WELL COMPLETION

WELL COMPLETION

Introduction - generalities

Well completion:

It covers the process and equipment (down-hole &

surface) allowing to produce the well after it has
been drilled.

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Completion F.J.P.B
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 WELL COMPLETION

Introduction - generalities
Objectives of the well completion

to ensure …
- a good and “Safe” link between the reservoir and the surface
- an optimal production, using specific equipment
- safety in case of incident, in the well or at surface.

and,
- to produce selectively several reservoirs,
- to isolate layers producing substantial water or gas,
- to control sand production from unconsolidated formations .

New technologies …Furthermore, completions have evolved to incorporate down-hole

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sensors that measure flow properties, such as rate, pressure and gas-to-oil ratio.
Known as intelligent wells or smart wells, these completions help to achieve optimum
production rates.
Completion F.J.P.B
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 WELL COMPLETION

Oil storage tanks

Surface treatment facilities

X-Mas tree Flow lines Flare. (obsolete)

Well

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Reservoir

Completion F.J.P.B
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 WELL COMPLETION

Introduction - generalities

Production wellhead
Christmas Tree section

Tubing spool – tubing

Drilling wellhead section hanger

Drilling wellhead
Drilling wellheadsection
Drilling wellhead section
Drilling wellhead section

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Completion F.J.P.B
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 WELL COMPLETION

Introduction - generalities
 Well completion will include :
• The design of the « liaison reservoir – bore hole” ,
• The design of the tubing (and therefore the design of the production casing),
• The design and installation of the tubing spool+hanger and of the christmas-tree,

But also …
• The design of the safety equipment to close the well normally or in case of an
emergency.
• The design and installation of all auxiliary equipment for the full control the well
production.
All these equipment must provide the necessary safety barriers to produce the well
safely.

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• (If necessary , the equipment necessary to lift the produced fluids).
Completion F.J.P.B
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 WELL COMPLETION

« Liaison reservoir – bore hole »

7
 WELL COMPLETION

« Liaison reservoir – bore hole »

Open hole completion

application: only with consolidated formation
advantages:
- better productivity
- savings on casing, cementation and perforations

Cased hole completion

advantages:
- to selectively produce several reservoirs,
- to isolate zones producing too much water or gas
but … requires perforations of casing/liner

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requires pre-perforated or slotted casing/liner

Completion F.J.P.B
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 COMMUNICATION RESERVOIR – WELL-BORE

This type of completion does not allow to produce a reservoir with several type fluids; no selective capability.
The formation (reservoir formation) must be stable during production.

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 COMMUNICATION RESERVOIR – WELL-BORE

Examples : Cemented casing or liner

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This type of completion allows selective production of fluids.

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WELL COMPLETION

Types of completion

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 WELL COMPLETION

X-MAS TREE Most simple form of a completion.

Either the well effluent is produced through the tubing.
TUBING HANGER
or/and the casing.
CASING VALVE

Drawback: when the well effluent is aggressive,(H2S, CO2 etc..)

it will attack the casing, which is difficult to replace.
EFFLUENT

Completions like this you’ll find in SA, some wells produce

TUBING
14 000 BOPD

RESERVOIR

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PERFORATIONS

Tubing without packer

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 WELL COMPLETION

Simple completion where the packer

X-MAS TREE
isolates the well effluent from the
casing.
TUBING HANGER
In general the completion or packer
CASING VALVE
Fluid is a “brine” (salt water) with
chemicals.
The function of the completion fluid is:
Create a hydrostatic pressure on the
EFFLUENT

packer to give a counter force on the

COMPLETION FLUID
reservoir pressure in order to balance
TUBING
the packer forces.

Hyd Pr completion fluid

PACKER

Reservoir pressure

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RESERVOIR

PERFORATIONS

Completion F.J.P.B Tubing with packer

13
 WELL COMPLETION

BRINE
A water-based solution of inorganic salts used
as a well-control fluid during the completion
and wor-kover phases of well operations.
Brines are solids free, containing no particles
that might plug or damage a producing
formation. In addition, the salts in brine can
inhibit undesirable formation reactions such
as clay swelling. Brines are typically
formulated and prepared for specific
conditions, with a range of salts available to
achieve densities ranging from 8.4 to over 20
lbs/gal (ppg) [1.0 to 2.4 g/cm3]. Common salts
used in the preparation of simple brine
systems include sodium chloride, calcium
chloride and potassium chloride. More

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complex brine systems may contain zinc,
bromide or iodine salts. These brines are
generally corrosive and costly.
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 WELL COMPLETION

Tubing hanger
Single completion
1 reservoir layer to produce

Tubing

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Perforations

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 WELL COMPLETION

Dual completion
2 reservoirs to produce

The x-mas tree consist out of 2x2 master

valves.

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Completion F.J.P.B
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 WELL COMPLETION

TUBING
TUBING
1 LATCH PROFILE

CASING

SEAL
2
SLEEVE SLOTTED PORTS

1
CASING

TUBING TUBING
2

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SSD CLOSED SSD OPEN
3 SSD Sliding Side Door
Completion F.J.P.B MULTIPLE ZONE COMPLETION (selective completion)
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 WELL COMPLETION

In a multiple zone completion we can produce:

 Produce only zone 1
SSD 1 closed
SSD 2 open
SSD 3 closed
Bottom of the tubing a plug is installed
 Produce only zone 2
SSD 1 closed
SSD 3 open
SSD 2 closed
Bottom of the tubing a plug is installed
 Produce only zone 3
SSD 1 closed
SSD 2 closed
SSD 2 closed

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Plug is removed from bottom of the tubing

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 WELL COMPLETION

9 5/8” casing

Tubing 6 ½” to surface

Liner hanger

Polished bore receptacle

Liner 7”

Perforations

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MONO-BORE COMPLETION
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 WELL COMPLETION

MONO-BORE COMPLETIONS

In highly prolific reservoirs, tubing of 6 ½” and larger diameters is required to meet

cost-effective production and injection objectives.
The use of big mono-bore completion techniques can increase production rates
significantly while decreasing both capital and operating expenses.
The advantages of the big mono-bore completion systems include the elimination of
gas-turbulence areas and restrictions on production.
This can translate to fewer wells required for optimized reservoir production, resulting
in a faster return on initial investments and lower long-term operating expense.

 MONO-BORE COMPLETIONS ARE MAINLY USED IN THE “DEEP” OFF-SHORE

 FEWER WELLS, MORE PRODUCTION PER WELL
 WELL INTERVENTION ALLMOST NOT POSSIBLE
 MONO-BORE COMPLETIONS ARE FITTED WITH PRESSURE AND TEMPERATURE

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TRANSMITTERS

Completion F.J.P.B
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 WELL COMPLETION

MONO-BORE COMPLETIONS

Mono-bore completions are basically liner-top completion systems.

The key is the large inside diameter (ID) tubing that allows increased production
rates and provides full-bore access to the production liner.
Full-bore access gives the operator the ability to run conventional tools through the
tubing to perform remedial work in the production liner without disturbing the
completion or pulling the production tubing.
There are many styles of mono-bore completions from which to choose.
The selection of the type system that is used depends largely on the pressure
integrity, and the pressure capability, of the liner top and intermediate casing string.

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Completion F.J.P.B
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 WELL COMPLETION

MONO-BORE COMPLETIONS

In the most basic mono-bore-completion design , the production liner is run and
cemented in the hole.
At the top of the liner hanger is a polished bore receptacle (PBR) to accept a seal
assembly.
The production tubing that is used has basically the same ID as the liner.
When the completion is run, a seal assembly is run on the bottom of the
production tubing and landed in the PBR.
The seal assembly and liner top provide the annular barrier for the tubing string.
The constraints of this system are:
 The ID of the polished bore receptacle can become damaged during liner
cleanout trips and fail to seal.
 The ability of the liner top to hold pressure is totally dependent on the quality

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of the cement job.
• Remedial work to the liner may be required before running the completion.

Completion F.J.P.B
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 WELL COMPLETION

ADVANCED MONO-BORE COMPLETION

A more reliable mono-bore system will use a packer above the liner top.
In this system, the liner is run and cemented as before.
When the completion is run, a large-bore hydraulic-set permanent packer is
installed.
The packer will have a PBR (Polished Bore Receptacle) located above it, with the
tubing seals run in place.
There is also a seal assembly on the tailpipe below the packer, which is stabbed into
the liner top. The packer provides a more positive annular barrier, and a new PBR
has been installed.

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Completion F.J.P.B
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 WELL COMPLETION

9 5/8” casing
6 ½” tubing

Polished bore receptacle

9 5/8” packer

Liner hanger
Polished bore receptacle
7” Liner

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ADVANCED MONO-BORE COMPLETION

Completion F.J.P.B
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COMPLETION EQUIPMENT
 WELL COMPLETION

THE MAIN ELEMENTS OF A COMPLETION

1) X-Mas tree c/w Tubing hanger

2) Tubing: the flow path for the well effluents to the x-mas tree

3) Packer: isolates the tubing from the annulus

4) Various seats and safety equipment

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Completion F.J.P.B
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 WELL COMPLETION

A BASIC SINGLE STRING COMPLETION

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Completion F.J.P.B
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 WELL COMPLETION

A SINGLE STRING COMPLETION IN TANZANIA SONGO SONGO 10 (GAS WELL)

1 1- Control line for TRSCSSSV
2 2- Flow-coupling
3
3- TRSCSSSV
4- Tubing 5”
5- Baker nipple AR bottom no-go 4,125”
4
6- Baker SB packer
7- Liner 7”
8- Baker nipple AF top no-go 3,125”
9- Perforated joint
10- Baker AR nipple bottom no-go 3,125”
11- SXAR wire-line entry guide
5
6
7
8

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9
10

11
Completion F.J.P.B
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CHRISMAS TREES
 CHRISMAS TREES

THE “CHRISTMAS TREE” IS FITTED ONTO THE “WELLHEAD”

IT CONSIST OUT OF A SERIES OF VALVES FITTED ONTO A CROSS BY FLANGES.
CHRISTMAS TREES ARE RATED TO THEIR WORKING PRESSURE, AND INTERNAL
DIAMETER.
THE VALVES ARE NORMALLY “GATE” VALVES
VERY OFTEN, A CHOKE IS FITTED ONTO THE OUTLET OF THE TREE.
FROM THE CHRISTMAS TREE THE WELL EFFLUENT IS ROUTED TO THE PROCESS
FACILITIES.

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Completion F.J.P.B
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 CHRISMAS TREES

Christmas tree

Control line for SCSSV

Pressure test port
Lock-down screw (or tie down screw)

Tubing hanger

Lateral outlet to control

the annulus

Tubing

Tubing head spool

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Casing

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 CHRISMAS TREES

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Completion F.J.P.B
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 CHRISMAS TREES

X-MAS TREE TYPES

 HORIZONTAL TREES
 CONVENTIONNAL VERTICAL TREES
 DUAL COMPLETION TREES
 SOLID BLOCK TREES

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Completion F.J.P.B
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 CHRISMAS TREES

CHRISMAS TREE DESIGN

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 CHRISMAS TREES

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 CHRISMAS TREES

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 CHRISMAS TREES

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 CHRISMAS TREES

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 CHRISMAS TREES

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 CHRISMAS TREES

“Y” DESIGN CHRISMAS TREE

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 CHRISMAS TREES

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“Y” Design Chrismas tree
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 CHRISMAS TREES

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Completion F.J.P.B
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 CHRISMAS TREES

GATE VALVE

 Used on x-mas trees

 WP:3 000 – 5 000 – 10 000 Psig
 ID ; depends on the tubing size
 Sour Service
 API Flanged
 Can hold pressure both sides
Seat

API Flange

Gate

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Completion F.J.P.B
 CHRISMAS TREES

ADJUSTABLE CHOKE
SEAT
TIP
WP: 10 000 Psig
Size: 3”
Tungsten seat and tip
OUT Choke size 2½”

In

Never have the choke closed completely

with pressure behind it.
Impossible to open it.

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Completion F.J.P.B
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 CHRISMAS TREES

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Completion F.J.P.B
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TUBING
 TUBING

TUBING

EIGHT TUBING DESIGN FACTORS

Tension-It must withstand its own weight in the running environment. Tubing must stand
additional loads when pulling out or setting packers and forces due to temperature and
pressure changes.
Burst-Tubing must maintain integrity with high internal pressure and little or no annular
Pressure support.
Collapse-Proper tubing must maintain integrity with high annulus pressure with little or
no internal pressure support.
Compression-The tubing must withstand compressive loads when setting some packers and in
high deviated wells or “dog legs”
Couplings-Should be free from leaks, maintain the ID clearance, strength through bend areas and
in compression and tension loads.
Corrosion-Tubing must designed to counter corrosion reactions with the following fluids over it’s
lifetime (ex:CO2, H2S, Acid, Cracking).

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Abrasion/Erosion-Equipment must withstand abrasion and erosion loads over lifetime.
Stimulation loads -Tubing must withstand loads from Acid, Fracturing or other stimulation

Completion F.J.P.B
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 TUBING

TYPES OF TUBING CONNECTIONS (thread)

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Hydril dopeless New VAM VAM TOP Hydril
Completion F.J.P.B
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 TUBING

VAM HWST premium thread

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Completion F.J.P.B
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 TUBING

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RTS6 Connection premium thread

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 TUBING

VAM TOP premium thread

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 TUBING

TUBING SPECIFICATIONS

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 TUBING

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 TUBING

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 TUBING

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 TUBING

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Completion F.J.P.B
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 TUBING

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Completion F.J.P.B
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 TUBING
Production tubing

aNominal
NominNominal
lNominal
Nominal Inside Drift Oil flow Gas flow rate NoNominal
mNominal
inal Nominal Inside Drift Oil flow Gas flow rate Inside
Inside Drift Oil flow Gas flow rate
(P == 15
15 MPa
MPa
tubing wetubing
igtubing
ht diameter rate (P= 15MPa tubingweight weight
weight diameter rate (P=15MPa diameter diameter rate (P
 2 20 psi) 2 20 psi)  2 200 psi)
2 200 psi)
ediameter
diamdiameter
tediameter
r diameter
(mm) (mm) (m3/d) (103 Sm3/d) (mm) (mm) (m3/d) (103 Sm3/d) (mm)
(mm) (mm)
(mm) (m3/d) (1033 Sm
Sm33/d)
/d)
(in) (lb/ft) ((in) in(in)
)(in)
(in) (b l/d) (106 cuft/d) (lb/ft)
(in) (lb/ft) (lb/ft)
(lb/ft) (in) (in) (b l/d) (106 cuft/d) (in)
(in) (in)
(in) (bbl/d) (1066 cuft/d)
cuft/d)
53/8"
0.7 48.3 150 150 50.7 48.3 150 150 50.7
50.7 48.3
48.3 150 150
2 3/8" 2224.6 3/8"3/8" 2 3/8" 4.64.64.6
1.945 1.901 90 5 1.945 1.901 90 5 1.945
1.945 1.901
1.901 900 5
5
67/8"
2 59.6 275 275 62 59.6 275 275 62
62 59.6
59.6 275 275
Nominal Nominal Inside Drift Oil flow Gas flow rate
tubing weight diameter (P = 15 MPa
rate

222 7/8" 6.4

 2 200 psi)

2 7/8" 6.4 7/8" 2 7/8" 6.46.4 6.4

diameter
(mm) (mm) (m3/d) (103 Sm3/d)
(in) (lb/ft) (in) (in) (bbl/d) (106 cuft/d)

2.4 1 2.347 1 70 10 2.4 1 2.347 1 70 10 2.441

2.441 2.347 1 700 10
2 3/8" 4.6 50.7 48.3 150 150
1.945 1.901 900 5
2 7/8" 6.4 62 59.6 275 275
2.441 2.347 1 700 10
3 1/2" 9.2 76 72.8 450 450

450 450
2.992 2.867 2 800 16

71/2"
6 72.8 450 450 76 72.8 450 450 76
76 72.8
88.3 85.1 700 700
4" 10.9
3.476 3.351 4 400 25

3 1/2" 3339.2 1/2"1/2" 3 1/2" 9.29.29.2

4 1/2" 12.6 100.5 97.4 1000 1000
3.958 3.833 6 300 35
124.3 121.1 1700 1700
5 1/2" 17

2.9 2 2.867 2 80 16 2.9 2 2.867 2 80 16 2.992

2.992 2.867
2.867 2 800 16
16
4.892 4.767 11 000 60
7" 29 157.1 153.9 3000 3000
6.184 6.059 19 000 105
220.5 216.5 7000 6000
9 5/8" 47
8.681 8.525 44 000 210

84"
.3 85.1 70 70 88.3
88.3 85.1
85.1 700 700
4" 10.9 4" 4" 10.9 8 .3 85.1 70 70
4" 10.9
10.9
10.9
3.476 3.351 4 40 25 3.476 3.351 4 40 25 3.476
3.476 3.351
3.351 4 400 25
25
101/2"
.5 97.4 10 0 10 0
1/2" 10 .5 97.4 10 0 10 0 100.5
100.5 97.4
97.4 1000 1000
4 1/2" 4414
2.6 1/2" 4 1/2" 12.6
12.6
12.6
3.958 3.83 6 30 35 3.958 3.83 6 30 35 3.958 3.833 6 300 35
121/2"
4.3 121.1 170 170 124.3 121.1 1700 1700
5 1/2" 5515
7 1/2" 1/2" 17 124.3 121.1 170 170
5 1/2" 17
17
17
4.892 4.767 1 0 0 60 4.892 4.767 1 0 0 60 4.892
4.892 4.767
4.767 11 000 60
60
157"
7.1 153.9 30 0 30 0 157.1
157.1 153.9
153.9 3000 3000
7" 29 7" 7" 7" 29 29 157.1 153.9 30 0 30 0
29
29
6.184 6.059 19 0 0 105 6.184 6.059 19 0 0 105 6.184
6.184 6.059
6.059 19 000 105
105
2 5/8"
0.5 216.5 70 0 60 0 220.5
220.5 216.5
216.5 7000 6000
99 5/8" 47 2 0.5 216.5 70 0 60 0

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9 5/8" 949
7 5/8" 5/8" 9 5/8" 47
47
8.681 8.525 4 0 0 210 8.681 8.525 4 0 0 210 8.681 8.525 44 000 210

CRITERIA a) OIL : Pfriction  0.25 MPa/1000 m (10 psi / 1000 ft) & velocity  2 m / s (6.5 ft / s)
b) GAS : Pfriction  1 MPa/1000 m (40 psi / 1000 ft) & velocity  10 m / s (33 ft /s)

Completion F.J.P.B
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 TUBING

 Completion string consist out of tubing lengths screwed together.

 Lengths are in general +/- 10 meter.
 To avoid thread galling, the thread has to be greased.
 Disadvantage of using grease is that a lot of grease will drop inside the tubing
and might fall on top of an installed plug, which makes it impossible to fish the
plug after packer setting. Excess of grease fallen in the well, might damage the
formation.
 In order to avoid the use of grease, new ways are found to “pre-grease” the
threads.
 We call this “dopeless”

© - IFP Training
Completion F.J.P.B
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 TUBING

GALLING WHILE SCREWING PIPE THREADS TOGETHER

Galling is a form of wear caused by adhesion between sliding surfaces.

When a material galls, some of it is pulled with the contacting surface, especially if
there is a large amount of force compressing the surfaces together.
Galling is caused by a combination of friction and adhesion between the surfaces,
followed by slipping and tearing of crystal structure beneath the surface.
This will generally leave some material stuck or even friction welded to the adjacent
surface, while the galled material may appear gouged with balled-up or torn lumps
of material stuck to its surface.
Once the “galling starts the parts are in a way welded together and almost
impossible to unscrew the two screwed parts.

© - IFP Training
Completion F.J.P.B
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 TUBING

 Dopeless® technology is a dry, multifunctional coating applied to TenarisHydril

premium connections for casing and tubing in the mill.
 The coating is applied in a fully automatic process, assuring that the exact
amount of the lubricant required by each connection is distributed in a
controlled and uniform way on its surface.
 The process is carried out on dedicated production lines at the mills and
manufacturing facilities.
 The main objective of the Dopeless® coating is to eliminate the thread
compounds used for casing & tubing, providing a “ready-to-use” product

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Completion F.J.P.B
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 TUBING

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PIN

Completion F.J.P.B
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 TUBING COMPLETION

BOX

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 TUBING

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 TUBING

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 TUBING

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 TUBING

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Over “Greasing”
Completion F.J.P.B
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 TUBING COMPLETION

Advantages of “dopeless” technology:

(According to the vendor)
 0% grease spillage (environment)
 Nearly “0” re-makes and rejects
 10% savings of total pipe cost
 Running time reduced by 25%

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Completion F.J.P.B
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 TUBING

TUBING MOVEMENTS / FORCES

due to
Pressure Changes
Temperature Changes

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 TUBING

 Tubing calculations depends on how the tubing is attached in/onto the packer.
(The tubing is fixed with the tubing hanger in the well-head, so no movement will occur)

 Two ways to attach the tubing in or to the packer:

 Tubing fixed onto the packer, which means no tubing movement in the packer. In this
case only forces on the packer or tubing hanger have to be calculated.
 Tubing can move in or around the packer with a seal bore and expansion joint
mechanism. In this case only tubing length changes have to be calculated

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Completion F.J.P.B
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 TUBING

There are four factors that tend to cause a change in the length or force in the tubing string:

 Temperature effect, which is directly influenced by a change in the average temperature of the string.
 Piston effect, caused by a change in the pressure in the tubing or annulus above the packer acting on a specific
area.
 Ballooning effect, caused by a change in average pressure inside or outside the tubing string.
 Buckling effect, which occurs when internal tubing pressure is higher than the annulus pressure.

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Tubing movements due to pressure and temperature changes
Completion F.J.P.B
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 TUBING

Tubing in a landed position.

X-MAS TREE
Able to move inside of the packer.
So everybody happy, but during the well’s life, the tubing
TUBING HANGER Is directly attacked by it’s enemies.
CASING VALVE Not only by corrosive effluents, but as well by pressures and
temperature changes.

EFFLUENT

TUBING

STINGER IN SEAL-BORE

PACKER

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RESERVOIR

PERFORATIONS

Completion F.J.P.B
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 TUBING

TEMPERATURE CHANGES:

 Temperature changes will occur when the well is put on

production.
Downhole temperatures are higher than the surface
temperature ,therefore the tubing will become longer
 Temperature changes will occur when the well is treated from
the surface. (acid job, frack, etc..) It cools down the surface
temperature and therefor the tubing will shorten.

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Completion F.J.P.B
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 TUBING

PRESSURE CHANGES

 Pressure changes may occur when the well is put on production.

 Annulus pressure increases due to the warm up of the completion fluid, when
the well is put on production.
 Annulus pressure increases during reverse circulation, pumping fluid into the
annulus from the surface.
 Tubing pressure increases when the packer is hydraulically set, by means of a
plug inside the tubing.

© - IFP Training
Completion F.J.P.B
74
 TUBING : PISTON EFFECT

 The length change or force induced by the piston effect is caused by pressure
changes inside the annulus and tubing at the packer, acting on different areas.
The length and force changes can be calculated as follows:

∆L1 ∆L1

ΔL1 = length change because of the piston effect,

Pr Annulus F1 = force change because of the piston effect,
Pr Annulus
L = tubing length,
E = modulus of elasticity (30,000,000 for steel),
As = cross-sectional area of the tubing wall,
Ap = area of the packer bore
Pr Tubing Pr Tubing
(values for common sizes can be found in table )
Ai = area of the tubing ID,
Ao = area of the tubing OD,
Δpi = change in tubing pressure at the packer
Δpo = change in annulus pressure at the packer.

© - IFP Training
Completion F.J.P.B
75
 PISTON EFFECT

© - IFP Training
Completion F.J.P.B
76
 TUBING CALCULATIONS

© - IFP Training
Completion F.J.P.B
77
 BUCKLING EFFECT

Tubing strings tend to buckle only when the

internal tubing pressure (pi) is greater than the
X-MAS TREE annulus pressure (po). The result is always a
shortening of the tubing string, but the actual force
TUBING HANGER
exerted is negligible. The decrease in length occurs
CASING VALVE
because of the tubing string being in a spiral shape
rather than straight. The tubing-length change is
calculated with the following:
ΔL2 = length change because of the buckling effect;
EFFLUENT r = radial clearance between tubing OD and casing ID,[(ID C – ODt)/2];
Ap = area of the packer bore;
TUBING Ai = area of the tubing ID;
Ao = area of the tubing OD;
STINGER IN SEAL-BORE
Δpi = change in tubing pressure at the packer;
PACKER Δpo = change in annulus pressure at the packer;
E = modulus of elasticity (30,000,000 for steel);
I = moment of inertia of tubing about its diameter I = π/64 (D4 – d4), w

© - IFP Training
RESERVOIR

PERFORATIONS
D = the tubing OD and d is the tubing ID*;
Ws = weight of tubing per inch*;
Wi = weight of fluid in tubing per inch*; and
Wo = weight of displaced fluid per inch.*
Completion F.J.P.B
(* = values for common tubing sizes can be found in Tables 2 and 3). 78
 TEMPERATURE EFFECT

Thermal expansion or contraction causes the

major length change in the tubing. Heated
X-MAS TREE
metal expands, and cooled metal contracts. In
TUBING HANGER
a long string of tubing with a temperature
CASING VALVE
change over its entire length, this contraction
or elongation can be considerable. The three
operational modes that influence
temperature effect are producing, injecting
EFFLUENT
(water, gas, or steam), and treating.
The change in tubing length because of
TUBING
temperature effect is calculated as follows:

STINGER IN SEAL-BORE

PACKER
∆L=Lxẞx∆t
where ΔL= change in tubing length, L = tubing
length, ẞ = coefficient of thermal expansion

© - IFP Training
RESERVOIR

PERFORATIONS (0.0000069 for steel), and Δt = change in

average temperature

Completion F.J.P.B
79
 TEMPERATURE EFFECT

Length changes are calculated readily if the average temperature of the tubing can be
determined for the initial condition and then again for future operations. The average
string temperature in any given operating mode is approximately one-half the sum of
the temperatures at the top and the bottom of the tubing. Thus, in the initial
condition, the average temperature would be based upon the mean yearly
temperature and the BHT. The mean yearly temperature is generally considered to be
the temperature 30 ft below ground level; Δt is the difference between the average
temperatures of any two subsequent operating modes.

© - IFP Training
Completion F.J.P.B
80
 BALLOONING EFFECT

X-MAS TREE
The ballooning effect is caused by the change
TUBING HANGER
in average pressure inside or outside the
CASING VALVE
tubing string. Internal pressure swells or
"balloons" the tubing and causes it to
shorten. Likewise, pressure in the annulus
squeezes the tubing, causing it to elongate.
EFFLUENT This effect is called "reverse ballooning.“
The ballooning effect will always result in
TUBING tubing-length changes, but it does not
become a force unless the tubing movement
STINGER IN SEAL-BORE
is restrained at the packer.
PACKER
The ballooning and reverse ballooning length
change and force are given by:

© - IFP Training
RESERVOIR

PERFORATIONS

Completion F.J.P.B
81
 BALLOONING EFFECT

ΔL = length change because of ballooning/reverse

ballooning,
F = force change because of ballooning/reverse
ballooning,
L = tubing length,
γ = Poisson’s ratio (0.3 for steel),
E = modulus of elasticity (30,000,000 for steel),
Δpia = change in average tubing pressure,
Δpoa = change in average annulus pressure,
Ai= area of the tubing ID,
Ao = area of the tubing OD, and
R = ratio of tubing OD to ID (given in Table) for
common tubing sizes and weights.

© - IFP Training
Completion F.J.P.B
82
 COMPLETION EQUIPMENT

Completion F.J.P.B
 COMPLETION

COMPLETION EQUIPMENT
Some completion equipment suppliers:
 Halliburton
 Baker
 Camco
 Weatherford
 Hunting
Etc…

© - IFP Training
Completion F.J.P.B
84
 WELL COMPLETION

 CROSS-OVERS
 NIPPLES
 SLIDING SIDE DOORS
 FLOW COUPLINGS
 BLAST JOINTS
 PERFORATED JOINTS
 ENTRY GUIDE

© - IFP Training
 SIDE POCKET MANDRELS

Completion F.J.P.B
85
 WELL COMPLETION

Cross Over (X-over)

BOX PIN

Cross-overs are used when we want to connect two

© - IFP Training
different sized tubing with different thread sizes.
Ex: 4 ½” x 3 ½”

Completion F.J.P.B
86
 NIPPLES

HALLIBURTON LANDING NIPPLES

“X” “XN” “R” “RN”

© - IFP Training
Completion F.J.P.B
87
 NIPPLES

BAKER LANDING NIPPLES

(“sure set” family)

© - IFP Training
Top No-Go Bottom No-Go

Completion F.J.P.B
88
 COMPLETION EQUIPMENT

BAKER LANDING NIPPLES

Profile for the dogs

Top No-Go Seal bore

Seal bore

Bottom No-Go

A nipple is fitted in the tubing, in which

we can hang-off gauges or set plugs.

© - IFP Training
AF AR They come in different sizes, main
dimensions are their “no-go” and
“seal bore”
Completion F.J.P.B
89
 COMPLETION EQUIPMENT

The flow coupling is used to protect the

integrity of the tubing from erosive
turbulence.
Flow couplings are often used above and
below a geometric restriction in a flow
path, depending on the well conditions.
API recommended practices 14B advises
use of two flow couplings above and
below safety valves.

FLOW COUPLING

© - IFP Training
Completion F.J.P.B
90
 COMPLETION EQUIPMENT

The blast joint positioned opposite the perforations

in the casing, is used in the tubing string of a flowing
well to protect it from the abrasive action of the
flowing well. It exposes the maximum of metal in
the abrasive area, maintaining at the same time API
tubing ID and coupling OD.
Length 10’ or 20’

© - IFP Training
BLAST JOINT

Completion F.J.P.B
91
 COMPLETION EQUIPMENT

The perforated tubing is used at the end of

a tubing string to provide an alternate flow
path in cases where wireline measuring
devices are used.

Nipple in which

© - IFP Training
we can hang-off
gauges.

PERFORATED TUBING
Completion F.J.P.B
92
 COMPLETION EQUIPMENT

The wire line entry guide is designed to

be run on the bottom of the tubing
string.
It will aid wire line tools re-entry in the
tubing especially in deviated wells

Casing

Tubing

WIRE LINE ENTRY GUIDE

Wire-line string

© - IFP Training
Completion F.J.P.B
93
 COMPLETION EQUIPMENT

PACKERS

© - IFP Training
Completion F.J.P.B
94
 PACKERS

F F

RETRIEVABLE
MECHANICAL PACKER

© - IFP Training
Tension setting Compression setting
Completion F.J.P.B
95
 PACKERS

THE “PACKER” FORMS THE BASIS OF THE CASED HOLE COMPLETION DESIGN.
The Packer is a sealing device that isolates and contains produced fluids and
pressures within the well bore to protect the casing and other formations above or
below the producing zone
This is essential to the basic functioning of most wells.

© - IFP Training
Completion F.J.P.B
96
 PACKERS

USES OF PACKERS
In addition to providing a seal between the tubing and casing, other benefits of a
packer are as follows:

 Prevent downhole movement of the tubing string

 Support some weight of the tubing
 Often improve well flow and production rate
 Protect the annular casing from corrosion from produced fluids and high
pressure
 Provide a means of separation of multiple producing zones
 Limit well control to the tubing at surface for safety purposes
 Hold well-servicing fluid (kill fluids, packer fluids) in the casing annulus

© - IFP Training
Completion F.J.P.B
97
 PACKERS

PACKER COMPONENTS

Packers have four key features:

 Slip
 Cone
 Packing element system
 Body or mandrel

The slip is a wedge-shaped device with wickers (or teeth) on the face, which
penetrates and grip the casing wall when the packer is set. The cone is a beveled to
match the back of the slip and forms a ramp that drives the slip outward and into
the casing wall when setting forces are applied to the packer. Once the slips have
anchored into the casing wall additional applied setting force energizes the packing
element system and creates a seal between the packer body and the inside
diameter of the casing.

© - IFP Training
Completion F.J.P.B
98
 PACKERS

F F
SETTING THE PACKER
The slip is a wedge-shaped device with wickers
(or teeth) on the face, which penetrates and grip the
Slips casing wall when the packer is set.
The cone is a beveled to match the back of the slip
and forms a ramp that drives the slip outward and
Cone into the casing wall when setting forces (F)
Are applied to the packer. Once the slips have
Packer seals anchored Into the casing wall additional applied
setting force (F)energizes the packing element system
and creates a seal between the packer body and the
inside diameter of the casing.

© - IFP Training
Completion F.J.P.B
99
 PACKERS

Packer classification
Production packers can be classified into two groups:
 Retrievable
 Permanent

© - IFP Training
Completion F.J.P.B
100
 PACKERS

PERMANENT PACKERS

Permanent packers can be removed from the wellbore only by milling.

Retrievable packers may or may not be reusable, but removal from the wellbore
normally does not require milling.
Retrieval is usually accomplished by some form of tubing manipulation.
This may necessitate rotation or require pulling tension on the tubing string.

The permanent packer is fairly simple and generally offer higher performance in
both temperature and pressure rating than does the retrievable packer.
In most instances, it has a smaller outside diameter (OD) offering greater running
clearance inside the casing string than do a retrievable packers.
The smaller OD and the compact design of a permanent packer help the tool to
negotiate through tight spots and deviations in the wellbore.
The permanent packer also offers the largest inside diameter (ID) to make it
compatible with larger-diameter tubing strings and mono-bore completions.

© - IFP Training
Completion F.J.P.B
101
 PACKERS

RETRIEVABLE PACKERS

The retrievable packer can be very basic for low pressure/low temperature (LP/LT)
applications or very complex in high pressure/high temperature (HP/HT)
applications.
Because of this design complexity in high-end tools, a retrievable packer offering
performance levels similar to those of a permanent packer will invariably cost more.
However, the ease of removing the packer from the wellbore as well as features,
such as reset ability and being able to reuse the packer often, may outweigh the
added cost

© - IFP Training
Completion F.J.P.B
102
 PACKERS

RETRIEVABLE TENSION PACKER

The tension packer is typically

used in medium- to shallow-depth (LP/LT)
production or injection applications.
The tension packer has a single set of
unidirectional slips that grip only the
casing when the tubing is pulled in tension.
Constant tubing tension must be maintained to
keep the packer set and the packing element
energized.
Tension packers, typically, are set mechanically
and are released by means of tubing rotation.
Most models also have an emergency shear-release

© - IFP Training
feature should the primary release method fail.

Completion F.J.P.B
103
 PACKERS

RETRIEVABLE TENSION PACKER WITH BY-PASS AND HOLD-DOWN ANCHOR

More common models of the compression packer with bypass

have an additional set of hold-down slips, or an anchor system
above the packing-element system. This packer sets and
releases in much the same manner as the compression packer
discussed previously. In this model, however, the addition of
The hold-down slip helps to keep the pack-off force and bypass
valve locked in place when pressure below the tool is greater
than the pressure in the annulus. This variation can be used in
limited treating operations, in gas lift applications, or in
production applications in which tubing pressures are greater
than annular pressures. However, there are limitations to the
ability of the anchor to keep the bypass closed, and any
operational modes that will result in loss of set-down weight
must be planned carefully.

© - IFP Training
Completion F.J.P.B
104
 PACKERS

HYDRAULIC SET SINGLE STRING PACKER

The hydraulic-set packer has a bidirectional slip
system that is actuated by a predetermined amount
of hydraulic pressure applied to the tubing string. To
achieve a pressure differential at the packer and set
it, a temporary plugging device must be run in the
tailpipe below the packer. The applied hydraulic
pressure acts against a piston chamber in the packer.
The force created by this action sets the slips and
packs the element off. Some models have an
atmospheric setting chamber and use the hydrostatic
pressure of the well to boost the pack-off force.
Regardless of design, all of the force generated during
the setting process is mechanically locked in place
until the packer is later released. Once the packer is
set, the tubing may be landed in tension (limited by
the shear-release value of the packer), compression,

© - IFP Training
or neutral

Completion F.J.P.B
105
 PACKERS

HYDRAULIC-SET SINGLE-STRING PACKER.

 Because no tubing manipulation is required to set a hydraulic packer, it can be

set easily after the wellhead has been flanged up and the tubing has been
displaced. This promotes safety and allows better control of the well while
displacing tubing and annulus fluids. The hydraulic-set packer can be run in a
single-packer installation, and because no packer body movement occurs during
the setting process, it can be run in tandem as an isolation packer in single-string
multiple-zone production wells. The hydraulic-set single-string packer is ideal for
highly deviated wells in which conditions are not suitable for mechanical-set
packers.

Special considerations include the following:

 Well stimulation must be planned carefully to avoid premature shear release of
the packer.
 Maximum tensile capabilities of the tubing string when selecting the shear-
release value of the packer are required.
 A temporary plugging device must always be incorporated below the lowermost

© - IFP Training
hydraulic-set packer to facilitate hydraulic setting of the packer.

Completion F.J.P.B
106
 PACKERS

RETRIEVAL OF THE PACKER

Retrieval of the hydraulic-set single-string packer is accomplished by pulling tension
with the tubing string to shear a shear ring, or shear pins, located within the packer.
Most models also have a built-in bypass system that allows the pressures in the
tubing and annulus to equalize, or balance, as the packer is released. The tension
load required to release the packer must be considered carefully in the initial
completion design and in the selection of the shear-ring value. The shear-release
value must not be set too high so that it will not be beyond the tensile capabilities of
the tubing string, yet it must be high enough so that the packer will not release
prematurely during any of the planned operational modes over the life of the
completion.

© - IFP Training
Completion F.J.P.B
107
 PACKERS

DUAL STRING PACKERS

This is basically a “mid-string” isolation packer that is designed to

seal off approximately two strings of tubing. The dual packer
allows the simultaneous production of two zones while keeping
them isolated. Most multiple-string packers are retrievable;
however, some permanent models exist for use in HP/HT
applications. Standard configurations have bidirectional slips to
prevent movement and maintain pack-off with the tubing landed
in the neutral condition.

© - IFP Training
Completion F.J.P.B
108
 PACKERS

 For the most part, multiple-string retrievable packers are set hydraulically
because the tubing manipulation required to set a mechanical packer is not
desirable or (often) not feasible in a dual-string application. However,
mechanical-set models do exist, and in applications in which the tubing strings
are run independently, the mechanical-set dual packer can be set with applied
slack-off force by the upper tubing string.
 The dual-string hydraulic-set packer is set much the same as the hydraulic-set
single-string packer. The setting pressure typically is applied to the upper tubing
(short string), but some models are designed to be set with pressure applied to
the lower tubing (long string). A temporary plugging device is required to be run
below the dual packer on the appropriate string to allow the actuating pressure
to be applied.

© - IFP Training
Completion F.J.P.B
109
 PACKERS

PERMANENT AND RETIEVABLE SEAL-BORE PACKERS

The permanent and retrievable seal-bore

packers are designed to be set on electric
wireline or hydraulically on the tubing
string. Wireline setting affords speed and
accuracy; however, the one-trip
hydraulic-set versions offer the advantage
of single-trip installations and allow the
packer to be set with the wellhead
flanged up.

© - IFP Training
Completion F.J.P.B
110
 PACKERS

SEAL-BORE PACKERS
 Seal bore packers have a honed and polished internal seal-bore. A tubing seal
assembly with elastomeric packing forms the seal between the production
tubing and the packer bore. Well isolation is accomplished by the fit of the
elastomeric seals in the polished packer bore. To accommodate longer seal
lengths, a seal-bore extension may be added to the packer.
 In the case of the one-trip hydraulic-set seal-bore packer system, the production
tubing, tubing seal assembly, and packer are made up together and run as a unit.
However, if the packer is to be installed on electric wireline or set on a work
string, the seal assembly is run on the production tubing after the packer is
installed and stabbed into the packer bore downhole.

© - IFP Training
Completion F.J.P.B
111
 PACKERS

© - IFP Training
Completion F.J.P.B
112
 PACKERS

LOCATORS
 The seal assembly may be a
locator type, which allows seal
movement during production and
treating operations, or an anchor
type, which secures the seals in
the packer bore and restricts
tubing movement. The decision
about the best seal assembly to
run depends on tubing movement
and hydraulic calculations based
on:
 Initial landing
 Flowing or shut-in conditions
 Any stimulation or treatment that
may be planned for the well.
 The removable seal assembly
allows tubing to be retrieved for

© - IFP Training
Anchor type Locator type
work-over without the need of
pulling and replacing the packer.

Completion F.J.P.B
113
 PACKERS

Generally, the permanent seal-bore packers, both wireline and hydraulic set, afford
much higher performance in both temperature and pressure ratings than do any of
the retrievable packers. The one disadvantage is that the permanent packer must be
milled over to remove the packer from the wellbore. For the most part, milling is not
prohibitive and, in many cases, may never be required. However, removal may be
necessary if subsequent work-over operations require full-bore access to the casing
below the packer or if a packer failure should occur.

© - IFP Training
Completion F.J.P.B
114
 PACKERS

 Landing conditions
 The tubing string is attached to the packer by two methods:
 It is latched or fixed to the packer by means of an anchor seal assembly (in the
case of a seal-bore packer) or tubing thread (most retrievable packers).
 The tubing is landed with a seal assembly and locator sub in the polished bore of
a permanent or retrievable seal-bore packer. In this case, the upward tubing
movement at the packer is limited only by the length of the seal assembly. Any
downward movement is restricted by the locator sub.

© - IFP Training
Completion F.J.P.B
115
 PACKERS

 Excessive tubing buckling can severely limit the length and diameter of through-
tubing tools that can be run through the tubing string. Tubing buckling is caused
by:
 Tubing landing conditions that require compression on the packer
 An overall increase in tubing temperature, which will cause the tubing to
elongate
 An increase in internal tubing pressure
 The piston effect on locator type seal assemblies.
 These conditions can be minimized if the completion is designed properly. Care
should be taken when planning the completion to thoroughly review the various
operating conditions to which the well will be subjected and to select a packer to
fit the operation.

© - IFP Training
Completion F.J.P.B
116
 PACKERS

CASING CLEAN-UP OPERATIONS

Any debris or obstruction that is present in the wellbore can cause most packers to
malfunction. Any cement that may have been left on the casing wall from previous
cementing operations, as well as scale buildup in the case of old wells, can also lead
to poor packer performance. To properly grip the casing and form a leak-proof seal,
the packer slip and element system must make 100% contact with the casing wall. It
is advisable to run a casing scraper or other suitable casing cleanout tool and
circulate the well clean before installing the production packer. A casing scraper
should always be run in instances in which a packer is to be conveyed through new
perforations.

© - IFP Training
Completion F.J.P.B
117
 PACKERS

Casing scraper (left) wire-line junk basket and

Gauge ring (right)

© - IFP Training
Completion F.J.P.B
118
 PACKERS

Before running any packer on electric wireline, it is advisable to run a wireline junk
basket and gauge ring. The gauge ring has a slightly larger outer diameter (OD) than
the packer and “gauges” the hole to ensure that there are no tight spots that might
cause the packer to become stuck, or accidentally set in the hole. The junk basket is
also designed to collect any debris that is suspended in the completion fluid that
otherwise might interfere with running the packer.

© - IFP Training
Completion F.J.P.B
119
 PACKERS

OTHER CASING CONSIDERATIONS

Before installing the packer, a cement bond log should be considered to verify the
integrity of the primary cementing job on the casing string. If a poor cement bond
exists in the interval in which the packer is to be set, the packer’s ability to serve as a
barrier may be compromised should a leak in the casing string occur. Such a leak
could allow the formation below to communicate to the annulus above the packer. If
such a channel is created, the annulus could be exposed to high formation
pressures, or the formation itself may be damaged. Either case could lead to a costly
work-over.
There are special applications in which the packer is intentionally set in unsupported
or un-cemented casing. Care should be taken in these instances to ensure that the
design of the packer is such that radial loads and stresses created by setting the
packer, and those anticipated to be encountered during various operating
conditions, do not exceed the stress limitations of the casing.

© - IFP Training
Completion F.J.P.B
120
 PACKERS

METALLURGY FOR DOWNHOLE EQUIPMENT

© - IFP Training
Completion F.J.P.B
121
 PACKERS

Corrosive conditions
Metallurgical requirements are dictated both by the downhole well environment
and the design and performance requirements of the packer. Consideration must be
given to both when selecting and specifying materials for corrosive environments.
Many types of materials that are applicable for tubing and casing in corrosive
environments are not always suitable (or practical) for packer manufacture. The
NACE International (formerly National Association of Corrosion Engineers) Standard
MR-01-75 establishes guidelines and acceptance criteria for material selection for
sour service in H2S environments.

© - IFP Training
Completion F.J.P.B
122
 PACKERS

COMMON MATERIALS USED FOR DOWNHOLE EQUIPMENT

Some commonly used materials for manufacture of downhole equipment are as

follows:
• Low-alloy steels with minimum yield strengths of 110 kpsi are used for standard
service in noncorrosive environments. These materials are similar in property to
P110 tubing and do not meet NACE MR-01-75 requirements for sour service.
• Low-alloy steels with a maximum hardness of Rockwell 22C, which meet NACE
MR-01-75 requirements, are intended for use in both standard service and
service in sour H2S environments. Materials that fall into this range would be
similar in properties to J-55 to L-80 grades of tubing.
• Martensitic steels such as 9% chromium, 1% molybdenum, and 13% chromium
alloy steels are used in some wet CO2 environments. Certain grades of these
steels meet NACE MR-01-75 requirements and can be used in limited H2S
applications.
• 22% chromium and 25% chromium duplex stainless steel are commonly used in
some wet CO2 and mild H2S environments.

© - IFP Training
• Austenitic stainless steels, cold worked 3% Mo high-nickel alloy steels, and
precipitation-hardening nickel-based alloys are suitable for some environments
containing high levels of H2S, CO2, and chlorides at moderately high
temperatures
Completion F.J.P.B
123
 PACKERS

The successful application of any of these materials depends strongly on the specific
downhole well environment. Many factors such as temperature, pH, chlorides,
water, H2S, and CO2 concentrations can have adverse effects on the material
performance and can lead to failures associated with:
• Pitting.
• Corrosion.
• Chloride stress cracking.
• Hydrogen embrittlement.

© - IFP Training
Completion F.J.P.B
124
 PACKERS

MATERIALS USED IN PACKERS

Ideally, the packer should be built out of materials that will last the life of the well.
Also, in the case of retrievable packers that may be reconditioned and used
elsewhere, the advantage of being able to reuse the packer may be lost if the well
environment corrodes or damages the tool beyond repair. In potentially corrosive
environments, material failure can lead to a packer leak or difficulty in removing a
retrievable packer from the wellbore. In these cases, corrosion-resistant alloy
materials must be properly selected that are best suited to the downhole well
environment.
Because of the vast number and variations of packer designs and tensile
requirements of their components, the consumer cannot know which materials are
appropriate for each particular design. Ultimately, the user must rely on the packer
manufacturer to help make the determination as to which materials will meet the
downhole requirements without sacrificing packer performance and reliability.

© - IFP Training
Completion F.J.P.B
125
 PACKERS

PACKER ELASTOMERS

© - IFP Training
Completion F.J.P.B
126
 PACKERS

CONSIDERATIONS IN SELECTING AN ELASTOMER

There are many suitable elastomers on today’s market to match almost any downhole
condition. Care must be taken to ensure that the elastomer selected for the packer and
seal assembly meets all the downhole conditions to which it will be subjected. Things
that must be considered are:
Downhole operating temperature
Exposure to produced or injected fluids and gases
Exposure to completion fluids such as oil-based mud, brine, bromides, high pH
completion fluids, and amine base inhibitors
Exposure to solvents such as xylene, toluene, and methanol.
There is no single best elastomer that will perform under all conditions combined, and
selection must be tailored to suit individual well requirements and application.
By far, the most common elastomer used in downhole completion packers is nitrile.
Nitrile is used in low- to medium-temperature applications for packers and packer-to-
tubing seal assemblies in one form or another. It shows good chemical resistance to

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oils, brines, and CO2 exposure. However, its use is limited in wells that contain even
small amounts of H2S, amine inhibitors, or high-pH completion fluids. Exposure to high
concentrations of H2S and bromides generally is not recommended.
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TYPES OF ELASTOMERS

Hydrogenated nitrile (HNBR)

Hydrogenated nitrile or HNBR (chemical name: hydrogenated acrylonitrile

butadiene) has a somewhat higher temperature rating and shows slightly better
chemical resistance to H2S and corrosion inhibitors than standard nitrile. HNBR is
more prone to extrusion than standard nitrile and, as a result, requires a more
sophisticated mechanical backup system similar to that found on most permanent
and higher-end retrievable packers.

Fluor elastomers

Two fluoroelastomers that are commonly used in the oil and gas industry are:
• Hexafluoropropylene (vinylidene fluoride, commonly known by the trade name
Viton)
• Tetrafluoroethylene (propylene, trade name Aflas)

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These compounds are used in medium- to high-temperature applications. Both
compounds show excellent resistance to H2S exposure in varying limits, CO2, brines,
and bromides. However, the use of Viton should be questioned when amine
inhibitors are present in packer fluids and in the case of high-pH completion fluids.
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Examples of Fluor elastomers

Aflas will swell when exposed to oil-based fluids and solvents. Swelling, because of
exposure of Aflas to hydrocarbons, is generally only a concern when running the
tool in the well. Element swell may cause the packer to become stuck on the trip in
the hole, and swelling of the seals can result in seal damage during stab-in. After the
packer is set and seals are in place, the swelling generally is no longer a concern.

The use of Kalrez and Chemraz in the packer industry is by and large limited to
chevron-type “vee” seals and “o”-rings. On the cost scale, they are by far some of
the most expensive materials used in these designs. Kalrez and Chemraz show good
resistance to most chemicals found in oil-well and gas-well environments. Because
of their ability to maintain stability at extreme temperatures, they are normally
recommended for use in HP/HT applications and in most environments in which high
levels of H2S are encountered.

Ethylene propylene (EPDM) is an elastomer commonly used in steam-injection

operations. EPDM exhibits poor resistance to swelling when exposed to oil and

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solvents; however, EPDM can operate in pure steam environments to temperatures
of 550°F.

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PACKING ELEMENT

The term “packing element” is used to describe the elastomeric sealing system that
creates the seal between the outside diameter (OD) of the packer and the inside
diameter (ID) of the casing. The ability of the packing element to hold differential
pressure is a function of the elastomer pressure, or stress across the seal. To form a
seal, the elastomer pressure must be greater than the differential pressure across
the packer. The elastomer pressure is generated by the pack-off or setting force
applied to the packer.

The packing-element system consists of the seal or packing element and a packing-
element backup system. When energized, the packing element expands to conform
to the ID of the casing wall. The packing-element backup system contains the
energized packing element and restricts the element from extruding or losing its
elastomer pressure

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PACKING ELEMENT SYSTEM DESIGN

There are many different packing-element-system designs. Each element-system

design is suited to a specific application and covers a myriad of well environments.
The most basic packing-element system consists of a single packing element with
fixed metal backup rings located above and below the element. More sophisticated
designs may consist of multidurometer elastomers using a lower durometer element
between two elements of a higher durometer. In this design, the lower durometer,
or softer-center element, creates the working seal while the higher durometer, or
harder-end, elements expand to the casing ID to restrict extrusion. Fixed metal
backup rings also may be replaced with flexible or expandable backup rings to
further restrict the extrusion of the elastomer.

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 PACKERS

PACKER-TO-TUBING SEAL STACKS

Permanent and retrievable seal-bore packers contain a honed seal-bore to accept

packer-to-tubing seals or seal assembly to connect the tubing string to the packer.
This seal assembly, or stinger, consists of a seal sub with multiple packing units or
seal stacks fixed on its OD.
The packing units come in a variety of configurations and elastomeric compounds to
suit a wide range of downhole conditions.
There are two basic types of packing units:
• Bonded
• Chevron

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BONDED PACKING UNIT

The bonded packing unit is composed of one or more metal rings, with a specific
elastomer compound bonded or molded to the ring. The bonded seal by design is
slightly larger than the ID of the seal-bore, and a predetermined amount of stress on
the elastomer is created when the seals are inserted into the honed packer bore.
The elastomer pressure generated by this stress creates a seal between the seal
assembly and the honed packer bore.

Because the bonded seals are self-energized, they are particularly useful in low
pressure/low temperature (LP/LT) gas-injection operations such as CO2 flood
projects. The bonded seals are also less susceptible to dynamic unloading damage
and should be selected any time that the seals must leave the honed bore under
pressure.
Only a few elastomer compounds are suitable for use in bonded seal designs. The
three most common compounds found on bonded seal stacks are:
• Nitrile
• Viton

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• Aflas
• Because the bonding tends to fail at higher temperatures, most bonded seals are
generally not recommended for service above 300°F.
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CHEVRON PACKING UNIT

Chevron seal stacks come in a wide variety of designs and elastomeric compounds.
They consist of a number of “vee”-shaped chevron seal rings supported by metal (or
a combination of metal and non-elastomeric) backup rings such as Ryton or Teflon.
Each individual chevron seal ring holds pressure in one direction only, so each seal
stack must contain a number of seal rings facing in either direction.
The chevron seal stacks are the most versatile and widely used. They are available
with various elastomers and designs. Common materials used for the “vee”-type
seal rings include:
• Nitrile (the most common)
• Viton
• Aflas
• Kalrez
Some specialized premium seal stacks can handle pressures up to 15,000 psi (and
beyond) at temperatures approaching 550°F. Each has its own environmental
application, as well as temperature and pressure rating. Matching the proper
elastomer to the environment is a key to long-term sealing success.

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The Chevron seal stacks do not lend themselves well to differential unloading
conditions that might be experienced during fracturing or treating operations in
which locator-type seal assemblies are used in seal-bore packers. The temperature
and piston effects will cause the tubing to shorten, and the seal assembly will move
upward out of the packer bore.
Any Chevron seal that is allowed to leave the polished seal-bore will be subject to
severe damage, because of the sudden change in differential pressure. Because of
this, locator-type seal-assembly designs should be such that the working seals are
never allowed to leave the polished packer bore under differential pressure.

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EFFECTS OF SEAL MOVEMENT

To reduce the possibility of seal failure and greatly extend the life of the seal
assembly, it is recommended that seal movement be restricted whenever possible.
While both chevron and bonded seals are designed to hold pressure under dynamic
conditions, completion designs that allow continuous seal movement over the life of
the well can significantly shorten the life of the seal. Seal movement should be
eliminated altogether if possible by anchoring the seals in the packer bore. Locator
seal assemblies should be landed so that the locator sub will be in constant
compression when the well is producing, thus limiting movement to those cases in
which the well is either treated or killed.

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