Bandung Abstract Corrosion poses a significant and costly challenge with an estimated $1,372 billion has been attributed to this damage in the US oil and gas industry. This study addresses hostile corrosion issues, notably in gas well completion design, by estimating the production system performance, predicting erosion-corrosion damage, perform tubing stress analysis, and proposing a new recompletion plan based on the results. The case study revolves around an existing well “X” located in Central Java Region, penetrating Kujung formation where three DSTs were performed indicating the substantial presence of H 2S and CO2 as sour gas. The completion plan incorporates a cased hole perforation, optimal tubing selection, and consideration of alloy materials for the required sour service equipment. Based on the available field data from DST findings, bottomhole pressure surveys, and the existing conceptual well design, the basic aim is to convert this well to be completed prior to put on production. This study also emphasizes the significance of material selection for every OCTG where CRA is recommended to be utilized in this application. In consequent, a maximum corrosion rate of 15.04 mm/yr with no erosion damage show that Nickel Alloy SM253 and SM2242 (3% Mo) are the most suitable materials for this case. The chosen materials can be associated with the tubing weight and grade selection followed by a comprehensive tubing stress analysis resulting a safe, dependable, and effective tubing design for this abrasive operation. Keywords: corrosion, sour gas, completion, material selection, tubing stress analysis Sari Korosi dikenal sebagai sebuah tantangan yang signifikan dan membutuhkan biaya tinggi, dengan perkiraan biaya sekitar $1.372 miliar di industri minyak dan gas AS. Studi ini akan membahas masalah korosi dalam desain penyelesaian sumur gas dengan memperkirakan kinerja sistem produksi, memprediksi kerusakan erosi- korosi, melakukan analisis tegangan tubing, dan mengusulkan rencana penyelesaian baru berdasarkan hasil penelitian tersebut. Studi kasus dilakukan pada sumur “X” yang terletak pada Wilayah Jawa Tengah, menembus formasi Kujung dimana sejumlah tiga tes DST telah dilakukan dan menunjukkan konsentrasi tinggi dari H 2S dan CO2 sebagai gas asam. Rencana penyelesaian sumur menggabungkan perforasi lubang yang telah dipasang casing, pemilihan tubing produksi yang optimal, dan pertimbangan bahan paduan untuk peralatan kegiatan yang erat hubungannya dengan gas asam. Berdasarkan data lapangan yang tersedia dari hasil DST, survei tekanan lubang dasar, dan desain sumur konseptual yang ada, rencana dasar dari studi ini adalah mengubah sumur “X” untuk dapat dipersiapkan sebelum diproduksi. Studi ini juga menekankan pentingnya pemilihan material untuk setiap OCTG dimana CRA direkomendasikan untuk digunakan dalam aplikasi ini.