INTRODUCTION

WELL COMPLETION

The word “completion” itself means conclusion, and more particularly in the case we are
concerned with, the conclusion of a borehole that has just been drilled. Completion is therefore
the link between drilling the borehole as such as producing phase.

As a result, completion involves all of the operations designed to make the well produce, in
particular connecting the borehole and the pay zone, treating the pay zone (if any treatment),
equipping the well, putting it on stream and assessing it. Pay zone is a zone consisting of
reservoir rocks which contain oil and/or gas that can be recovered.

Generally speaking, it is usually considered that certain measurement and maintenance

operations in the well along with any workover jobs that might be required also come under the
heading of completion.

Completion is highly dependent on the phases that precede and follow it and is often even an
integral part of them. We can therefore say that completion begins with well positioning and
ends only at well abandonment.

Whatever the operational entity in charge of well completion and workover, its actions are
greatly influenced by the way that has been designed and drilled and by the production problems
the reservoir might cause. The “completion man” will therefore have to work in close
cooperation with the “driller” and also with reservoir engineers and production technical staff.

Lower completion

This refers to the portion of the well across the production or injection zone. The well designer
has many tools and options available to design the lower completion according to the conditions
of the reservoir. Typically, the lower completion is set across the productive zone using a liner
hanger system, which anchors the lower completion to the production casing string. The broad
categories of lower completion are listed below.

Open hole completion

Open hole completion is that completions where the tubulars across the production zone are not
cemented in place. Openhole completions have seen significant uptake in recent years, and there
are many configurations, often developed to address specific reservoir challenges. There have
been many recent developments which has boosted the success of openhole completions, and
they also tend to be popular in horizontal wells, where cemented liners are more expensive and
technically more difficult. The common options for openhole completions are;

1) pre-holed liner (also often called pre-drilled liner). The liner is prepared with multiple small
drilled holes, then set across the production zone to provide wellbore stability and an
intervention conduit. Pre-holed liner is often combined with openhole packers, such as swelling
elastomers, mechanical packers or external casing packers, to provide zonal segregation and
isolation. It is now quite common to see a combination of pre-holed liner, solid liner and
swelling elastomer packers to provide an initial isolation of unwanted water or gas zones.
Multiple sliding sleeves can also be used in conjunction with openhole packers to provide
considerable flexibility in zonal flow control for the life of the wellbore.

This type of completion is also being adopted in some water injection wells, although these
require a much greater performance envelope for openhole packers, due to the considerable
pressure and temperature changes that occur in water injectors.

Openhole completions (in comparison with cemented liners) require better understanding of
formation damage, wellbore clean-up and fluid loss control. A key difference is that perforating
penetrates through the first 6-18inches (15-45cm) of formation around the wellbore, whilst
openhole completions require the reservoir fluids to flow through all of the filtrate-invaded zone
around the wellbore and lift-off of the mud filter cake.

Many openhole completions will incorporate fluid loss valves at the top of the liner to provide
well control whilst the upper completion is run.

There are an increasing number of ideas coming into the market place to extend the options for
openhole completions; for example, electronics can be used to provide a self-opening or self-
closing liner valve. This might be used in an openhole completion to improve clean-up, by
bringing the well onto production from the toe-end for 100 days, then self-opening the heel-end.
Inflow control devices and intelligent completions are also installed as openhole completions.

Pre-holed liner may provide some basic control of solids production, where the wellbore is
thought to fail in aggregated chunks of rubble, but it is not typically regarded as a sand control
completion.
2) Slotted liner can be selected as an alternate to pre-holed liner, sometimes as a personal
preference or from established practice on a field. It can also be selected to provide a low cost
control of sand/solids production. The slotted liner is machined with multiple longitudinal slots,
for example 2 mm x 50mm, spread across the length and circumference of each joint. Recent
advances in laser cutting means that slotting can now be done much cheaper to much smaller slot
widths and in some situation slotted liner is now used for the same functionality as sand control
screens.

3) Openhole sand control is selected where the liner is required to mechanically hold-back the
movement of formation sand. There are many variants of openhole sand control, the three
popular choices being stand-alone screens, openhole gravel packs (also known as external gravel
packs, where a sized sand 'gravel' is placed as an annulus around the sand control screen) and
expandable screens. Screen designs are mainly wire-wrap or premium; wire-wrap screens use
spiral-welded corrosion-resistant wire wrapped around a drilled basepipe to provide a consistent
small spiral gap (such as 0.012-inch (0.30 mm), termed 12 gauge). Premium screens use a woven
metal cloth wrapped around a basepipe. Expandable screens are run to depth before being
mechanically swaged to a larger diameter. Ideally, expandable screens will be swaged until they
contact the wellbore wall.

Cased hole completion

This involves running casing or a liner down through the production zone, and cementing it in
place. Connection between the well bore and the formation is made by perforating. Because
perforation intervals can be precisely positioned, this type of completion affords good control of
fluid flow, although it relies on the quality of the cement to prevent fluid flow behind the liner.
As such it is the most common form of completion...

Completion components

The upper completion refers to all components from the bottom of the production tubing
upwards. Proper design of this "completion string" is essential to ensure the well can flow
properly given the reservoir conditions and to permit any operations as are deemed necessary for
enhancing production and safety.
Wellhead

This is the pressure containing equipment at the surface of the well where casing strings are
suspended and the Blowout preventer or Christmas tree (oil well) is connected. A wellhead is a
general term used to describe the component at the surface of an oil well that provides the
structural and pressure containing interface for the drilling and production equipment.

The primary purpose of a wellhead is to provide the suspension point and pressure seals for the
casing strings that run from the bottom of the hole sections to the surface pressure control
equipment.

Whilst drilling the oil well the surface pressure control is provided by a Blowout preventer or
'BOP'. If the pressure is not contained during drilling operations by the casings, wellhead and
BOP, then a well blowout can occur.

Once the well has been drilled, a completion is placed in the well that provides an interface with
the reservoir rock and the tubular conduit for the well fluids. The surface pressure control is
provided by a christmas tree which is installed on top of the wellhead, and has isolation valves
and choke equipment to control the flow of well fluids during production.

Wellheads are typically cemented in place during drilling operations and form an integral
structure of the well. In exploration wells which are abandoned, the wellhead may be recovered
for refurbishment and re-use.

Where wellheads are located on the production oil platforms/onshore they are called a surface
wellhead, and if located beneath the water then are referred to as a subsea wellhead or mudline
wellhead

Christmas Tree

This is the main assembly of valves that controls flow from the well to the process plant (or the
other way round for injection wells) and allows access for chemical squeezes and well
interventions. In petroleum and natural gas extraction, a Christmas tree, or "Tree", (not
"Wellhead" as sometimes incorrectly referred to) is an assembly of valves, spools, and fittings,
used for an oil well, gas well, water injection well, water disposal well, gas injection well,
condensate well and other types of wells. It was named for its crude resemblance to a decorated
tree.
A tree and wellhead are separate pieces of equipment not to be mistaken as the same piece. For
clarity, a wellhead must be present in order to utilize a Christmas Tree and a wellhead is used
WITHOUT a Christmas Tree during drilling operations, and also for riser tie-back situations
which would then have a tree included at riser top. Producing surface wells that require pumps
(pump jacks, nodding donkeys, etc.) frequently do not utilize any tree due to NO pressure
containment requirement.

Tree complexity has increased over the last few decades. They are frequently manufactured from
blocks of steel containing multiple valves rather than made from multiple flanged valves. This is
especially true in subsea applications where the resemblance to Christmas Trees no longer exists
given the frame and support systems into which the main valve block is integrated.

It is common to identify the type of tree as either "Subsea Tree" or "Surface Tree". Each of these
classifications has a number or varieties within them. Subsea examples include conventional,
dual bore, mono bore, TFL (Through Flow Line), horizontal, mudline, mudline horizontal, side
valve, and TBT (Through Bore Tree) trees,

The primary function of a tree is to control the flow into or out of the well, usually oil or gas. A
tree often provides numerous additional functions including chemical injection points, well
intervention means, pressure relief means (eg annulus vent), tree and well monitoring points
(such as pressure, temperature, corrosion, erosion, sand detection, flow rate, flow composition,
valve and choke position feedback, connection points for devices such as down hole pressure and
temperature transducer (DHPT), etc.

When the operator, well, and facilities are ready to produce and receive oil or gas, valves are
opened and the release of the formation fluids is allowed to flow into and through a pipeline. The
pipeline then leads to a processing facility, storage depot and or other pipeline eventually leading
to a refinery or distribution center (for gas). Subsea wells and thus trees usually flow through
flowlines to a fixed or floating production platform or to a storage vessel (known as a Floating
Storage Offloading vessel (FSO), or Floating Processing Unit (FPU), or Floating Production and
Offloading Vessel or FPSO or other combination of structures).

A tree may also be used to control the injection of gas or water injection application on a
producing or non-producing well in order to sustain economic "production" volumes of oil from
other well(s) in the area (field). A tree burning excess natural gas particularly looks like a
Christmas tree, though wet Christmas trees never do this.
On producing wells, injection of chemicals or alcohols or oil distillates to prevent and or solve
production problems (such as blockages) may be used. Functionality may be extended further by
using the control system on a subsea tree to monitor, measure, and react to sensor outputs on the
tree or even down the well bore.

The CONTROL SYSTEM attached to the tree controls the downhole safety valve (scssv, dhsv,
sssv, etc) while the tree acts as an attachment and conduit means of the control system to the
downhole safety valve.

Christmas trees are used on both subsea (current technical limits are up to around 3000 metres
and working temperatures of -50°F to 350°F with a pressure rating up to 15,000 psi). The
deepest installed subsea tree is in the USA Gulf of Mexico at approximately 9000 feet.

Valves in Chrirstmass Tree

Subsea and Surface Trees have a large variety of valve configurations and combinations of
manual and/or actuated (hydraulic or pneumatic) valves. Examples are identified in API
Specifications 6A and 17D.

A basic surface tree consists of two or three manual valves (usually gate valves because of their
robustness)

A typical sophisticated surface tree will have at least four or five valves, normally arranged in a
crucifix type pattern (hence the endurance of the term "Christmas tree"). The two lower valves
are called the master valves (upper and lower respectively) because they lie in the flow path,
which well fluids must take to get to surface. The lower master valve will normally be manually
operated, while the upper master valve is often hydraulically actuated, allowing it to be a means
of well control while an actuated wing valve is normally the primary well remotely (from control
room or control panel) controlled valve. Hydraulic tree wing valves are usually built to be fail
safe closed, meaning they require active hydraulic pressure to stay open.

The right hand valve is often called the flow wing valve or the production wing valve, because it
is in the flowpath the hydrocarbons take to production facilities (or the path water or gas will
take from production to the well in the case of injection wells).
The left hand valve is often called the kill wing valve. It is primarily used for injection of fluids
such as corrosion inhibitors or methanol to prevent hydrate formation. In the North Sea, it is
called the non-active side arm (NASA). It is typically manually operated.

The valve at the top is called the swab valve and lies in the path used for well interventions like
wireline and coiled tubing. For such operations, a lubricator is rigged up onto the top of the tree
and the wire or coil is lowered through the lubricator, past the swab valve and into the well. This
valve is typically manually operated.

Some trees have a second swab valve, the two arranged one on top of the other. The intention is
to allow rigging down equipment from the top of the tree with the well flowing while still
preserving the Two barrier rule. With only a single swab valve, the upper master valve is usually
closed to act as the second barrier, forcing the well to be shut in for a day during rig down
operations. However, avoiding delaying production for a day is usually too small a gain to be
worth the extra expense of a having a Xmas tree with a second swab valve.

Subsea trees are available in either Vertical or Horizontal configurations with further speciality
available such as Dual Bore, Monobore, concentric, Drill-Through, Mudline, Guidlineless or
Guideline. Subsea Trees may range in size and weight from a few tons to approximatley 70 tons
for high pressure, deepwater (>3000 feet) guidelineless applications. Subsea trees contain many
additional valves and accessories compared to Surface trees. Typically a Subsea tree would have
a Choke (permits control of flow), a floline connection interface (hub, flange or other
connection), subsea control interface (direct hydraulic, electro hydraulic, or electric) and sensors
for gathering data such as pressure, temperature, sand flow, erosion, MultiPhase flow, single
phase flow such as Water or Gas.

Tubing hanger

This is the component, which sits on top of the wellhead and serves as the main support for the
production tubing. A tubing hanger is a component used in the completion of oil and gas
production wells. It is set in the tree or the wellhead and suspends the production tubing and/or
casing. Sometimes it provides porting to allow the communication of hydraulic, electric and
other downhole functions, as well as chemical injection. It also serves to seal-in the annulus and
production areas.
Production tubing

Production tubing is the main conduit for transporting hydrocarbons from the reservoir to surface
(or injection material the other way). It runs from the tubing hanger at the top of the wellhead
down to a point generally just above the top of the production zone. Production tubing is a
tubular used in a wellbore through which production fluids are produced.

Production tubing is run into the drilled well after the casing is run and cemented in place. Along
with other components that constitute the production string, it provides a continuous bore from
the production zone to the wellhead through which oil and gas can be produced. It is usually
between five and ten centimeters in diameter and is held inside the casing through the use of
expandable packing devices.

If there is more than one zone of production in the well, up to four lines of production tubing can
be run.

Downhole safety valve

A downhole safety valve refers to a component on an oil and gas well, which acts as a failsafe to
prevent the uncontrolled release of reservoir fluids in the event of a worst case scenario surface
disaster. It is almost always installed as a vital component on the completion.

This component is intended as a last resort method of protecting the surface from the
uncontrolled release of hydrocarbons. It is a cylindrical valve with either a ball or flapper closing
mechanism , it is installed in the production tubing and is held in the open position by hydraulic
pressure from surface contained in a 1/4" control line that is attached to the DHSV's hydraulic
chamber and terminated at surface to an hydraulic actuator.

This allows fluids to pass up or be pumped down the production tubing. When closed the DHSV
forms a barrier in the direction of hydrocarbon flow, but fluids can still be pumped down for well
kill operations. It is placed as far below the surface as is deemed safe from any possible surface
disturbance including cratering caused by the wipeout of the platform.

Operation

These valves are commonly uni-directional flapper valves which open downwards, such that the
flow of wellbore fluids try to push it shut, while pressure from surface pushes it open. This
means that when closed, it will isolate the reservoir fluids from surface.
Most downhole safety valves are controlled hydraulically from surface, meaning they are opened
using a hydraulic connection linked directly to a well control panel. When hydraulic pressure is
applied down a control line, the hydraulic pressure forces a sleeve within the valve to slide
downwards. This movement compresses a large spring and pushes the flapper downwards to
open the valve. When hydraulic pressure is removed, the spring pushes the sleeve back up and
causes the flapper to shut. In this way, it is failsafe and will isolate the wellbore in the event of a
loss of the wellhead. The full designation for a typical valve is 'tubing retrievable, surface
controlled, subsurface safety valve', abbreviated to TR-SCSSV.

Positioning

The location of the downhole safety valve within the completion is a precisely determined
parameter intended to optimise safety. There are arguments against it either being too high or too
low in the well and so the final depth is a compromise of all factors. MMS regulations state that
the valve must be placed no less than 100' below the mudlin

Reasons to keep it high

The further down the well the DHSV is located, the greater the potential inventory of
hydrocarbons above it when closed. This means that in the event of loss of containment at
surface, there is more fluid to be spilled causing environmental damage, or in the worst case,
more fuel for a fire. Therefore, placing the valve higher limits this hazard.

Another reason relates to the hydraulic control line. Hydraulic pressure is required to keep the
valve open as part of the failsafe design. However, if the valve is too far down the well, then the
portion of the control line below the surface is larger. If it is too large, then the weight of the
hydraulic fluid alone may apply sufficient pressure to keep the valve open, even with the loss of
surface pressurisation.

Reasons to keep it low

As part of the role of the DHSV to isolate the surface from wellbore fluids, it is necessary for the
valve to be positioned away from the well where it could potentially come to harm. This implies
that it must be placed subsurface in all circumstances, i.e. in offshore wells, not above the
seabed. There is also the risk of cratering in the event of a catastrophic loss of the topside
facility. The valve is specifically placed below the maximum depth where cratering is expected
to be a risk.
If there is a risk of methane hydrate (clathrate) plugs forming as the pressure changes through the
valve due to Joule-Thomson cooling, then this is a reason to keep it low, where the rock is
warmer than 30 C.

Deploying and retrieving

Most downhole safety valves installed as part of the completion design are classed as "tubing
retrievable". This means that they are installed as a component of the completion string and run
in during completion. Retrieving the valve, should it malfunction, requires a workover. The full
name for this most common type of downhole safety valve is a Tubing Retrievable Surface
Controlled Sub-Surface Valve, shortened in completion diagrams to TRSCSSV.

If a tubing retrievable valve fails, rather than go to the expense of a workover, a "wireline
retrievable" valve may be used instead. This type of valve can fit inside the production tubing
and is deployed on wireline after the old valve has been straddled open.

Legal requirement

The importance of DHSVs is undisputed. Graphic images of oril wells in Kuwait on fire after the
First Gulf War after their wellheads were removed, demonstrate the perils of not using the
components (at the time, they were deemed unnecessary because they were onshore wells). It is,
however, not a direct legal requirement in many places. In the United Kingdom, no law mandates
the use of DHSVs. However, the 1974 Health & Safety at Work Act requires that measures are
taken to ensure that the uncontrolled release of wellbore fluids is prevented even in the worst
case. The brilliance of the act is that it does not issue prescriptive guideline for how to achieve
the goal of health and safety, but merely sets out the requirement that the goal be achieved. It is
up to the oil companies to decide how to achieve it and DHSVs are an important component of
that decision. As such, although not a legal requirement, it is company policy for many operators
in the UKCS.

Issues

While the DHSV isolates the production tubing, a loss of integrity could allow wellbore fluid to
bypass the valve and escape to surface through the annurlus. For wells using gas lift, it is often a
requirement to install a safety valve in the 'A' annulus of the well to ensure that the surface is
protected from a loss of annulus containment. However, these valves are not as common and
they are not necessarily installed at the same position in the well, meaning it is possible that
fluids could snake their way around the valves to surface.

Annular safety valve

On wells with gas lift capability, many operators consider it prudent to install a valve, which will
isolate the 'A' annulus for the same reasons a DHSV may be needed to isolate the production
tubing in order to prevent the inventory of natural gas downhole from becoming a hazard as it
became on Piper Alpha.

Side pocket mandrel

This is a welded/machined product which contains a 'side-pocket' alongside the main tubular
conduit. The side pocket, typically 1" or 1½" diameter is designed to contain gas lift valve,
which allows hydrocarbon gas from the 'A' annulus to be injected into the flow stream.

Electrical submersible pump

A submersible pump (or electric submersible pump (ESP)) is a device which has a
hermetically sealed motor close-coupled to the pump body. The whole assembly is submerged in
the fluid to be pumped. The main advantage of this type of pump is that it prevents pump
cavitation, a problem associated with a high elevation difference between pump and the fluid
surface. Submersible pumps push water to the surface as opposed to jet pumps having to pull
water. Submersibles are more efficient than jet pumps.

This device is used for artificial lift to help provide energy to drive hydrocarbons to surface if
reservoir pressure is insufficient.

Working Principle

A system of mechanical seals are used to prevent the fluid being pumped from entering the
motor and causing a short circuit. The pump can either be connected to a pipe, flexible hose or
lowered down guide rails or wires so that the pump sits on a "ducks foot" coupling, thereby
connecting it to the delivery pipework
Applications

Submersible pumps are found in many applications. Single stage pumps are used for drainage,
sewage pumping, general industrial pumping and slurry pumping. They are also popular with
aquarium filters. Multiple stage submersible pumps are typically lowered down a borehole and
used for water abstraction or in water wells.

Special attention to the type of ESP is required when using certain types of liquids. ESP's
commonly used on board naval vessels cannot be used to dewater contaminated flooded spaces.
These use a 440 volt A/C motor that operates a small centrifugal pump. It can also be used out of
the water, taking suction with a 2-1/2 inch non-collapsible hose. The pumped liquid is circulated
around the motor for cooling purposes. There is a possibility that the gasoline will leak into the
pump causing a fire or destroying the pump, so hot water and flammable liquids should be
avoided.

ESP usage in oil wells

Submersible pumps are used in oil production to provide a relatively efficient form of "artificial
lift", able to operate across a broad range of flow rates and depths. By decreasing the pressure at
the bottom of the well (by lowering bottomhole flowing pressure, or increasing drawdown),
significantly more oil can be produced from the well when compared with natural production.
The pumps are typically electrically powered and referred to as Electrical Submersible Pumps
(ESP).

ESP systems consist of both surface components (housed in the production facility, for example
an oil platform) and sub-surface components (found in the well hole). Surface components
include the motor controller (often a variable speed controller), surface cables and transformers.
Subsurface components typically include the pump, motor, seal and cables. A gas separator is
sometimes installed.

The pump itself is a multi-stage unit with the number of stages being determined by the
operating requirements. Each stage consists of a driven impeller and a diffuser which directs
flow to the next stage of the pump. Pumps come in diameters from 90mm (3.5 inches) to 254mm
(10 inches) and vary between 1 metre (3 ft) and 8.7 metres (29 ft) in length. The motor used to
drive the pump is typically a three phase, squirrel cage induction motor, with a nameplate power
rating in the range 7.5 kW to 560 kW (at 60 Hz).
New varieties of ESP can include a water/oil separator which permits the water to be reinjected
into the reservoir without the need to lift it to the surface. Major brands are Schlumberger's Reda,
Woodgroup's ESP, Weatherford BORETS and Baker Hughes' Centrilift. Until recently, ESPs
had been highly costly to install due to the requirement of an electric cable downhole. This cable
had to be wrapped around jointed tubing and connected at each joint. New coiled tubing
umbilicals allow for both the piping and electric cable to deployed with a single conventional
coiled tubing unit.

The ESP system consists of a number of components that turn a staged series of centrifugal
pumps to increase the pressure of the well fluid and push it to the surface. The energy to turn the
pump comes from a high-voltage (3 to 5 kV) alternating-current source to drive a special motor
that can work at high temperatures of up to 300 °F (149 °C) and high pressures of up to 5,000 psi
(34 MPa), from deep wells of up to 12,000 feet (3.7 km) deep with high energy requirements of
up to about 1000 horsepower (750 kW). ESPs have dramatically lower efficiencies with
significant fractions of gas, greater than about 10% volume at the pump intake. Given their high
rotational speed of up to 4000 rpm (67 Hz) and tight clearances, they are not very tolerant of
solids such as sand.

Landing nipple

This is a receptacle to receive wireline tools. It is also a useful marker for depths in the well,
which can be difficult to accurately determine.

Sliding sleeve

The sliding sleeve is hydraulically or mechanically actuated to allow communication between the
tubing and the 'A' annulus. They are often used in multiple reservoir wells to regulate flow to and
from the zones.

A sliding sleeve is a standard component for the completion of an oil or gas well. Their main
uses are to shut off flow from one or more reservoir zones or to regulate pressure between zones.

There are two main categories of sliding sleeves: open/close and choking. Open/close sleeves are
shifted between a full open position and a closed position. They are used to shut off flow from a
zone for economic reasons or to shut off a zone that is depleting or producing too much water. In
multi-zone wells, they are used to regulate which zones to produce from and which ones to shut
off. Mechanically actuated sleeves are simple and inexpensive but require actuation by a "lock,"
which must be run in the well on wireline or coiled tubing. Hydraulically actuated sleeves are
more complicated but can be actuated from a small pump at surface. King sleeves can be used to
regulate the pressure between two or more zones. They are also used to regulate the flow of fluid
into a well during proppant fracturing or hydraulic fracturing operations. Choking sleeves are all
hydraulically actuated and have a much more complex design than open/close sleeves.

A "sliding sleeve is also:

1. Part of a pencil for heavy-handed users.

2. Sliding sleeve supports the lead for precise lines and retracts as the pencil is used.
3. The sleeve is designed to protect the lead and minimize lead breakage.
4. Ideal for heavy-handed writers needing to use fine lead

Production packer
The packer is the sealing device that isolates and contains produced fluids and pressures within
the wellbore to protect the casing and other formations above or below the producing zone. This
is essential to the basic functioning of most wells.

It is usually run in close to the bottom end of the production tubing and set at a point above the
top perforations or sand screens. In wells with multiple reservoir zones, packers are used to
isolate the perforations for each zone. In these situations, a sliding sleeve would be used to select
which zone to produce. Packers may also be used to protect the casing from pressure and
produced fluids, isolate sections of corroded casing, casing leaks or squeezed perforations, and
isolate or temporarily abandon producing zones. In waterflooding developments in which water
is injected into the reservoir, packers are used in injection wells to isolate the zones into which
the water must be injected.

There are occasions in which running a packer may not be desirable. For example, high volume
wells that are produced both up the tubing and annulus will not include a packer. Rod pumped
wells are not normally run with packers because the associated gas is produced up the annulus.
In general, well completions may not incorporate a packer when the annular space is used as a
production conduit.

A packer is run in the casing on production tubing or wireline. Once the desired depth is reached,
the slips and element must be expanded out to contact the casing. Axial loads are applied to push
the slips up a ramp and to compress the element, causing it to expand outward. The axial loads
are applied hydraulically, mechanically, or with a slow burning chemical charge.
PURPOSE

• Prevent down hole movement of the tubing string.

• Support some of the weight of the tubing string.

• Often improve well flow and production rate.

• Protect the annular casing from corrosion from produced fluids and high pressures.

• Provide a means of separation of multiple producing zones.

• Limit well control to the tubing at the surface for safety purposes.

• Hold well servicing fluid (kill fluids, packer fluids) in the casing annulus.

• Aid in forming the annular volume (casing/tubing/packer) required for gas lift or
subsurface hydraulic pumping systems.

• Separate producing zones, preventing fluid and pressure contamination.

• Keep gas mixed with liquids, by using gas energy for natural flow.
ELEMENTS OF PACKER

Packers have following main elements:

• Slip

• Cone

• Packing element system

• Body or mandrel.

• Circulating valve.

• Friction springs.

• Friction blocks.

Slip:

The SLIP is wedge-shaped device with wickers or teeth on its face, which penetrate and grip the
casing wall when the packer is set.
Cone:

The CONE is beveled to match the back of the slip and forms a ramp that drives the slip
outwards and into the casing wall when setting force is applied to the packer.

Packing element system and body:

Once the slips have anchored into the casing wall, additional applied setting force energizes the
PACKING-ELEMENT SYSTEM and create a seal between the packer BODY and the inside
diameter of the casing. It permits the use of rubber of different degrees of hardness. Under
certain conditions this provides a more effective pack-off with less pressure than a single
element. In a three element packer, the uppermost and lowermost elements are usually harder
than the middle element. These outside elements will bear most of the abrasion while the tool is
being run in the hole, and the softer middle elements will not be damaged. Most of the sealing
action is obtained as a result of compression of the central element.

Circulating valve:

Once the sealing element is expanded, the hole below the packer is isolated from the casing
annulus. This may be a disadvantage if

(1) It is desired to circulate drilling mud out of the annulus;

(2) It is desired to equalize pressures before unseating the packer;

(3) It is desired to circulate fluids while cementing, fracturing, treating, or testing a well.

For these reasons most packers are equipped with circulating valve (sometimes called an
equalizing valve) located above the sealing element. This valve can be opened by drill pipe or
tubing manipulation (rotation, pulling up, pushing down or a combination of these operations).
With the valve open communication is established between the inside of the tubing and the
casing annulus.

Friction springs:

These are similar to the springs on casing centralizer. They serve a different purpose, however.
On packers, the slips are held in a closed position until the packer has been lowered to the proper
position in the well. The slips are then released, usually by rotation of the tubing in a right hand
direction. Normally, the packer body rotates at the same time but the friction springs provide
sufficient drag so that the packer does not turn as the tubing is rotated. Thus the release
mechanism is actuated and the slips are allowed to spread out against the casing. Application of
tubing weight will complete the setting of the slips.

Friction blocks:

These perform the same function as function as friction springs but are thin blocks having
cylindrical surfaces that drag on the inside of the casing and prevent rotation of the packer during
the slip release operation.

When packers are inflated in a wellbore, the pressures above and below the packer can exerts
upward or downward force against the packer. If the force is great enough , the packing elements
and the slips can loss their grips on the casing and the fluid seal of the packer is lost. This is
called unseating the packer.

FIG 1: PACKER ELEMENTS

TYPES OF PACKER

Packers can be classified in several ways.

Classification of packer based on retrievability:

(1) Retrievable packer.

(2) Permanent packer.

Classification based on mode of setting:

(1) Mechanical set packer (compression or tension).

(2) Hydraulic set packer.

 (3) Wireline set packer.

Classification based on use:

(1) Testing.

(2) Production.

(3) Injection.

(4) Straddle.

General classification:

1. Anchor packers

2. Hook-wall packers

3. Disk-wall packers

4. Tension packers

5. Permanent-completion packers

6. Hydraulic packers

4.1 Classification of packer based on retrievability:

4.1.1 RETRIEVABLE PACKERS:

Retrieval is usually accomplished by some form of tubing manipulation. This may

necessitate rotation or require pulling tension on the tubing string. In situations where a packer
must be easily removed from the well, such as secondary recoveries, re-completions, or to
change out the production tubing, a retrievable packer must be used. To unset the tool, either a
metal ring is sheared or a sleeve is shifted to disengage connecting components. Retrievable
packers have a more complicated design and generally lower sealing and gripping capabilities,
but after removal and subsequent servicing, they can be reused. The retrievable packers may or
may not be resettable; however, removal from the wellbore normally does not require milling.

When selecting a packer for cased hole completion, the differential pressure and temperature
requirements of the applications must be considered. The well depth, deployment and setting
method desired and final tubing landing conditions are also factors that come into play. The
various operational models (flowing, shut in, injection and stimulation) that are anticipated over
the entire life of the well are critical and must be considered carefully in the design phase. The
changes in the operational modes that influence changes in temperature, differential pressure and
axial loads all have a direct impact on the packer. Understanding the uses and constraints of the
different types of packers will help clarify the factors to consider when making a selection.

TO SET THE PACKER: The packer is set by picking up, rotating to the right and then slacking
off on the tubing. Set-down weight closes and seals the bypass valve, sets the slips and packs-off
the packing element.

TO RELEASE THE PACKER: Picking up the tubing releases the packer (no rotation
required). When the tubing is raised, the bypass valve opens to permit circulation through and
around the packer. When the tubing string is raised the full length of the packer, the J-pins (on
the bottom sub) are oriented for automatic re-engagement. By then lowering the tubing slightly,
the J-pin engages the J-slot thus assuring complete release and preventing accidental resetting
while retrieving the packer.
FIG 2: Running in of Retrievable packer

RETRIEVABLE TENSION PACKER:

Retrievable tension packers generally are used when pressure below the packer is greater than
the annulus pressure above the packer, such as in an injection well or low-pressure and –volume
treating. These packers also are used in shallow wells where the tubing weight is insufficient to
set a compression packer properly.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 release by means of tubing rotation. Right hand torque is applied to
the tubing. While right hand torque is applied, the tubing is picked up and the appropriate
amount of tension is applied to the tubing. The packer does not have an equalizing (or bypass)
valve to aid in pressure equalization between the tubing and annulus to facilitate the retrieval of
the packer. These types of packer should be avoided in deeper application for which hydrostatic
pressure and differential pressures can be greater. Because high differential pressure can make
the packers difficult to release because of the forces created by the pressure acting on the cross
sectional area of the packer.
The tension packer is suited for applications in which pressure below the packer is always
greater than the annulus pressure at the tool such as in an injection well or low-pressure and –
volume treating.
Constraints of the solid-head retrievable tension packer are:
1. Release is difficult with high differential pressure across the packer.
2. Tubing could part if a change in the operational mode results in a temperature decrease.
3. Packer could release if a change in the operational mode results in a temperature increase.

RETRIEVABLE TENSION PACKER SCHEMATIC.

 RETRIEVABLE TENSION PACKER

SOLID HEAD RETRIEVABLE COMPRESSION PACKER:

Retrievable compression (weight-set solid-head) packers are applied when annulus pressure
above the packer exceeds pressure below the packer, as in a producing well with a full annulus.
This situation precludes gas lift.

HEAD RERETRIEVABLE COMPRESSION PACKER SCHEMATIC.

The constraints of a retrievable compression packer are:
1. Packer release can be hampered by high differential pressure across packer.
2. Packer may unseat if a change in the operational mode results in a tubing temperature decrease
(tubing shortens).
3. Tubing may corkscrew permanently if a change in the operational mode results in a tubing
temperature increase (tubing lengthens).
RETERIEVABLE COMPRESSION PACKER WITH BYPASS:

The control-head retrievable compression packer has a bypass valve to alleviate the packer
release problem resulting from excessive differential pressure. The valve is on top of the packer.
It is opened, equalizing the pressure across the packer, by picking up the tubing without moving
the packer. As with the solid-head packer, using tubing weight, this packer holds pressure from
above only. It is not suitable for injection wells or low-volume and pressure treating.

The retrievable compression packer with fluid-bypass valve is also recommended for low to
medium pressure/medium temperature oil or gas production applications. The packer is
prevented from setting by means of a mechanical interlock while it is being run in the hole. Once
the packer has been run to the desired depth, the tubing string is rotated to initiate the setting
sequence. As the tubing is being rotated, the drag blocks on the packer are used to hold the
packer in place and provide the resistance to set it. Once the interlock system is released, the
tubing string is lowered to close the bypass seal and set the slips. The continued application of
slackoff force energizes the packing element system and creates a seal. The packer is released
simply by picking up on the tubing string-a desirable feature.
The packing element system is enhanced over that of the tension packer to make it suitable for
moderately higher pressures and temperatures. The addition of the integral bypass valve assists
equalization of pressures in the tubing and the annulus and aids in releasing the packer. The
valve can be opened by picking up on the tubing string without releasing the packer. Constant
compression or tubing weight must be maintained to sustain the pack off and keep the bypass
valve closed. Because of these design constraints, compression packers generally are not suitable
for injection wells or low volume pressure treating operations.

CONTROL HEAD COMPRESSION PACKER SCHEMATIC

RETEIEVABLE COMPRESSION PACKER WITH BYPASS

Constraints are:
(1) The bypass or equalizing valve could open if an operational mode change results in a tubing
temperature decrease, and
(2) Tubing could corkscrew permanently if an operational mode change results in a tubing
temperature increase.
WIRELINE SET- TUBING RETRIEVABLE PACKER:

On the top of wire line set packer a special nipple is located. The nipple has a polished seal
surface on its OD and has j-jugs that are used to anchor a seal housing or washer shoe in place.
The polished nipple also has a landing nipple profile in its ID. This allows the installation of a
slickline retrievable blanking plug if desired.

The packer is first run and set on electric wireline. The electric wireline setting tool provides the
force necessary to anchor the slips in the casing wall and energize the packing element. Once the
packer is installed and the wireline is retrieved a seal housing is run in the hole on the bottom of
the production tubing. The housing has internal seals that, when landed on the polished nipple,
creates a seal between the tubing and the annulus. The housing also has an internal j profile that
engages the lugs of the nipple and anchors the tubing string to the packer.

The tubing can be retrieved from the wellbore at any time without disturbing the packer by
unjaying the seal housing from the polished nipple, or (if desired) the packer can be released and
retrieved mechanically with the tubing.

WIRELINE SET- TUBING RETRIEVABLE PACKER

The main advantage of this system is that it can be run and set under pressure on electric wireline
(with a blanking plug preinstalled in the nipple profile) in a live oil or gas well. Once the packer
is set, the electric line is removed. And the pressure above the packer can be bleed off. With the
plug in place, the packer will act as a temporary bridge plug for well control while the tubing
string and seal housing are run and landed. Because the plug is located near the top of the packer
assembly, it can be circulated free of any debris before landing the tubing. Once the tree has been
installed, the plug is removed with slickline, and the well is placed on production.

Applications

• High formation, unloading differential, or stimulation pressure areas

• Pulling tubing without unseating packers
• High bottomhole temperatures
• Downhole conditions demanding special running clearance
• Twin-flow chemical injections systems

RETRIEVABLE TENSION/COMPRESSION SET VERSATILE LANDING:

Tension or compression set packers that allow the tubing to be landed in tension, compression or
neutral are the most common types of mechanical set retrievable packers run today. This group
of mechanical set retrievable packers will vary greatly in design and performance and may
require tension, compression or a combination of both to set and pack off the element. These
packers are suitable for HP/HT applications.

Once the element is sealed off and the packoff force is mechanically locked in place, the tubing
string may be landed in compression, tension or neutral. Slips located above and below the
packing element (or a single set of bidirectional slips) are design to hold axial tubing loads from
either direction to keep the packer anchored in place. An internal lock system mechanically traps
the packoff force and keeps the element energized until the packer is released. A bypass valve is
present to aid in equalization and the release of the packer.

It can be used in production or injection applications, as well as in completion for which well
stimulation is planned, and it is almost universal in application. The only constraint is in deep
deviated wells, where tubing manipulation or getting packoff force to the tool may present a
problem.

Care must be taken to ensure that tubing movement during production or injection operation does
not exceed the tensile or compression limitations of either the packer or the tubing string.
RETRIEVABLE TENSION/COMPRESSION SET VERSATILE LANDING

RETRIEVABLE HYDRAULIC-SET SINGLE STRING PACKER:

The retrievable hydraulic-set packer has slips above and below the packing element. No tubing
movement is required or generated to set the packer. It is set by applying the hydraulic pressure
in the tubing to some preset level above hydrostatic pressure. Once the packer is set, the tubing
may be put in limited tension, compression, or left neutral. The packer generally is released with
tension-actuated shear pins. It is universally applicable, the only constraint being its high cost.

It is recommended for deviated wells where conditions are not suitable for mechanical or
wireline setting packers. To achieve a pressure differential at the packer and set it, a temporary
plugging device must be run in the tail pipe 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 packoff 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 shear release
value of the packer), compression or neutral.
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
fluid. The hydraulic set packer can be run in a single packer installation. It is ideal for highly
deviated wells in which conditions are not suitable for mechanical set packers.

FIG 10: RETRIEVABLE HYDRAULIC-SET SINGLE STRING PACKER SCHEMATIC

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

hydraulic set packer to facilitate hydraulic setting 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, but 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.

FEATURES AND BENEFITS -

• Sets securely in any hardness casing, including premium grades

• Recommended for deviated wells
• Tubing pressure actuated
• Three piece packing element system
• Straight pull or rotational release
• Bi-directional one-piece slips below the packing
 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.

Dual string packers are generally 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 slackoff 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 string (short string);
however, some models are designed to be set with pressure applied to the lower tubing (long
string). The hydraulic set dual packers are released by applying tubing tension to shear an
internal shear ring.

Dual string packers are also use in electrical submersible pump applications in which both the
electrical cable and the production tubing must pass through the packer. Multiple packers are
also used in tandem to isolate damaged casing.

Applications:

• Deviated and horizontal wells

• High-volume instrumented applications
• Well monitoring, gas venting, chemical injection, and hydraulic-line access
• Multiple-zone isolation
Features, Advantages and Benefits

• The packer can be pressure tested on-site to save rig time.

• The straight-pull, shear-release pins are unaffected by differential pressure, enabling easy
changes to the release force before running.
• The compact design eases passage through doglegs and deviated wells to help prevent sticking
and improve running efficiency.
• All components are locked to prevent pressure buildup or debris from presetting the packer,
improving reliability when running the packer in the wellbore.
• The setting cylinder is below the packing elements, eliminating all critical O-rings after setting.
• The packer has a cone design instead of hydraulic hold-down buttons to prevent pressure-
induced packer release.

DUAL STRING PACKER

PERMANENT PACKER:

Permanent packers can be removed from the wellbore only by milling. The permanent
packer is fairly simple and generally offers higher performance in both temperature and pressure
ratings 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 retrievable packers. The
smaller OD and the compact design of the permanent packers help the tool 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 monobore
completion. The retrievable packer can be very basic for LP/LT applications or very complex in
HP/HT applications. .

4.1.2.1 SEALBORE PACKER:

The polished sealbore packer is a permanent type or semipermanent packer that can be set with
precision depth control on conductor wireline. It also can be set mechanically or hydraulically on
the tubing. A locator sub and seal assembly is attached to the bottom of the tubing and is stung
into the polished bore receptacle of the packer. Isolation is achieved by the fit of the seals inside
the polished bore.

Sealbore packers have a honed and polished internal sealbore. 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 sealbore extension may be added to the packer.

In case of the one-trip hydraulic-set sealbore 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 spring, the seal assembly is run on the production
tubing after the packer is installed and stabbed into the packer bore downhole.

The seal assembly may be a locator type which allows seal movement during production and
treating operation, 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, as well as any
stimulation or treatment that may be planned for the well. The removable seal assembly allows
tubing to be retrieved for workover without the need of pulling and replacing the packer.

Generally, the permanent sealbore 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 workover operations require full bore access
to the casing below the packer or if a packer failure should occur.

There is one important constraint with this packer-if the tubing remains in a place for a long time
at the same temperature and no movement occurs between the seals and the polished bore, the
seals may stick to the polished bore surface, creating a tubing retrieval problem
 SEALBORE PACKER SCHEMATIC

SEALBORE PACKER

METHODS OF CONVEYANCE

For the most part, both permanent and retrievable packers can be run and set on the production
tubing string, requiring no additional trips for installation. This one trip system is both cost
effective and efficient. However, it may be necessary or desirable to install the packer in the
wellbore first and then run the production tubing. In these instances, a packer is selected that can
be run and set either on a workstring or on electric wireline. Once the packer is installed, a
sealing device is attached to the end of the production tubing and connected to the packer
downhole to form a seal.

Electric wireline setting of the packer affords several benefits. First it offers fast installation and
accurate placement of the packer. This is important in instances in which the packer must be set
in very short interval or in cases in which the zones are very close together. Electric wireline
deployment also can allow the packer to be installed and set under pressure in a live well without
the need for a snubbing unit. In this case, a temporary plugging device is used in conjunction
with the packer to allow the well pressure above the packer to be bled off once it is installed.

Running and setting the packer on a work string may be necessary in highly deviated wells in
which the hole angle is too high to run the packer in on electric wireline. Although this method
requires the most time for packer installation, it does afford the benefit of being able to
hydraulically pressure test the packer and ensure that it is properly set before picking up and
running the production tubing.

Consideration should be given to the run in speed of the packer, whether run on tubing or electric
line. Too fast of a run in speed in fluid can cause the rubber element to begin to pack off or swab.
This will inflict damage to the element and lead to packer failure.

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
sealbore packer) or tubing thread (most retrievable packer).

• The tubing is landed with a seal assembly and locator sub in the polished bore of a
permanent or retrievable sealbore packer.

The term landing conditions refers to the amount of slackoff weight or tension that is left on the
packer when the tree is landed and the wellhead is flanged up.

THROUGH TUBING OPERATIONS:

Considerations should be given to future through tubing operations such as coiled tubing
operations, swabbing, slickline or electric wireline work to ensure that the internal diameter of
the completion equipment is adequate to allow passage of the tool. Ideally, the inside diameter of
the packer should be equal to that of the tubing string to facilitate through-tubing operations.

CASING CLEANUP OPERATIONS:

Any debris or obstruction that is present in the wellbore can cause most packers to malfunction.
To properly grip the casing and form a leak proof seal, the packer slip and element must take
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.

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 OD than the packer and gauges the hole to
ensure that there are no tight spots that might cause the packer to become stuck.

CONSIDERATIONS FOR PACKER SELECTION

Packer selection requires an analysis of packer objectives or the anticipated well operations, such
as initial completions, production stimulation, and workover procedures. Considering both
current and future well conditions, the packer with the minimum overall cost that will
accomplish the objectives should be selected. Initial investment and installation costs should not
be the only criteria. Overall packer cost is related directly not only to retrievability and failure
rate but to such diverse factors as formation damage during subsequent well operations or
replacement of corkscrewed tubing. Retrievability will be enhanced greatly by using oil or solid-
free water rather than mud for the packer fluid. Frequency of packer failures may be minimized
by using the proper packer for the well condition and by anticipating future conditions when
setting the packer. Permanent packers are by far the most reliable and, when properly equipped
and set, are excellent for resisting the high pressure differentials imposed during stimulation.
They are used widely when reservoir pressures vary significantly between zones in multiple
completions. Weight-set tension types of retrievable packers will perform satisfactorily when the
force on the packer is in one direction only and is not excessive.
PACKER MECHANICS

The end result of most packer setting mechanisms is to

(1) Drive a cone behind a tapered slip to force the slip into the casing wall and prevent packer
movement, and
(2) Compress a packing element to effect a seal. Although the end result is relatively simple, the
means of accomplishing it and subsequent packer retrieval varies markedly between the several
types of packers.
Some packers involve two or more round trips, some require wireline time, and some eliminate
trips by hydraulic setting. The time cost should be examined carefully, especially on deep wells
using high-cost rigs. In some cases higher initial packer costs may be more than offset by the
saving in rig time, especially offshore.
METALLURGY

Some commonly used materials for manufacture of production packers are as follows:

• Low alloy steel with minimum yield strength of 110psi 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 steel with 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
environment.
• Martensitic steels such as 9% chromium, 1% molybdenum and 13% chromium alloy
steels are used in some wet CO2 environments.
• 22% chromium and 25% chromium duplex stainless steel are commonly used in some
wet CO2 and mild H2S environments.
• Austenitic stainless steels, cold worked 3% Mo high-nickel alloy steel and precipitation-
hardening nickel based alloys are suitable for some environments containing high levels
of H2S, CO2 and chlorides at moderately high temperatures.

ISO AND API STANDARDS

The INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO) and the

AMERICAN PETROLEUM INSTITUTE (API) have created a standard intended to established
guidelines for manufacturers and end users in the selection, manufacture, design, and laboratory
testing of many types of packers available on today’s market. There are three grades or levels,
established for quality control and six grades for design verification.
The quality standard range from grade Q3 to Q1, with grade Q3 carrying the minimum
requirements and Q1 outlining the highest level of inspection and manufacturing verification
procedures.
The six standard design-validation grades range from V6 to V1. V6 is the lowest grade, and V1
represents the highest level of testing. A special V0 grade was included to meet special
acceptance criteria requirements.

GRADE V6:
This is the lowest grade established. The performance level in this instance is defined by the
manufacturer for products that do not meet the testing criteria found in grades V0 through V5.
GRADE V5 LIQUID TEST:
In this grade, the packer must be set in the maximum ID casing it is rated for at the maximum
recommended operating temperature. The testing parameters require that it be set with the
minimum packoff force or pressure as specified by the manufacturer. The pressure test is
performed with water or hydraulic oil to the maximum differential pressure rating of the packer.

GRADE V4 LIQUID TEST+ AXIAL LOADS:

In this grade, the packer must hold differential pressure in combination with compression and
tensile loads.
GRADE V3 LIQUID TEST + AXIAL LOADS + TEMPERATURE CYCLING:
To achieve V3 certification, the packer must pass a temperature cycle test. The packer must hold
the maximum specified pressure at the upper and lower temperature limits in which the packer is
design to work.
GRADE V2 GAS TEST + AXIAL LOADS:
The test medium is replaced with air or nitrogen. A leak rate of 20cm3 of gas over the hold period
is acceptable; however, the rate may not increase during the hold period.
GRADE V1 GAS TEST + AXIAL LOADS+ TEMPERATURE CYCLING:
The test is similar to V2 test.
SPECIAL GRADE V0 GAS TEST + AXIAL LOADS + TEMPERATURE CYCLING+
BUBLE TIGHT GAS SEAL:
This is a special validation grade that is added to meet customer specifications in which a tight-
gas seal is required. During the hold period gas leak rate is not allowed.
Downhole gauges

This is an electronic or fibre optic sensor to provide continuous monitoring of downhole pressure
and temperature. Gauges use a 1/4" control line clamped onto the outside of the tubing string to
provide an electrical or fibre optic communication to surface.

Perforated joint

This is a length of tubing with holes punched into it. If used, it will normally be positioned below
the packer and will offer an alternative entry path for reservoir fluids into the tubing in case the
shoe becomes blocked, for example, by a stuck perforation gun.

Formation isolation valve

This component, placed towards the foot of the completion string, is used to provide two way
isolation from the formation for completion operations without the need for kill weight fluids.
Their use is sporadic as they do not enjoy the best reputation for reliability when it comes to
opening them at the end of the completion process.

Centraliser

In highly deviated wells, this components may be included towards the foot of the completion. It
consists of a large collar, which keeps the completion string centralised within the hole.

Wireline entry guide

This component is often installed at the end of the tubing (the shoe). It is intended to make
pulling out wireline tools easier by offering a guiding surface for the toolstring to re-enter the
tubing without getting caught on the side of the shoe.

Perforating and stimulating

In cased hole completions (the majority of wells), once the completion string is in place, the final
stage is to make a connection between the wellbore and the formation. This is done by running
perforation guns to blast holes in the casing or liner to make a connection. Modern perforations
are made using shaped explosive charges, similar to the armor-penetrating charge used on
antitank rockets (bazookas).
Sometimes once the well is fully completed, further stimulation is necessary to achieve the
planned productivity. There are a number of stimulation techniques.

Acidising

This involves the injection of chemicals to eat away at any skin damage, "cleaning up" the
formation, thereby improving the flow of reservoir fluids. Acid can also be used to clean the
wellbore of some scales that form from mineral laden produced water.

Fracturing

This means creating and extending a fracture from the perforation tunnels deeper into the
formation increasing the surface area for formation fluids to flow into the well as well as
extending past any possible damage near the wellbore. This may be done by either injecting
fluids at high pressure (hydraulic fracturing), injecting fluids laced with round granular material
(proppant fracturing) or using explosives to generate a high pressure and high speed gas flow
(TNT or PETN up to 1,900,000 Psi) and (propellent stimulation up to 4,000 Psi).

Acidising and fracturing (combined method)

This involves use of explosives and injection of chemicals to increase acid-rock contact.

Nitrogen circulation

Sometimes, productivity may be hampered due to the residue of completion fluids, heavy brines,
in the wellbore. This is particularly a problem in gas wells. In these cases, coiled tubing may be
used to pump nitrogen at high pressure into the bottom of the borehole to circulate out the brine.