SPE 90678
A Methodology for Selecting Interventionless Packer Setting Techniques
James G. King, Alvaro J. Arrazola -Baker Oil Tools, SPE
Copyright 2004, Society of Petroleum Engineers Inc.
This paper was prepared for presentation at the SPE Annual Technical Conference and Exhibition
held in Houston, Texas, U.S.A., 26–29 September 2004.
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Abstract
Eliminating intervention during well completion reduces
operating expense and risk. In deepwater, horizontal, and
extended-reach applications, interventionless actuation systems
for setting completion tools are reducing well intervention and
completion time and associated costs without compromising
reliability or safety. This paper details the operation of three
commercially successful technologies that permit
interventionless actuation and provides a methodology for
selecting the optimum solution for a particular application.
Introduction
Throughout the offshore oil and gas industry, focus is turning
toward the prolific but challenging area of deepwater. Waters
greater than 1,000 ft are the largest growth segment of the
industry. The technologies that enable this growth economically
are those that provide improvements in operational reliability,
flexibility, and cost effectiveness. Well completion is one phase
of well construction that contains technologies providing these
improvements.
Conventional completion “best practice” requires setting a
production packer to isolate pressure and fluids from the
producing zone and manage production tubing movement and
loads. To enhance efficiency, the preferred packer setting
method is a one-trip hydraulic system. The packer is run in on
the production string in a single trip. The tubing is plugged by
landing a wireline or coiled tubing-conveyed blanking plug into
a seating nipple below the packer. The packer is then set using
hydraulic pressure. The one-trip hydraulic system requires well
intervention, which can consume from 12 hours to two days of
rig time, and introduces the risk of losing the wireline or coiled
tubing and associated tools in the well.
An improved setting system would include all the features of
the existing one-trip hydraulic system, but would eliminate the
well intervention. Three one-trip, remotely actuated, completion
systems currently have these capabilities. For actuation, these
systems rely either on pressure-pulse communication, absolute
well pressure, or a hydro-mechanical valve. With three viable
technologies, the completion designer has flexibility in choosing
the right actuation method for the application.
Absolute Well Pressure Actuation System
System Basics. Completion packers actuated by absolute
well pressure are commonly known as “hydrostatic” or “annular
set” packers. Equipment operated by absolute well pressure is
commonplace in other phases of well construction, particularly
in drill stem testing and perforating equipment. Such tools hold
atmospheric air pressure in a chamber as they are run to depth
and use a rupture disc for actuation. When the absolute pressure
in the well exceeds the differential pressure rating of the rupture
disc, the disc ruptures, allowing wellbore fluid into the tool. The
pressure difference between wellbore pressure and the
atmospheric chamber provides the driving force for setting the
tool. (Figure 1)
Any hydrostatically powered tool will have a range of
hydrostatic pressure at which the tool will operate. At the
minimum extent of the hydrostatic range, the pressure is just
sufficient to set the packer, while at the maximum hydrostatic
pressure the deflections of the atmospheric chamber will impede
the tool operation.
Operational Procedures. When using the absolute well
pressure actuation system, the packer is made up and run in hole
in exactly the same manner as a conventional hydraulic set
packer in a one-trip completion. Once the completion system
reaches setting depth, the well can be circulated with the desired
completion fluid. Pressure in the wellbore is then increased to
the point where the pressure ruptures the disc, actuating the
packer. The packer is completely packed off by the hydrostatic
pressure of the well.
It is important to take into consideration that the tool is
actuated by absolute well pressure, and that at any time when the
pressure in the wellbore exceeds the rupture disc rating, the
packer will set. For example, if the fluid in the well when the
packer is initially run has a higher weight than the completion
fluid, the rupture disc must be selected with respect to the more
2 SPE 90678
dense fluid. Another important consideration is that in deep
wells, the applied hydraulic pressure at the surface required to
raise the absolute pressure at the packer from the lower weight
completion fluid to the higher weight fluid that was in the well
when the packer was initially run plus the extra margin to the
rupture disc rating may be quite high. The high applied surface
pressure must be compared against the casing burst rating in the
“A” annulus.
Many hydrostatic packer designs incorporate a secondary
actuation method, which may be used should the primary
method fail to set the packer. The secondary setting method is
preformed through conventional rig intervention methods by
landing a blanking plug on wireline or coiled tubing at the
packer or in the tailpipe below the packer and applying hydraulic
pressure.
Run History. Absolute well pressure actuation systems have
resulted in dramatic savings for operators in the Atlantic’s
Northern frontier, which claims some of the world’s harshest
drilling conditions.1 The BP Schiehallion and Foinaven oilfields,
for example, are benign shallow reservoirs, but lie in a harsh
subsea environment, in water depths from 1,150 to 1,800 feet.
(Figure 2)
With operating costs approaching US$250,000 per day per
rig, savings in rig time represent substantial cost savings. High-
angle and extended-reach wells are common in this area, often
putting completion packers beyond wireline access. Early
completions in the Foinaven and Schiehallion fields relied
extensively on coiled tubing operations to run and pull plugs as
part of completion installation. As a result, completion
operations often suffered from non-productive time and waiting
on weather associated with the coiled tubing work. Completions
typically required approximately 15 days, excluding installation
of the subsea tree. The operator sought a completion system that
required no coiled tubing intervention, in order to reduce these
risks and costs.
Simplicity was a deciding factor in choosing absolute well
pressure-activated tools for these completions in 1998. The
incorporation of a liner top isolation valve as a robust fluid loss
device was an enabling technology. These completions were the
first ever to use absolute well pressure activation on a
completion packer. Since the introduction of this technology,
the run history in these fields has been unquestionably
successful. To date, more than 56 tools have been run without
failure at Foinaven and Schiehallion. More than 125 absolute
well pressure-activated tools have been run worldwide by the
authors’ service company.
Absolute well pressure activated completion packers have
saved up to $1,000,000 per well, largely by eliminating coiled
tubing mobilization and operation costs.
Pressure–Pulse Telemetry Remote Actuation System
System Basics. Completion packers actuated by pressure-pulse
telemetry are commonly known as “EDGE” packers, in
reference to the trade name of the single product that
successfully uses this technology. The pressure-pulse remote
actuation system is based on one-way fluid-conveyed
communication using pressure pulses down the tubing or
annulus fluid to an electronically enhanced packer. The system
consists of a surface module, a communication medium, which
is the fluid column in the completion tubing or annulus, and a
packer. The surface module’s function is to transmit a pre-
programmed frequency of pressure pulses. The fluid column
carries the pulses to the electronically enhanced packer, which is
preprogrammed to actuate upon receiving the correct frequency
of pulses. (Figure 3)
Similar to absolute well pressure activated packers, the
pressure-pulse telemetry technology relies on in-situ hydrostatic
pressure for the driving force to set the packer. The tool will
have a range of hydrostatic pressure at which it will operate. At
the minimum extent of the hydrostatic range, the in-situ pressure
is just sufficient to set the packer, while at the maximum
hydrostatic pressure the deflections of the atmospheric chamber
will impede the tool operation.
Component Descriptions. The surface module consists of a
computer controller, an interface box with manual controls, and
a computer-controlled pulse-generating unit. The pulse-
generating unit transmits a discrete pressure pulse of specific
amplitude and frequency through the tubing fluid. Its
components include two piston accumulators, an air-driven
water pump, and two pneumatic actuator-operated valves that
control discharge of fluid into and out of the well. The surface
unit also includes gages that monitor the charging of the
accumulators, and bleeder valves that purge air from the system.
The frequency of the pulse transmission is automatically
controlled through a laptop computer.
The electronically enhanced packer is fitted with a frequency
detector, an onboard electronic controller, an actuator, and a
battery power pack. The frequency detector, which is mounted
on the packer’s body, constantly measures pulses traveling
through the fluid column. The onboard electronic controller is
preprogrammed to register the pressure pulses. When the
controller acknowledges receipt of the proper profile and
frequency of pulses, a preprogrammed time delay begins. After
the time delay, the actuator receives power from the battery pack
and sets the packer via hydrostatic pressure.
Operational Procedures. Before the packer is run in the well,
it is checked and preprogrammed with a hand-held terminal to:
1) recognize a discrete pulse frequency; and 2) actuate after a
predetermined time delay.
As the completion is being run, the computer controller of
the surface module is preprogrammed to transmit the discrete
pulse frequency, and the surface system is primed so the only
additional time spent is in connecting hoses for transmission of
pulses through the fluid column. Once in the wellbore, the
downhole tool’s receiver constantly samples all pulses traveling
through the completion fluid, while its control system filters and
recognizes only pulses of a predetermined profile and amplitude.
The tool will not actuate until the preprogrammed, discrete
frequency is matched.
SPE 90678
Once the completion system reaches setting depth, the well
can be circulated with the desired completion fluid. Generally,
before the matching pulse frequency is sent, a single pressure-
pulse is transmitted through the fluid column. The reflected
pulse received at surface is recorded via the laptop computer’s
data acquisition system. This “test pulse” allows the user to
assess, in real time, the quality of pulses delivered and,
therefore, ensures that effective communication is established
between the surface system and the downhole tools.
Following the communication check, the pressure-pulse
generating process continues automatically, under the
computer’s control. After the matching frequency has been sent,
received and confirmed by the control system of the downhole
tool, and the preprogrammed time delay has occurred, the tool
sets hydrostatically.
Should the laptop computer system fail to send the matching
frequency, the actuator may be controlled manually.
Should the primary actuator fail to set the completion tool,
secondary actuation is achievable through conventional rig
intervention methods. This secondary actuation method for the
packer requires landing a blanking plug in the tubing below the
packer and applying hydraulic pressure.2, 3
Run History. Previous literature on pressure-pulse remote
actuation of completion tools introduced this innovative
technology to the industry and documented case studies to
support its continued use. 4, 5
The Gulf of Mexico area has seen continuous use of
pressure-pulse-telemetry-actuated equipment since 1996, when
the technology was first introduced on Shell Mars Subsea #4.
This completion was performed in 2,940 feet of water, at a depth
of 16,894 feet. (Figure 4)
Pressure-pulse telemetry technology has also been used
successfully in record-setting extended reach drilling (ERD)
applications. In wells off the coast of Tierra del Fuego,
Argentina, packers have been set at measured depths up to
26,450 feet, and at aspect ratios up to 5.2.6 (Figure 5)
Optimization of on-line vs. off-line preparation has lowered
packer setting time to around 15 minutes. In one application,
concurrent circulating and pressure pulse transmission
(thumping) permitted the total rig time attributed to packer
setting to be reduced to zero.
Managing time in this manner moves well operations toward
the technical time limit of well completion efficiency. In these
wells, the alternate process of running, setting, and retrieving a
wireline- or coiled tubing-conveyed blanking plug to a seating
nipple below the packer requires several hours. The primary cost
saving from this technology is direct rig time reduction.
However, additional economic benefits accrue from avoiding
costs and risks associated with intervention.
Hydro-Mechanical Valve Systems
System Basics. Hydro-mechanical devices, run as part of the
completion tailpipe, provide a third method of actuating
completion packers without intervention with coil tubing or
wireline. Hydro-mechanical valves as commonly referred to as
3
“disappearing plugs.” This obvious reference to wireline plugs
belies the sophistication of these systems. These devices
typically operate by pressure cycles down the tubing and may
enable the pressure testing of the completion tubing before
setting the packer. Uni-directional and bi-directional devices are
available. Some varieties of hydromechanical valve are single
action, while others may be re-cocked to the closed position by a
mechanical device. Advanced models have additional
functionality allowing them to be used as barriers for well
control or well suspension. (Figure 6)
When run in hole, the device has a ball, flapper, plug, or disk
type obstruction in the tubing. Commonly, if the valve does not
permit self-filling of the tubing, a separate device is run to
accomplish this action. Pressure down the tubing will set the
completion packer. Additional pressure cycles down the tubing
then actuate the tool, removing the obstruction. (Figure 7)
Usually, hydro-mechanical valves leave a full-open internal
diameter.
Hydro-mechanical valves have wide applicability. In general,
the pitfalls of hydro-mechanical valve use are debris tolerance
and overbalance issues. Some designs have much more debris
tolerance than others. Hydro-mechanical valves generally
operate as a result of differential cycles between the tubing
pressure and the pressure in the annulus or the tubing below the
valve. An extreme overbalance situation will interfere with the
“return” cycle. So the pressures at the valve must be considered
when evaluating this technology.
Operational Procedures. Completion designs vary from region
to region in the world and even from well to well within a field.
For the purposes of this discussion, running a hydro-mechanical
valve in the upper completion of a deepwater well featuring a
sandface completion will be described.
After a lower completion, such as a gravel pack or frac pack,
is run, the upper completion is made up and run in hole. (Figure
8) The completion hookup generally consists of:
1. A locator type seal to cover the gravel pack ports in the
lower completion;
2. Ported sub to allow locator to enter lower completion
without hydraulic resistance;
3. Hydro-mechanical barrier tool;
4. Self filling apparatus;
5. Profile nipple;
6. Completion packer;
7. Other equipment such as gas lift mandrels, permanent
downhole gauges, and tubing retrievable safety valves.
Space out is essential to success. Operators use different
methods to insure proper spacing of the locator into the lower
completion when landing the tubing hanger, such as shearable
centralizers or telescoping joints.
Once the upper completion is landed, the completion fluid is
forward or reverse circulated into the annulus, with fluid passing
through the self-filling device. The self-filling device is closed
by circulating from tubing to annulus at a pre-determined rate,
faster than the circulation rate used to place the completion fluid.
4 SPE 90678
The pre-determined circulation rate creates a known
backpressure, which closes the self-filling device.
With the self-filling device closed, hydraulic pressure is
increased to the full setting pressure of the completion packer as
in a traditional hydraulic-set packer scenario.
At this point the hydromechanical valve may be “opened” by
the addition of the correct number of pressure cycles. Various
devices on the market open by different mechanisms including
cutting a disc with a hydrostatic pressure powered cutter,
dissolving a salt plug from within a rubber bladder, rotating a
ball, and lifting a flapper from a seat.
Additional Functionality - Temporary Suspension. In subsea
wells with vertical trees, one advanced variety of hydro-
mechanical valve provides a “disappearing” barrier that permits
bringing the well onto production directly from the host, without
intervention. In one method of vertical tree subsea well
completion, the BOP stack is removed prior to running the tree.
Commonly, a back pressure valve or blanking plug is run to
temporarily suspend the well during the time between BOP stack
removal and tree installation. The TRSSSV provides an
additional barrier. Intervention is required to remove the BPV or
blanking plug from the well when the well is brought on line,
and this action requires the running of a completion riser to the
tree.
By running a bi-directional barrier hydro-mechanical valve,
the well may be temporarily suspended by leaving the valve
closed after setting the completion packer, and again using the
TRSSSV as an additional barrier. In this case the hydro-
mechanical valve is tested for pressure integrity before being run
in the hole. The TRSSSV is inflow tested after the completion
packer is set.
The tree, jumpers, and flowlines are installed while the well
is controlled by the closed hydromechanical valve and TRSSSV.
To bring the well on line, the TRSSSV is opened hydraulically
through the umbilical. The hydromechanical valve is opened
from the host by pressure cycles through the flowline or through
a chemical injection line. A completion riser does not have to be
rerun to pull the BPV or blanking plug from the well to put the
well on production. 8
Additional Functionality - Tubing Testing. Advanced
varieties of hydro-mechanical valve also can provide the ability
to test the entire tubing of a completion to a pressure higher than
the initiation pressure of the completion packer.
Operators use a combination of internal hydro-testing,
external pressure testing, and “torque turn” techniques to ensure
proper thread make-up and pressure integrity in their casing and
tubing strings. The efficacy and efficiency of these methods of
testing tubing are outside the scope of this paper. However, in
the case where the tubing is internally hydro-tested to a higher
pressure than the initiation pressure of the hydraulic set
completion packer, either the test must occur from a point above
the packer, or the tubing pressure must be prevented from setting
the packer.
In one embodiment, sufficient pressure cycle capability is
built into the hydro-mechanical valve to allow internal hydraulic
tubing tests without opening the valve or setting the completion
packer. The system permits autofill and circulation through the
self-filling device. When a pre-determined forward circulation
rate is achieved, the self-filling device shuts off circulation,
allowing a tubing pressure test. After the tubing test, the self-
filling device re-opens, permitting self fill and circulation to
resume. This process is repeated for each tubing test. After a
pre-determined number of tubing tests have been performed, the
self-filling device locks closed. A subsequent pressure cycle will
open a control line port to the completion packer, allowing the
packer to be set by hydraulic tubing pressure. At this point the
well may be left in a suspended mode, or more pressure cycles
may be applied to open the “disappearing plug.”
Run History. As previously noted, there are several varieties of
hydro-mechanical valves in the marketplace. Some of these
devices have reached a point of product maturity and are used
throughout the world for setting completion packers. At least
one design has more than 350 runs, attesting to its maturity.
The added functionality of temporary suspension with a bi-
directional flapper has been used in the North Sea, Gulf of
Mexico, and off the West Coast of Africa.
The tubing testing function, with control line set packers, has
been used in the North Sea and in other markets.
Methodology for Technology Selection
Interventionless or Conventional Setting. The first step in
selecting an interventionless method for setting the completion
packer in a well is to determine whether the wells are good
candidates for the technology. Candidate wellbores are
characterized by high rig rates, WOW risk, NPT sensitivity, high
deviation, horizontal wellbores, extended reach, and extreme
depths.
Choosing an Interventionless Method. Well construction
factors drive the process of selecting an interventionless method.
(Figure 9)
The primary applications of hydro-mechanical valves are
when functionality is added to the completion beyond setting the
packer. As described above, some advanced hydro-mechanical
valve systems permit hydro-testing of the completion string and
suspension of a well in a sub-sea application, in addition to
packer setting.
Pressure-pulse-telemetry-activated tools may be used in
wells that will support a full column of fluid. Generally the
pressure pulse is transmitted down through the fluid in the
tubing. However, in some instances it is better to pulse through
the annulus. This technology is ideal in a dry tree deepwater
application where a frangible fluid loss device is deployed in a
lower sandface completion. There are also temperature
limitations due to the electronics on board the packer.
Absolute well-pressure-activated tools may be used in any
well where sufficient pressure can be applied to the rupture disc.
There are several parameters to consider when analyzing the
pressure that must be applied to rupture the disc which are
discussed above. This technology is ideal in wells where an
SPE 90678
unperforated liner or robust liner-top isolation valve are present
and 2,500 psi hydraulic pressure can be applied.
Absolute well pressure activation requires the well to be
unperforated or to have the lower completion hydraulically
isolated. Thus, pressure-pulse telemetry technology has wider
application, but the simplicity of the absolute well pressure
activation system would encourage an operator to use that
technology whenever feasible.
The technologies that permit interventionless setting do add
to the capital expenditure directly associated with equipment for
the well. Depending on the technology, metallurgy, and other
factors, the interventionless technology may far exceed the cost
of the completion packer itself. The most direct value of an
interventionless technology is the rig time savings. The
increased capital expense must be balanced against not only the
spread cost over rig time saved but also the less tangible costs of
NPT, WOW, and RiskEX. This economic balance in
combination with the technical evaluation will aid in selecting
the best packer setting method for a completion.
Conclusions
1. Setting completion packers without intervention has
taken place in the harshest and most remote working
environments throughout the world, including the North
Sea, North Atlantic frontier, and Tierra del Fuego.
2. Pressure-pulse-telemetry-activated tools can be used in
wells that will support a full column of fluid.
3. Absolute-well-pressure-activated tools can be used in
wells with an unperforated liner or liner top isolation
valve.
4. Hydro-mechanical valves can be used to set packers
without intervention.
5. Rig time associated with wireline and coiled tubing
intervention to set completion packers can largely be
eliminated through the use interventionless techniques.
6. Added value may be gained in completion design by
using hydromechanical valves, including tubing testing
and temporary well suspension in subsea applications.
7. Value is added to the completion phase of well
construction by decreasing operational complexity of the
completion and thus reducing HSE, waiting on weather,
and NPT risks.
8. Interventionless packer setting techniques should be
considered when reduction of intervention-associated
risk and rig time are drivers of completion design.
Acknowledgments
The author wishes to thank Baker Oil Tools for permission to
publish this paper, and thanks Shell, BP, Total and various other
operators for their investment in the future of interventionless
packer setting.
5
Abbreviations
BOP = Blow Out Preventer
BPV = Back Pressure Valve
ERD = Extended Reach Drilling
TSL = Tubing Stability Latch
ILT = Invisible Lost Time
NPT = Non-Productive Time
TLP = Tension Legged Platform
HSE = Health, Safety and Environment
TRSSSV = Tubing Retrievable Sub-Surface Safety Valve
WOW = Waiting on Weather
RiskEX = Risk Expense
CapEX = Captial Expense
OpEX = Operating Expense
References
1. Mason, John N.E., Moran, Paul, and King, James G. - Baker
Oil Tools, and Cameron, Paul D. - BP: “Interventionless
Hydrostatic Packer Experience in West of Shetland
Completions,” OTC 13288 presented at the 2001 Offshore
Technology Conference, Houston, April 30 - May 3.
2. Jones, Kevin R.: “Electronics Add New Dimensions to Well
Completions,” Oil & Gas Journal (Oct. 2, 1995), 68.
3. Bussear, Terry: “Remote Actuation System Speeds Deepwater Well
Completions,” Oil & Gas Journal (Oct. 7, 1996), 56.
4. Godfrey, D.G., et al.: “The Mars Project Overview,” paper OTC
8368 presented at the 1997 Offshore Technology Conference,
Houston, May 5-8.
5. Smith, Michael V., Lowe, Evan, Coull, Craig - Baker Oil Tools
“Deewater Remotely Actuated Completions for the 21st Century,”
OTC 8844, paper presented at the Offshore Technology
Conference, 4-7 May 1998.
6. Proano, Enrique M. Baker Oil Tools, Clergier, Alberic, Total Austral
S.A.: “Advanced Completion Techniques For Extended Reach
Wells,” OTC 8805 presented at the 1998 Offshore Technology
Conference, 4-7 May 1998.
7. Azuara, Aurelio, King, James G., Walker, Graeme J.-Baker Oil
Tools: “Summary of Remotely Actuated Disappearing Plug
Technology in Deepwater Wells,” OTC 16534 presented at the
2004 Offshore Technology Conference, 3-6 May 2004.
8. Stair, Craig – Shell, Nelson, Ron N. –Shell, Stuckey, Joe, and
Walker, Graeme – Baker Oil Tools: “Riserless Subsea
Completion with Disappearing Plug Technology,” SPE
77712 presented at the 2002 SPE Annual Technical
Conference, San Antonio, September 29 - October 2, 2002.
6 SPE 90678

Figure 1. – Absolute Well Pressure Activated System For Down-Hole Completion Tools

Figure 2. First Absolute Well Pressure Completions in North Atlantic Frontier in 1998.

5 4 3 2 1 0 3
9 8 7 6

Schiehallion Shetland
Islands

60

A T L AN T I C
OCE AN

59
Orkney
Islands

Wick

58

Scotland

Aberdeen
57
SPE 90678 7

Figure 3 – Pulse Communications System For Down –Hole Completion Tools

Figure 4 – First Pressure Pulse Telemetry Completion on Mars in 1996

New Orleans

Tahoe

GULF Pompano
OF
MEXICO
Mars

Auger
8 SPE 90678

Figure 5. Pressure Pulse Telemetry Completions in Extended Reach Applications - Tierra Del Fuego, Argentina
SPE 90678 9

Figure 6. Hydro-Mechanical Valve:

Figure 7. Hydro-mechanical Valve Completion:

10 SPE 90678

Figure 8. Hydro-mechanical Valve Completion with Temporary Suspension Functionality.

SPE 90678 11

Figure9. Interventionless Decision Tree.

High Rig Rate

WOW Risk
NPT Sensitive Conventional
Deviated No Completion
Horizontal Methods
Extended Reach
Extreme Depth

Yes

Consider
Interventionless
Completion

Test Tubing
Prior to Packer Yes
Setting?

No
No

Suspend Yes
Yes
Subsea Well

No
No
No

High Fluid Loss

No

Can Entire Wellbore Economic Hydro-Mechanical

Withstand 2,500 psi Applied Yes or No Yes
Justification Valve
Hydraulic Above Max
Hydrostatic?

Economic Absolute Well

Yes Yes
Justification Pressure

Economic Pressure Pulse

No Yes Telemetry
Justification