Session2 Production Packers PDF

Completions and Sand Control Systems
Production Packers
Course No.: CHC-11102
Completions & Sand Control Training Manual - The Complete Packers Course
© 2010 Weatherford. All rights reserved. Doc.Rev:00

Table of Contents
Table of Contents ...................................................................................................... 2
Session Objectives .................................................................................................... 2
2.0 Introduction ........................................................................................................ 3
2.1 Four Typical Modes of Operation ...................................................................... 4
2.2 Packer classification and comparison ............................................................... 5
2.3 Packer tubing interface and landing condition ................................................... 8
2.3.1 Unlimited or Free ............................................................................................ 8
2.3.2 Limited Motion ................................................................................................ 8
2.3.3 Latched or Fixed ............................................................................................. 8
2.4 Typical Operation of Permanent Production Packers ........................................ 9
2.4.1 Wireline ...........................................................................................................9
2.4.2 Three types of Retrievable Packers most often used .................................... 10
2.4.3 Setting and Retrievable Method ..................................................................... 13
2.4.4 Spare Parts and Technical Reference Material .............................................. 13
2.4.5 Regulatory Limits ............................................................................................ 13
2.5 Packer Operational Tips .................................................................................... 14
© 2010 Weatherford. All rights reserved. Doc.Rev:00

2.0 Introduction
Packers are separated into three main classifications.
? Retrievable
? Permanent – Drillable
? Permanent – Retrievable.
All of these may be found both in the service and production functions.
Service packers are capitalized by the service company over an average life of approximately
seven years. These service tools perform multiple operations on a daily basis, although in some
instances they may be secured by the operator on “extended rental” (such as after the well is
swabbed and on production). Production packers are sellable.
Production
Packers
Retrievable Permanent
Mechanical Hydraulic Wireline

Set Set Set
Hookwall Pressure Activated Electric Line

(Drag blocks, (Setting Cylinder, (Charge, Wireline adaptor kit,
Slips & Cone) Slips & Cone, Body lock ring) slips and cone, body lock ring)
Isolation
(weight set,
elements only)
Figure 1 – Packer Classification
© 2010 Weatherford. All rights reserved. Doc.Rev:00 Page 3

2.1 Four Typical Modes of Operation
There are four typical modes of operation that any given well might
undergo:
? Shut-in
? Production
? Injection
? Treating
Production packers must be so selected as to accommodate these

modes and differential changes throughout the well's life.
The usual approach in selecting the production packer is to base it

on its production mode; that is the flow rate and corresponding
pressure drop and access requirements for thru-tubing tools.
Subsequent operations, their pressures and temperatures, are

likely to be extremely important in the selection process.
Production packers attain one or more of the following objectives.

When they are properly employed.
1) Isolate well fluids and pressures.

2) Keep gas mixed with liquids, utilizing gas energy for natural
flow.
3) Separate producing zones, preventing fluid and pressure
communication.
4) Aid in forming the annular volume (casing, tubing packer)
required for gas lift of subsurface hydraulic pumping systems.
5) Limit well control to the tubing at the surface, for safety
purposes.
Figure 2 – Seal Bore Packers


2.2 Packer Classification and Comparison
There are very many different packers on the market. There are many
manufacturers, some of whom offer an extensive variety of packers, with
each differing in some degree from those of the other manufacturers.
This rather bewildering array can, however, be grouped into principal

classes or types, and may be further categorized by method of setting,
by direction of pressure across the packer, and by the number of bores
through the packer.
Packers can be classified as:

a) Retrievable
b) Permanent
c) Permanent – retrievable
d) Inflatable
i) single string
ii) dual string
iii) triple string

We may classify Retrievable Packer Types into eight groups based on
their setting and retrieval method. (Type I to VIII)

We may classify Retrievable Packer Types into eight groups based on
their setting and retrieval method. (Type I to VIII)

2.3 Packer Tubing Interface And Landing Condition
Production packers are connected to the production tubing in one of three methods:
2.3.1 Unlimited or Free

The tubing movement in unrestricted by design of sufficient length seal bore extensions (SBE)
under the packer, or by a PBR (Packer Bore Receptacle) or Overshot Seal Assembly above the
packer. The tubing's seal nipple assembly is strung into the seal bore and allowing free vertical
travel (permanent or permanent/retrievable and double grip packers permit this type of
completion.)
2.3.2 Limited Motion

To aid space out of seal assemblies, a Location Shoulder is often used so that the unit will bottom-
out on the packer or receptacle. This provides the option of landing the tubing such that the seals
will not move during normal production operations but are free to move up if the well is cooled.
Instead of tubing movement, heating will carry increased packer force and tubing buckling.
2.3.3 Latched or Fixed

The tubing is latched or fixed on the packer allowing no movement (retrievable production packer,
anchor seal assemblies are of this type.) Any change in production conditions results in a change
in the tubing axial loading (tension or compression) and packer force. Cool down can be critical if
the packer has a tension or shear pin release mechanism or if the upper tubing joints are heavily
loaded.
1. Free Motion 2. Limited Motion 3. No Motion

Packer tubing seal can Tubing seal can move Tubing seasl cannot
move freely up or down freely upwards only move
Figure 5 – Packer Landing Conditions

2.4 Typical Operation of Permanent Production Packers
2.4.1 Wireline
The permanent production packer (and expandable plug) is run to the desired setting depth and
set with the appropriate size wireline pressure setting assembly PSA and adapter kit. The
maximum pressure differential across the packer may occur while the plug is in place. Once the
packer is set the pressure setting assembly is retrieved, the tubing, seal assemblies, and
production tube are lowered into the well.
The expendable plug is normally pushed out with approximately 4000 to 5,000 Ibs. set down
weight. If possible the well should be circulated as the production tube is lowered in order to
minimize the possibility of debris that might make it necessary to apply excessive set-downweight
or spudding to push the plug from the packer (an option for stuck plugs is to knock the plug free on
sandline with a sinker bar – assuming pressure differential is from the top of the plug).
A wireline adapter kit is used in conjunction with the “pressure setting assembly” (PSA). An
electrical impulse triggers an explosion within the pressure setting tool's piston chamber to propel
the piston and outer sleeve against the top slips; thus setting the packer. Bottom slips are set
automatically with an upward strain to a specified valve.
These adapter kits are for a specific casing weight and “pressure setting assembly” (PSA) size.
Check that the recommended explosive charge is used. For packers with tailpipes use Slow Set
(437-66-2100) charge in the Baker setting tool. The standard charge (437-64-2113) is only suitable
for the smaller packers and bridge plugs that have no tailpipe. Do not use 437-66-2000 or 437-64-
2013!
Do not set running tool back onto packer or plug to confirm setting as it is possible to get stuck
and/or to knot the cable. Loss of tension will confirm packer setting, if not at once, at least during
the pulling.
IMPORTANT POINT!!
Remember that in order for the PSA to function properly, it must be
filled with hydraulic oil to the proper level. Look in the service hand's
tech manual for the correct cubic centimeter (cc) of hydraulic oil, and
use a beaker to measure the correct amount. Too much oil will blow
out the PSA's seals. Too little oil will cause a lack of driving energy.
Also, the o-ring on the PSA's bleeder valve should be changed after
every trip. A leak can result in premature ignition due to well
hydrostatic pressure invading the tool. Also, make sure you see the

2.4.2 Three Types of Retrievable Packers most often used
1) Hook Wall/Mechanical (See Fig.6 ) (ARROWSET 1-X)

This packer is actuated by tubing rotation and/or pulling/pushing. It is available
in weight set or tension models. A feature worthy of consideration when
selecting a compression set retrievable production packer intended for future
well stimulation, is the incorporation of a hydraulic hold-down. This “sub”
incorporates hydraulic piston slips actuated by tubing pressure (same as on
the retrievable squeeze packer service tools). When tubing pressure is
elevated, the piston slips “anchor” into the casing or when formation pressure
is higher than annulus pressure. This enables the tool to stay “planted” during
high treating pressure and to keep it from pumping itself up the hole. Another
worthy feature is an equalizing valve to equalize differential pressure across
the packer prior to retrieval.
Mechanical set permanent production packers have drag blocks which allow
torque to be transmitted to the packer for setting. The seal assembly is made
up to the tubing then to the packer (the square threads in the packer allow for
proper torque make up of the seal assembly into the packer bore). The packer
is then run to depth using the normal precautions for running a packer on
tubing. Rotation of the tubing string at the tool , followed be lowering of the
tubing sets the lower slips. Continued slack off of string weight will compress
and pack off the elements. An upward strain is then initiated at the tool to set
the upper slips and further pack-off the elements. (typically 20,000 Ib., for 4-
1/2" through 7-5/8" tools; 30,000 Ib. For 8-5/8" and larger). Once the packer
has been set the seal assembly is retrieved from the well and replaced by a
locator seal assembly (with appropriate accessories) and the well is placed on
production.
2) Isolation
Isolation packers are more commonly found as a top packer in a dual zone
single string completion. They do not typically have slips to anchor themselves
to the casing but rely on strictly weight for a pack-off. Old perforations can be
“isolated” in this manner, with the isolation packer on top of the perforations
and a hookwall packer below them.
3) Hydraulic
The hydraulic retrievable production packer (See Fig.7 )(Hydrow 1) has found
large successes in deviated wells and multizone completions where
conventional mechanical set and wireline set production packers are limited.
An additional attribute lies in its ability to be set after the surface tree is
“buttoned-up” and well control is made.
Figure 6 – Hookwall / Mechanical Packer


NOTE: Special one trip hydraulically set completion packers are used in many
deviated wells. The “hydro-set” packer is made up to a special designed seal
assembly and secured to the production tubing. Once the tool is “on depth” a
setting ball is dropped into the production tubing allowing it to free fall and
seat in the packers ball seat. Special one piece molded seal assemblies are
available in lieu of the chevron type to maximize retrievability in heavy
weighted muds (11 Ib. gal and higher).
NOTE: As can be seen from this can take a considerable time. The proper ball
density must be considered when calculating a time in various fluid densities.
The ball may also be pumped to seating depth to reduce waiting time.
Pressure is applied to the tubing and held for a specified time to allow the
packer to compress and set.
NOTE: The required setting pressure could in certain packer sizes exceed the
rig's pump pressure ratings. After the packer is set, a further elevation in tubing
pressure will shear loose the ball seat allowing it to be blown to bottom.
Permanent Drillable Packers - permanent packers are sometimes referred to
as drillable, however, more often than not, removal necessitates extensive
milling operations.
Figure 7 – Hydraulic Retrievable Packer


Approx. Time
to allow Bronze
ball to freefall
on seat (minutes)
0
Depth to Pump
Out Seat (feet)
50
20,000
19,000
100 18,000
17,000
Density of Fluid 16,000
in Tubing (lbs/gal.)
150 8 15,000
9
10 14,000
11
12 13,000
13
200 14 12,000
15
16
11,000
10,000
250
9,000
8,000
7,000
300
Example: 6,000
1. Depth to Pump Out Seat 6,000ft 5,000
2. 8lbs/gal. Fluid in the tubing
350 3. Allow 60min for ball to fall 4,000
3,000
2,000
400 1,000
Figure 8 – Ball Dropping Nomograph

2.4.3 Setting and Retrievable Method
1) Mechanical -Drillpipe/Tubing
2) Wireline - Conductor/Slickline
3) Hydraulic - Well Hydrostatic/Surface Pumps.
2.4.4 Spare Parts and Technical Reference Material

Have critical parts been addressed and spares ordered? Do you have a technical data sheet on
each tool including part number, redress parts, etc.?
2.4.5 Regulatory Limits

Are the tools intended for operation in a “regulated area”, such as outer continental shelf, requiring
special certification or other regulatory compliance?
2.4.6 Technical Specifications

?Have all constraints been properly addressed; such as, tool / components?
? Tensile Strength
? Collapse Strength
? Burst Strength
? Corrosion/Abrasion
? Length Changes
? Forces

2.5 Packer Operational Tips
1) Be certain tool is working properly before running downhole. Make sure of all string
connections and crossovers.
2) If tool to be set is a hydraulic type requiring a ball seal, make sure ball will pass through
setting tools, pipe and seat properly in packer prior to going in hole. i.e. drift pipe and all
components.
3) Be certain you have the correct size tool on location for the intended casing size and
weight range. Check tech manual for slip travel, gage ring clearances, etc.
4) Check ID for passage of standard wireline equipment.
5) On all offshore tool jobs, bring a second tool for back up. Also, bring extra packing
elements of correct durometer (hardness), spare o-rings; any seal that could potentially
result in downtime due to failure.
6) If heavy muds are present, be cautious about barite settling out on top of packer.
7) Never tong on tool surfaces only at proper locations when making up string.
8) Check drag block compression prior to lowering retrievable tools through BOPs. Block
must collapse sufficiently to pass BOPs and gauge joint. Check tool's gauge and guide
ring ODs and rubber element ODs.
9) Always discuss tool operation with driller and rig crew prior to job initiation.
10) Always be on location (on rig floor if possible) during entire job with his tech manual readily
accessible.
11) Draw a sketch of the wellbore and complete string of tools to be run in well prior to start of
job. Use a tally book, notebook, etc., and log in ODs, IDs, type tools, location by depth,
etc. (It is important to show all DV tools, doglegs, liner tops, old packer intervals and
perforation locations as these are potential trouble areas.
12) Inspect all tools as soon as they arrive on location and make sure they meet the required
specifications.
13) Insist on redress metal and rubber kits with each tool brought on location. This can ensure
against considerable downtime; especially offshore.
14) Perform all hydraulic and force load calculations and go over each phase with company
man prior to job.
15) Always use sufficient backup (tongs) when making connections. This may prevent any
mechanical set permanent tool prematurely setting.
16) On mechanical set tools, mark pipe and use this as an indication (and check) against
slack-off calculations necessary to transfer weight to the tool.
17) Make sure of rig's weight indicator calibration. Check against known string weight. You
may ask the tool pusher for certification of recent calibration.
18) After setting any permanent tool on wireline, never put more pipe weight on the tool (i.e.,
slack-off) than the strength of the tension sleeve used to set the tool originally. Consult
with the tech manual.
19) When tubing is run in cold, particularly in deep wells and landed with too much weight on
the packer, expansion from the temperature increase could buckle the tubing.
20) In setting set-down (compression) tools in shallow application, be aware of potential
leakages due to a lack of sufficient force at the tool especially during treatment (pressure)
operations. Use a tension type tool instead. Consult tech manuals for depth limitations and
recommendations.

2.5 Packer Operational Tips
21) If you have a tension release tool, you should be very careful not to exceed the minimum
yield of the tubing during pulling operations.
22) If you have a locator seal assembly in a permanent packer, be very cautious to allow
sufficient seals on bottom to counter any tubing contraction during treatments.
23) Anytime that the top of the tubing is flanged up or is not free to move. you can usually
disregard the effects of pressure pushing up on the inside area of the tubing. Be very
cautious of jobs where the pipe is free to move, thus, having the potential to unload the
packer.
24) When using any tool with top hydraulic hold-downs, always pressure the annulus to help
retract the hold-downs prior to releasing the tool for retrieval. This safeguards against
dragging hold-downs up the casing and catching a collar.
25) When retrieving a packer with hydraulic hold-downs, the pressure across these pistons
(differential) must be favoring the annulus casing side or be zero. Any positive tubing
pressure above annulus hydrostatic can cause the buttons to not release (move back
inside the tool) or drag coming out of the hole. Always pressure the annulus slightly to
push the hold-down button in (retract them).
26) When swabbing through tension retrievable tools, always calculate exactly how much fluid
you can effectively remove before the tool will “transfer” (i.e., move down the hole).
27) When setting tools in hard high strength casing, ensure that the tool's slips are sufficiently
harder (i.e., Rockwell Re) than the pipe. Consult tech manuals, pipe data books and
engineering if needed.
28) Permanent packers are designed mainly for electric line running but can be run on tubing.
When using these tools on hydraulic setting tools, be cautious in running the packers too
fast, swabbing effect can prematurely set tools by shearing pins and allowing packing
elements to “cup”. Shear pin values can be specified if required for special conditions
(such as highly deviated wells, etc.); consult with tech manuals.
29) With compression squeeze tools, you have to get a certain amount of weight on the tool.
We know that hole angle and buckling of the tubing are going to work against us;
therefore, we must know exactly how much slack-off (in inches at the rotary) we need to
transfer the pipe weight. This can be readily done and compared to the rig's weight
indicator. Consult charts for casing/tubing configurations.

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Completions and Sand Control Systems

Course No.: CHC-11102

© 2010 Weatherford. All rights reserved. Doc.Rev:00

© 2010 Weatherford. All rights reserved. Doc.Rev:00

Mechanical Hydraulic Wireline

Hookwall Pressure Activated Electric Line

© 2010 Weatherford. All rights reserved. Doc.Rev:00 Page 3

Production packers must be so selected as to accommodate these

The usual approach in selecting the production packer is to base it

Subsequent operations, their pressures and temperatures, are

Production packers attain one or more of the following objectives.

1) Isolate well fluids and pressures.

Figure 2 – Seal Bore Packers

© 2010 Weatherford. All rights reserved. Doc.Rev:00 Page 4

This rather bewildering array can, however, be grouped into principal

Packers can be classified as:

© 2010 Weatherford. All rights reserved. Doc.Rev:00 Page 5

© 2010 Weatherford. All rights reserved. Doc.Rev:00 Page 6

© 2010 Weatherford. All rights reserved. Doc.Rev:00 Page 7

2.3.1 Unlimited or Free

2.3.2 Limited Motion

2.3.3 Latched or Fixed

1. Free Motion 2. Limited Motion 3. No Motion

© 2010 Weatherford. All rights reserved. Doc.Rev:00 Page 7

© 2010 Weatherford. All rights reserved. Doc.Rev:00 Page 7

1) Hook Wall/Mechanical (See Fig.6 ) (ARROWSET 1-X)

Figure 6 – Hookwall / Mechanical Packer

© 2010 Weatherford. All rights reserved. Doc.Rev:00 Page 7

Figure 7 – Hydraulic Retrievable Packer

© 2010 Weatherford. All rights reserved. Doc.Rev:00 Page 11

© 2010 Weatherford. All rights reserved. Doc.Rev:00 Page 12

2.4.4 Spare Parts and Technical Reference Material

2.4.5 Regulatory Limits

2.4.6 Technical Specifications

© 2010 Weatherford. All rights reserved. Doc.Rev:00 Page 13

© 2010 Weatherford. All rights reserved. Doc.Rev:00 Page 14

© 2010 Weatherford. All rights reserved. Doc.Rev:00 Page 15

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