WELL COMPLETION

A well completion is a technique, which allow to produce a fluid from a hydro

carbon-bearing reservoir to the surface.
The ideal completion is the lowest cost completion (considering initial and
operating cost) that meets or nearly meets the demands placed upon for most of
its life.
The aim of a completion design is obviously to deliver the fluid with the m
aximum safety and efficiency throughout the life of a well.
This will necessitate:
1. The analysis of the environmental risk and production objective.
2. The evaluation of the capacity of the reservoir to produce a fluid under
various well bore conditions.
3. An estimation of the ability of the fluid to flow to the surface and ove
rcome any resistance to flow, including the effect of surface conditions.
The above assessments will allow:
Equipment to be chosen to allow for safety considerations and predicted producti
on characteristics throughout the life of the well.
Procedure to be established for operations covered by the completion phas
e.
The quantity of data ,constraints and objective which have to be analysed, treat
ed and
diagnosed to solve a completion engineering problem calls for a certain number
of guidelines These guidelines are:
Data gathering.
Production object analysis
A general project flowchart
The general project flowchart allows for the fact that most of the time the ob
jectives
Cannot all be met simultaneously. It is a trial and error procedures which could
lead to several satisfactory design. In order to select a reliable completion,
a discussion with all parties involved will be needed and a compromise found.
The extreme variety of possible cases meant this completion design volume has
been split up into three main sections.
1. A review of existing completion configurations with their advantages and
disadvantages and limitations.
2. The completion design guidelines.
3. An application to specific cases as an illustration of the design proced
ures.

WELL COMPLETION DESIGN

The completion engineer should aim for SAFETY. OPERATIBILITY, and SIMPLIC
ITY within the requirements dictated by the optimum (cost vs .recovery) developm
ent of the field.
Major factors which influence design are:
1. Reservoir parameter:
• Fluid volumes, depth, lithology of formation, sand consolidation, number of Zon
es, pressure, temperatures, stimulation requirements, etc
 2. Operating requirements:
• Producers/Injectors, secondary recovery, artificial lift(Gas lift, jet pumps, Su
cker rod pumps, Submergible pumps, Progressive cavity pumps, etc )
3. Type of completion:
• Single zone completion, Multi zone completion, Sub-sea completion, Horizontal Co
mpletion, Gravel pack completion etc.
4. Operational fluid conditions:
• Surface pressure/temperature, corrosion, scale, paraffin, sand etc
5. Workover
• Methods of workover and frequency.
6. Environmental:
• Onshore, offshore, sub sea, hilly terrain, thickly populated, river bed, or slus
hy land location.
7. Government legislation:
• Requirement for specific safety requirements, pollution control west disposal et
c.
8. Throughput of surface process plant
• Particularly important in offshore.
9. Safety:
• It is essential to select the correct equipment to satisfy well and environment
safety Requirement.
• Where it is possible, the equipment with fail-safe capability should be specifie
d.
• The well must be capable of being controlled at all times during its operational
life, using wellhead equipment, kill systems and/or subsurface safety valves.
10. Production capabilities
• It is important to design for optimum well production(or injection) rate through
out the expected well life .If more reservoirs are to be produced simultaneously
then multiple completion is possible, using single, dual or triple strings of t
ubing and one or more packers. The choice will depend on
a) Production rates,
b) Reservoir-control requirements
c) Workover possibilities,
d) Artificial lift requirements,
e) Costs and standardization,
f) Other factors particular to area of operation.
11. Corrosion
• Corrosion in oil and gas wells generally involves carbon dioxide or hydrogen sul
phide ,both in the presence of water. The problems associated with both sweet co
rrosion and sour corrosion can be minimized through the correct selection of cor
rosion resistant materials and/or the circulation of corrosion inhibiting chemic
als in the well.
• Corrosion can be compounded through excessive gas or liquid velocities i.e erosi
on.
12. Tubing selection.
• Tubing size selection requires evaluation of pressure losses in vertical flow, f
or a range of present and future inflow conditions. In gas well, the erosional
velocity is often a critical parameters. It is also important to select proper
thread connections.
13. Annulus/Tubing seals.
• Apart from the tubing head and the integrity of the tubing and tubing connection
s, sealing between annulus and tubing rests with the packer and the sealing elem
ents in such equipments as anchor seals locator seals, telescopic/swivel/travel
joints, tubing seal receptacles and sliding sleeve/side pocket mandrel.
• Seal elements can be in the form of ‘O’ rings, elastomer seals, moulded elastomer
seals or chevron seals (‘V’-packings).They must be selected for their suitability re
garding resistance to well fluids, temperature and pressure, their wear rate and
ageing characteristics.
14. Circulation and communication Devices.
• The capability to establish tubing/annulus communication in order to equalize pr
essure and circulate fluids, is an important feature of any completion design. T
his also allows inhibitors to be introduced for counteracting wax, scales, corro
sion and injection of gas in gas lift. Circulation and communication devices inc
lude sliding sleeves, side pocket mandrels and ported nipple.
• In some cases communication for killing may be obtained by puncturing tubings by
electric/mechanical wireline methods.
15. Safety Valves
• Safety valves can be used in various locations on/in a well depending upon the w
ell site requirements.
• In case of well located in offshore or slushy land, a river bed or densely popul
ated land, the subsurface safety valve is used as third level of safety on the w
ell. Surface safety valve on a well or in a flow lines is used as fourth level o
f safety.
• The safety valve provides final control of the well, when all other controls hav
e ceased to function. Since it is the most important control device, the designe
r must select the best valve for the well.

COMPLETION METHODS
There are three basic ways to complete a well
• Open-hole completion.
• Cased-hole completion.
• Liner completion.
1. OPEN HOLE COMPLETION
In the open-hole completion, casing is set only to the top or slightly into the
completion interval
Advantages of open hole completion
• Adaptable to special drilling techniques to minimize formation damage or to prev
ent lost circulation into the producing zone.
• With gravel pack provides excellent sand control method where productivity is im
portant.
• No perforating expenses and saving of rig time.
• Log interpretation is not critical since entire interval is open.
• Full hole diameter is available to flow.
• Can be easily deepened.
• Easily converted to liner or perforated completion.
• Facilitates ultra short radius multiple radial completion.
Limitations of Open Hole Completion
• Excessive gas or water production difficult to control.
• Difficult to selectively stimulate producing interval.
• Difficult to fracture selectively.
• Casing set “in the dark” before the pay zone is drilled or logged.
• Require more rig time on completion.
• May require frequent cleanout.
• No way to regulate fluid flow from or into well bore.
• Subsequent cased hole completion will restrict well bore and completion string d
iameter.
2. CASED HOLE COMPLETION
 In the cased and perforated completion, Casing is set into or through the pro
ducing formation and cemented. The casing is then perforated to provide communic
ation between the well bore and formation.
Advantages of the Cased Hole Completion
• Ease of selective completion and work over operation in the producing intervals.
• Can effectively control gas and water producing by selectively perforating and i
solating.
• Can effectively control and monitor zonal fluid production.
• Permits multiple completions.
• Can stimulate selectively.
• Can fracture selectively.
• DST’s Logs and formations samples provided information on casing setting depth or
abandon.
• Can be deepened, but with smaller hole.
• Can be adopted to sand control, selectively, both as pre-pack or conventional gr
avel pack.

Limitations of the Cased Hole and Perforated Completions

• Long interval perforation can be expensive.
• Effectively well bore diameter and productivity may be reduced.
• Good cement job through production interval required.
• More expensive than open hole completion.
• Not adoptable to special drilling techniques to minimize formation damage.
• Log interpretation sometimes critical in order not to miss commercial sand, yet
avoid perforating submarginal zones
3. LINER COMPLETION
In a liner completion, casing is lowered much above the pay zone and a liner
hanger is set in the casing. Liner is extended through the pay zone Liner is
used to control a sloughing formation.
Completion using a liner is also to reduce casing cost.
Sometimes casing run is to the top of the pay zone and a slotted liner is se
t across the producing formation. This type of completion(slotted liner) is prim
arily applied to sand control .Cementation is not done in slotted liner completi
on.
Liner completion will restrict well bore completion string diameter.
Advantages and disadvantages of the uncemented liner are the same as the open
hole completion
Advantages and disadvantages of the cemented liner are same as the cased and
perforated completion.

WELL COMPLETION EQUIPMENTS

Well completion equipments consists of
• The Wellhead equipments and Christmas Tree for control and monitoring of the pro
duced fluid.
• The bottom hole equipment, which provides communication between the producing fo
rmation and the well.
• The production string and accessories, which provide a means for the produced fl
uid to flow from the bottom hole to the surface.

WELLHEAD EQUIPMENTS
Wellhead equipments are attached to the top of tubular goods used in a well, to
support the tubular string, hang them, provide seals between strings and control
production from the well.
These equipment are covered by American Petroleum Institution (API) Speci
fication-6A
Wellhead consists of four parts:
• Casing Head
• Intermediate Casing head.
• Tubing head.
• Tubing Hanger.
CASING HEAD
The lowermost casing head is a unit or housing attached to the top e
nd of the surface casing to provide a means for supporting the other string o
f casing and sealing the annular space between the two string of casing.
It has a flange connection at the top to accommodate Blow Out Preven
tor or Intermediate casing head. A ring groove is provided in the top flange to
seal next equipments at above i.e intermediate casing head or BOP. Bottom connec
tion is either threaded or slip-on type to connect first casing or surface casin
g.
The slip-on casing heads are machined so that the head can be slippe
d over the casing for welding. Test ports are provided to test the weld after in
stallation,
Casing head mainly consists of three parts.
a. Housing.
b. Casing hanger.
c. Primary seal.
d. Tubing hanger.
A typical casing head is designed for universal use on all depth of well and on
all type completions. The bore of the head is cylindrical and provided with two
shoulders. The upper shoulder supports the pack-off hydraulic pressure and test
loads, while the lower shoulder independently supports the casing load.
Casing head will hang the heaviest casing string without being damaged
and can be salvaged and used repeatedly without machining.
Sometimes lock-screws are provided, if specified. They may be externally adju
sted at any time during the life of the well.
Standard sizes are available of flange sizes 9”,11”,13-3/8”,16-1/4”,21-1/4” and pressure r
ating of 2000,3000,5000 lbs.
Casing hanger consists of a set of slips and a sealing mechanism(primary sea
l).It supports casing weight load. It also provides the added capacity required
to permits hanging the casing in full tension when desired.
The casing hangers may be lowered through the preventer as soon as the cemen
t plug hit the bottom. They automatically set and support the entire weight of t
he casing in full tension and automatically seals the annulus. They should be te
sted to the full working pressure rating of the hanger under full casing load.
Slips are precision-machined with sharp inner teeth which provides a positi
ve bite to hold the casing securely. On the back of the slips are dull outer tee
th, contoured by precision machining, which contact the slip-bowl and automatica
lly control slip to bowl friction-increases the friction as the casing load incr
eases-and stopping the downward slip travel before the slips damage the casing.
Before loading
 Casing slips are in position in the casing head. At this point no load has
been applied to the casing hanger or the slips by either mechanical load or hydr
aulic pressure.
Being loaded
Sharp inner teeth immediately secure the casing and the slips and casing m
ove downward together. At light loading, the dull back teeth slide in the bowl w
ith little friction. As loading increases and travel progresses, the back teeth
begin to form slight shoulder in the soft bowl. These shoulders rapidly build up
friction until slip movement is stopped.
Loaded
The downward travel of the slips is stopped before they move inward enough
to damage the casing. The dull teeth rest securely on the shoulder they have fo
rmed.
INTERMEDIATE CASING HEAD
An intermediate casing head is a spool type unit or housing attached to
the top flange of the underlying casing head. The bottom flange will have the sa
me size and pressure rating of the top flange of casing head. A ring groove is p
rovided to have a sealing between two flanges with suitable ring gaskets. Top fl
ange may have different size and pressure rating matching to the bottom flange o
f tubing head with a ring groove. Side outlet may have threaded, integral
studded or extended flange outlet at both sides of the spool.
At the bottom of the spool, a recess is provided to accommodate secondary
seal. The secondary seals are hydraulically actuated by injection of plastic pa
cking under high pressures through a check valve to compress packing seal around
the casing. The seal can be packed any time by injecting more plastic through t
he injection port.
It is important to determine correct casing cut off length by measuring d
istance from the top flange of casing head. After cutting the casing at exact me
asurement, smoothly taper and clean up the pipe to prevent scoring the secondary
seal.
The bore of the head is cylindrical and provided with two shoulders. The u
pper shoulder supports the pack-off hydraulic pressure and test the loads, while
the lower shoulder independently support the casing load.
TUBING HEAD
The Tubing head is a spool type unit or housing attached to the top flange
of topmost intermediate casing head. The bottom flange will have the same size
and pressure rating of the top flange of intermediate casing head. A ring groove
is provided to have a sealing between two flanges with a suitable ring gaskets.
The top flange may have different size and pressure rating, matching to adopter
flange of the Christmas Tree with a ring groove. Side outlet may have threa
ded, integral studded or extended side outlet at both sides of Tubing Head.
At the bottom of the spool a recess is provided to accommodate secondary sea
l .The secondary seals are hydraulically actuated by injection of plastic packi
ng under high pressure through a check valve. The seal can be packed at any time
by injecting more plastic through the injection port.
It is important to determine correct casing cut off length by measuring the
distance from the top flange of intermediate casing head. After cutting the casi
ng at the exact measurement, smoothly taper and clean up the casing to prevent s
coring the secondary seal.
The bore is cylindrical and provide one shoulder to land tubing hanger.
Lock screw assembly is provided in the top flange. These lock screws may be
externally adjusted at any time during the life of the well to hold tubing hang
er down
Under light weight or to adjust body pack off of tubing hanger.
The bowl features elongated slots(orientation slots),located 90 degree from
the outlets providing for positive orientation of single/dual tubing hangers wit
hout removal of the Blow Out Preventer .This positive orientation can be accompl
ished through the visual inspection by removal of a lock screw assembly. This or
ientation is required to align control line port connection.
This feature is not essential in a completion without SCSSV.
TUBING HANGER
Main function of a Tubing hanger is to secure and hang tubings. Two f
emale threads are provided in the Tubing hanger, one at the top and one at the b
ottom. Tubing or completion string is connected to the bottom thread to hang. To
p female thread is required to land or to retrieve Tubing hanger with completion
string. Tubing hangers are equipped with threaded (Acme thread) back pressure v
alve preparations, with a polish bore to install Back pressure valve. Tubing han
ger can be lowered through Blow Out Preventer. Minimum I.D of Tubing hanger must
be same as I.D of tubings.
It has a body seal, which provides an adequate seal between tubing and tub
ing head .The body seal or hanger pack-off is energized by means of lock screws
in the tubing head.
Tubing hanger has an extended neck with one or more seal ring (T-Seal).Thes
e seals mate with the pocket in the adapter flange or lower master valve of Chir
stmas Tree. The seals may be plastic packed through ports in the adopter. These
seals isolate produced fluid from the atmosphere.
The hanger has porting connecting the bottom of the hanger to exit ports be
tween ”T” seals on the hanger neck. This porting is used to connect down hole contro
l lines to the adapter.
The Tubing hanger may be equipped with orientation key to align in the Tubin
g head for control line port connection.

Dual Tubing Hanger

The dual tubing hanger is consist of two half section. It is designed to perm
it both tubing strings to be run ,hung or pulled independently .A sandwitch-typ
e pack off is employed which can be landed through the blowout preventers, keepi
ng the annulus under positive closed protection at all times .The pack-off can b
e run either attached to the second string of tubing or separately. Pack-off can
be adjusted at any time with lockscrews in the tubing head flange and a perfect
annulus seal formed prior to removal of preventers. Treads for back pressure v
alves are machined into each hanger. Tubing hanger is designed with an extended
neck that is prepared to accept two “T” types seal. The extended neck fits into a ma
ting pocket in the bottom of the adapter or valve above hanger. Tubing hanger pr
ovides hydraulic access to a downhole safety valve in each string through a sepa
rate nipple.

CHRISTMAS TREE
A Christmas tree is an assembly of valves and fittings used to control producti
on and provide access to the production string. It includes all equipments above
well head.
The lower most part is tubing head adapters. The tubing head adapters are fla
nged bottom by studded top. The seal pocket in the bottom of the adapter is desi
gned to fit over the extended neck of the tubing hangers having control lines. T
hese adapters have plastic injection and bleeder ports to pressure-pack the “T” seal
 at the top of the hanger as well as test and bleeder ports for testing the flan
ge connection. The control line exit can be furnished with threads or flange out
let connections. The adapters are prepared for one or two control lines.
The vertical Run consists of three valves. The bottom most is known as lower m
aster valve, next one as master valve and the top most is known as crown valve o
r swab valve .A tree is provided between master valve crown valve to have side o
utlet. A Tree cap is connected at the top of crown valve with a threaded hammer
nut with a port to connect pressure gauge. A tubing female thread is provide in
the cap to land Christmas tree or to have a access for wireline operation. All v
alves in the vertical string should have same bore of tubing string. Side outlet
consists of two valves and a bean housing.

The size of the valve may be of same size or smaller size. These two valves are
known as wing valves. One of these wing
valves will be shut down valve (fails save closed)

In dual Christmas Tree, there will be two sets of vertical valves for two tubin
g strings and two sets of side outlets on both sides. Generally, they are of sol
id block type.

TUBINGS
The tubing is a part of completion equipment, allows the production of fluid f
rom the reservoir to the surface.
Functions of Tubing
The functions of tubing are:
• It is essential for well killing, circulation , and workover.
• Tubing provides optimized flow channel to produce optimum/maximum efficient rate
from a well.
• Tubing is used to isolate casing from effect of high pressure, high temperature
and corrosive fluids
• It facilitates completion, production and control of flow in multiple commingled
or parallel completion.
• it is essential for most common artificial lift operations.
• It is facilitates the installation of common wire line operated down hole tools.
• Hold a annular well killing fluid.
A tubing is defined by four parameters:
• Size.
• Nomanal weight.
• Steel grade.
• Tubing connections.
The tubing specifications are covered by American Petroleum Institution (AP
I) Specification-6 A.
It should be noted that the API tubing Classification covers tubular within
the range of 1.05”-4-1/2”, above this diameter of tubular referred to as casing. The
standard sizes of API tubings are 1.050”,1.315”,1.660”,1.900”,2.063”,2.375”,2.875”,3.500”
.500”.
Steel grades are defined by a letter and a number. The letters specify the
method of manufacture, heat treatment, etc or steel quality and numbers indicate
 the minimum yield strength in 1000 psi (N-80,P-105).
API tubings are limited to two standard connections which are:
• API non -upset (NU) which is a 10-round thread-form coupled joint, wherein the
threads has less strength then the pipe body.
• API external upset (EUE) which is an 8-round thread-form couple joint, wherein
the threads has more strength then the pipe body.
• In non-upset tubing, threads are cut directly on pipes, resulting the strength o
f threads become less stronger than the pipe.
• In upset tubing, end of pipes are upset and then threaded, resulting the strengt
h of threads become stronger than the pipe. Also thread length of upset tubing i
s longer than the non-upset tubing.
Thread Form
Thread form of API tubings are tapered, 30 degree round thread, non shouldering
(round crest and root V type-tapered ¾” per feet of length,)
Sealing
Seal is obtained by the use of a thread compound within non-mating threads. Th
e grease compound fills the helicoidal pathway between the crest and root.
Coupling
For the same size of tubings , couplings OD of upset tubing will be more than
non upset tubing.
When special clearance is needed, the tubing coupling can be machined down t
o a given O.D without loss of strength. The manufacturer’s tables usually give the
se special clearance value
When running dual or multiple completions, a special bevel should be ordered
to facilitate separate running or pulling of the tubings.
Tubing length range.
Tubing manufacturers generally deliver tubing of 20-24 ft length. This length
is known as Range-1.Tubing length of 28-32 ft is known as Range-2.Shorter length
of tubing of length 2-12 ft is known as pup joints
Non API Connections.
Special joints have been developed to overcome the limitations of API joint
s as regards leak and high tensile load resistance, The first improvement obtain
ed concerned the tensile load resistance and coupling clearance, by using the bu
ttress threaded coupled joints (Vam Thread). Then more improvements were achieve
d concerning leak resistance using by using metal to metal seals and/or gasket
seals. These joints are often called “premium” or “proprietary” joints. The common premi
um threads are Vam, Hydril and Atlas Bradford.
TUBING MAKE-UP TORQUE
For each tubing defined as above, the nominal size, thread, weight and steel
grade, and tables of recommended make-up torque value, are supplied by the manu
facturers and by API connections (API 5 C 1,table 1.2)
It should be remembered that it is strongly recommended to follow the table
torque values. Therefore correct measurement of these make-up torques on-field i
s essential; this will ensure effective sealing and load resistance and avoid po
ssible over screwing of the tubing joints.
The torque make-up measurement should be done with a direct reading Martin D
ecker or with a hydraulic torque gauge mounted on the power tong.
In order to obtain an accurate measurement, the back- up cable connected to
the tong arm must
a) be in the same horizontal plane,
b) be at a 90 degree angle.
If these two recommendations are not followed, the value read on the torque
indicator is of no use.
Friction correction factor
When making up a tubing, a special tubing thread compound is used. This comp
ound reduces the friction any resulted galling effect.
It should be noted that the make-up torque values indicated in the suppliers
tables are for a friction factor of 1. To obtain the correct make-up torque val
ue using a thread compound with a friction coefficient from 1, one should multip
ly the value indicated in the tables by this factor.
The large variations of tubing torque are due to establishment of the press
ure between the pin and box mating surfaces. Accurate make-up torque measuremen
ts are necessary to ensure that there is no risk of overstressing the pin or bo
x thread.
It should be noted that these torque values depend on joint cleanness, tool
speed, grease cleanness and similar factors. Therefore some manufacturers recomm
ended optimum torque values, while others the minimum value(below which an effec
tive seal is not made) and a maximum value(above which threads or joints may be
destroyed).
Where alloy, duplex or super alloy steel is concerned, making-up a joint bec
omes very delicate as the threads are very susceptible to galling. In this case
the recommendation of joint and grease cleanness become compulsory, moreover joi
nt alignment must be carefully checked and the proper engagement of these thread
s ensured before make-up.
Make-up control systems are available on the market (Tuboscope, Weatherford, B
aker etc) which records proper thread engagement and make –up torque.
SELECTION OF TUBING
Sizing production tubulars.
The size of the production string casing depends upon the diameter of flow
conduit (single or multiple) needed to produce the desired flow stream, the meth
od of artificial lift, if require, or specialized completion problems such as sa
nd control.
Sizing of the production tubing depends primarily on the desire production
rate. Maximum production rate in a given well depends upon:
- Static reservoir pressure.
- Inflow performance relation,
- Pressure drop in tubing.
- Pressure drop through the wellhead constriction.
- Pressure drop through the flow line.
- Pressure level in the surface separating facilities.
Where maximum flow rate is an objective of well completion design all of th
ese factors must be considered.
The corrosion erosion study: This can indicate a maximum flow velocity to avoid
a possible erosion of the steel or the destruction of an inhibitor film.
The production casing drift: To allow the completion equipment to be run in.
The artificial lift study : as artificial lift will produce additional pressur
e losses.
The choice of nominal weight, steel grade and connections will result from a com
promise between the recommendations of the following studies
- The tubing stresses and movement study which will indicate the forces to
be taken into account for the entire well life.
- The corrosion and erosion study which will choose the tubular metallurgy
.
- Completion and work over procedures which will introduce some constraint
s.
The production of highly corrosive fluids may require internal flush connections
or internally coated tubings.
Running a dual completion will require a special clearance coupling with a spe
cial bevel on the coupling.
Flow coupling may have to be introduced in the tubing string above and below r
estriction to avoid erosion due to turbulent flow
Blast joint may have to be introduced in the tubing string against the perforati
on to avoid abrasion
The joint strength should be sufficient and capable of taking all load during en
tire the life of a well including work over operation. It should not be exceed 7
5% of joint strength.
The burst and collapse pressures due to internal and external applied pressure e
ither during workover, stimulation, or during normal production should be checke
d. It should not be exceed 80% of pressure specified in the tubing performance d
ada.
PACKERS
A Packer is the part of the completion equipment which seals the casing –tubing a
nnulus.
Packers are usually run for the following reasons:
- Provides an effective isolation of the casing tubing annulus from the pr
oduced fluids for safety purposes, thus limiting well control to the tubing at s
urface.
- To isolate the casing from corrosive fluids and/or high pressure.
- To stabilize and control flow from pay zones.
- In conjunction with an artificial lift system (isolation and control) ,
in gas lift, Jet Pumps.
- To selectively produce multiple zones (isolation)
- Selective stimulation becomes feasible.
- Wire line and down hole operations become possible.
- Hold a annular well killing fluid.
A packer is basically defined by its setting and sealing mechanisms, its tubing-
to-packer connections and its retrievability.
The setting mechanism in which a cone driven behind tapered slips forces these s
lips into the casing wall.
The sealing mechanism in which packing elements are compressed against casing wa
ll.
The tubing-to-packer connection which can be done in one of three ways.
the tubing is latched or fixed onto the packer(no movements),
the tubing is landed allowing a limited movement.,
The tubing is stung into the packer allowing unlimited movement.
Packer retrievability which can be provided either by drilling, milling or by ac
tivating a releasing mechanism.
The means of accomplishing the four above functions has led to the development o
f numerous packer.
Considerations in Selection of Basic Packer Type.
1. Size of tubing and casing involved,
2. How many tubing strings involved.
3. Produced fluid or gas, especially as to corrosivity,
4. Well depth,
5. Pressure anticipated to hold, differential and absolute,
6. Direction of differential pressure,
7. Bottom hole temperature,
8. Anticipated cyclic changes in pressure or temperature,
9. Critical nature of position or placement,
10. Tubing to be in tension or compression,
11. Packer to be moved and reset
12. Completion fluid anticipated,
13. Extent of through-tubing work anticipated,
14. Anticipated future remedial work,
15. Setting and releasing mechanism and its compatibility to other completio
n equipment,
16. Extent of skill required to set, retrieve, or fish,
17. Location of well and availability of service, repair, or operational or
fishing advice.
The Packers can be classified in three categories:
Mechanical set Packer
Hydraulic set Packer
Permanent Packer

MECHANICAL SET PACKER

Mechanical Packer is a single string retrievable casing packer. It sets and retr
ieves mechanically. It is a service packer used in
- Layer wise testing,
- Squeeze cementing,
- Stimulation,
- To find injectivity,
- To find casing leakage.
There are two types of mechanical set packer:
a. Weight set Mechanical Packer
b. Single-Grip Mechanical Packer.
c. Double-Grip Mechanical Packer.
d. Tension set mechanical Packer.
Single-Grip Mechanical Packer
Single-Grip Mechanical Packer consists of:
1. A packer mandrel with a box connection at the top, to connect tubing/dri
ll string,
2. and a pin connection at the bottom to connect tail pipe
3. A packing element system of three elements, with sore hardness of 90-70
-90.
4. J-Slot assembly with drag block and a set of slips. The drag block holds
against the
5. casing and allow rotation of mandrel to engage or disengage with J-Slot
.
6. An effective bypass design to equalize and to avoid swabbing. The bypass
area is
7. controlled by a face seal-type bypass valve which is actuated by stroke
of the mandrel.

Tension Set Packer

To set the Packer
Run the packer with tubings or drill pipes in the jayed position. In jayed
position bypass valve will be in open position to permit free circulation both
through and around the Packer. The packer, which is mechanically set by means of
 a J-Slot arrangement, should be run one foot below setting depth and then raise
d to the required position (to properly position the J-Slot) To release from the
J-Slot, pick up the string, rotate to the right one-quarter turn at the packer,
and then slack off. The J-Pin will move clear of the J-Slot and the Cone will m
ove under the slips. Application of set-down weight closes and seals the bypass
valve, set the slips, and packs off the packing elements. The formation below th
e packer, which is now completely isolated from the annulus above, is accessibly
only through the tubing string.
Set-down weight required to pack off packing element system will depend upon
the size of the packer. It may range from 4000-15000 lbs.
To release the Packer
To release the packer, raise the tubing string the full length of the packer.
When the J-Pin shoulders, the J-Slot will be re-engaged, since the J-Pins on the
bottom sub are so spaced as to always have one J-Pin located in the J-Slot when
the tubing is picked up. When the tubing is lowered slightly, the J-Pin automat
ically engaged the J-Slot if no right-hand torque is in the tubing at the tool.
When the tubing is raised to release the packer, the bypass valve opens to per
mit circulation through and around the packer.
Double-Grip Mechanical Packer
The double-grip mechanical packer is used where pressure differential from be
low the packer is anticipated.

It features an integral hydraulic button-type hold-down that is located below th

e bypass valve .It also incorporates a built-in, ”differential lock” which utilizes
a balance sleeve actuated by pressure from below the packer. This pressure creat
e additional downward force which, combined with set-down weight, helps to maint
ain the force necessary to keep the bypass valve closed.
Running, setting and releasing procedures are same for both types of mechanical
packers.
Hold-down buttons should be energized with” protected “ fluid, so that sand or well
debris will not lock buttons in out position.
Tension Set Mechanical Packer
This packer is similar to single grip mechanical packer or it is just a invert
ed single grip mechanical packer.
To set the Packer.
Run the packer to the setting depth, making sure the last movement of the tubin
g string is down in order to position the J-pin in the top of the J-slot before
trying to set the packer. Rotate to the left one-quarter turn at the packer and
pick up the tubing string About 1500 lbs of tension is needed to set and pick-of
f the tool.
To release the Packer
Lower the tubing at least one foot more than is necessary to remove the appl
ied tension to move the J-pin to the top of the j-slot. Rotate to the right one-
quarter turn at the packer and pull out the string.

Double-Grip Mechanical Packer

Advantages of the Mechanical Packer
1. It is a very useful packer for well service/repairing job during work ov
er operation.
2. Can be released and reset at another depth at will, if sealing elements
stay intact.
3. The packer can be reused in other applications.
4. The packer does not have to be milled out, if it becomes necessary to re
move it,
5. thus saving rig time.
Limitations of the Mechanical Packer
1. Available only as single string packer.
2. Deviated well often limit the use of compression-set packer
3. Hold-down buttons can be expected to fail, ( at O-ring seals) after nume
rous reversal in pressure.
4. It can not stand for a higher differential pressure..
5. Cannot be used as a completion packer.

HYDRAULIC SET PACKER

Hydraulic packer is set by pressurizing tubing at required pressure differen
tial at the packer against a wire line installed blanking plug, standing valve o
r on expandable seat such as pump-out-plug located below the hydraulic setting p
orts of the packer.
It is consist of four single slips supported by two opposingly tapered cones
. Because of the design feature of the packer, these four slips set in unison, c
entralizing the packer in the casing before the main three-piece dual durometer
seal elements are set. A positive pack-off and anchor is established and maintai
ned by two twin ratchet-lock pistons. One piston is utilized to set the sealing
element and another piston sets the four-unit slips. The energy stored in the se
al during the setting of the packer is retained by the lower ratchet independent
ly from the slip assembly. Locking the total energy stored in the seal during th
e setting independently of slip cone movement ensures that this packer seal asse
mbly will sustain continued cycling of pressure differentials in excess of the y
ield pressure of the casing.
It also incorporate in the uppermost portion of the packer, a built-in equali
zing valve, a valve that is opened to afford circulation directly above the pack
er. Once this valve has been opened ,the differential pressure across the packer
will be equalized and thereby minimize the torque/tension required to release t
he packer.
Hydraulic packers feature bi-directional slips with extra large gripping area
to allow for high setting forces without casing deformation.
The location of the sealing element above the slips minimizes debris buildup.
The standard elastomers withstand a temperature up to 275 degree F. The elast
omers of the packers are supported by two back-up rings
In rotational release type hydraulic packer, bow spring is attached to each
slip. These springs do not have interference fit with I.D of the casing, but do
protrude above the O.D of the packer to approximately the drift diameter of the
casing. During the setting of this type of packer, these springs are depressed,
allowing the slip teeth to bite into the casing. Because of the short arc of th
ese springs, a force is required to depress each spring to the O.D of its slips.
This energy is stored in the springs and is used during the releasing of the pa
cker to provide rotation of packer mandrel.

RELEASING MECHANISMS FOR HYDRAULIC PACKER.

Three releasing methods are available:
1. Rotational release,
2. Straight pick-up release,
3. Straight pick-up plus optional one-quarter right-hand rotation.
Packers which require right-hand rotational release are preferred in wells a
s tubing contraction does not effect the release of packer .A smaller capacity w
ork over rig can be
FH Hydrostatic Packer
deployed for work over job in a well completed with this type of packer.
Packers which are released only by straight pull may be used in a completion
, where tubing rotation is not desired, like in deviated wells.
Packers which provide for release either by straight pick-up or by one-quart
er right hand rotation allow the operator for the option of releasing the packer
by either method.
HYDRAULIC SET DUAL PACKER
Hydraulic set dual packers are hydraulic set, dual string, retrievable packe
rs suitable for dual or stacked dual alternative completions. These types of pac
kers are straight pickup release and can be used when tubing rotation is not des
ired; however torque can be transmitted through the primary string when necessar
y after release.
The hydraulic set dual packers are available in short string or long string
set. To set the packer, the appropriate tubing string is pressurized to required
pressure differential at the packer against a wireline installed blanking plug
or standing valve located below the hydraulic setting ports of the packer.
To release, the long string is picked straight up after removal of the short
tubing string.
The hydraulic set dual packers can accommodate four types of stinger sub to lowe
r with short strings:
1. The snap in, snap out stinger,
2. The snap in, rotate out stinger,
3. The rotate in, rotate out stinger,
4. The bullnose Stinger.
The snap in, snap out stinger uses a collet to latch the stinger into the pa
cker. A.pull is required to release the stinger from the packer.
To set the Packer.
Run the packer to the setting depth, making sure the last movement of the tubin
g string is down in order to position the J-pin in the top of the J-slot before
trying to set the packer. Rotate to the left one-quarter turn at the packer and
pick up the tubing string About 1500 lbs of tension is needed to set and pick-of
f the tool.
To release the Packer
Lower the tubing at least one foot more than is necessary to remove the appl
ied tension to move the J-pin to the top of the j-slot. Rotate to the right one-
quarter turn at the packer and pull out the string.
To set the Packer.
Run the packer to the setting depth, making sure the last movement of the tubin
g string is down in order to position the J-pin in the top of the J-slot before
trying to set the packer. Rotate to the left one-quarter turn at the packer and
pick up the tubing string About 1500 lbs of tension is needed to set and pick-of
f the tool.
To release the Packer
Lower the tubing at least one foot more than is necessary to remove the appl
ied tension to move the J-pin to the top of the j-slot. Rotate to the right one-
quarter turn at the packer and pull out the string.
The snap in, rotate out stinger uses a collet to latch the stinger into the pack
er. A right hand rotation is required to release the stinger from the packer.
The rotate in, rotate out stinger uses a threaded assembly for both latchi
ng or releasing
The bullnose stinger has no latching mechanism and depends on tubing weight
to keep the stinger in place.
Dual String Hydraulic Packer
ADVANTAGES AND LIMITATION
Advantages
Perfectly suited to the case of deviated or crooked holes as no tubing movem
ent is required to actuate the setting mechanism.
The setting mechanism can be actuated after installation of X-mas tree and b
y displacing tubing volume by a lighter fluid (diesel ). This can be of great he
lp:
• To initiate production without swabbing or wireline work.
• In high pressures deep wells as perforation can be done in safe condition by thr
ough tubing perforation.
• Through tubing perforation in under balance conditions.
The setting mechanism allows the string to be landed in neutral condition or in
tension. The tubing string are straight, which helps the performance of wire lin
e jobs.
High setting forces can be applied to allow for large pressure differentials.
The packer does not have to be milled out if it becomes necessary to remove it,
thus saving rig time.
Are available in single or dual string configurations.
Are universally applicable.
Limitations
The well cannot be isolated from the producing zone while pulling out the comple
tion strings.
The setting-releasing mechanisms do not allow for very large packer internal dia
meters.
Removal of a struck retrievable packer is a difficult operation which could re
quire considerable rig time and expensive tool cost.(generally made of non-drill
able material )
Tubing length changes will result in force changes on the packer which could lea
d to packer unsetting if expansion joint lengths have been underestimated.
The sealing element may vulcanize and stick to the casing, creating retrieval pr
oblems. This effect can be minimized by the choice of right sealing materials.
Setting the packer may require wireline operations for tubing pressurizing. (she
aring ball seat-subs are available but not 100 % reliable )
Pulling may swab the well in if packer elements are not fully contracted. To avo
id swabbing, reciprocate the string for a while before pulling out the sting.
They have lower differential pressure rating unless otherwise called for.
Equalisation of pressure across the packer may be difficult, if provision of equ
alization ports are not available in the packer or ports have been chocked.
Sand or other deposits above the packer, may make it difficult to retrieve. Incl
usion of a safety joint above the packer to counter this, introduces a weak poin
ts in the tubing string and an additional possible leak source.

PERMANENT PACKER
This type of packer once set, can be regarded as part of the casing and can
only be removed destructively by milling/drilling. It can be retrieve by using a
special milling tool with a catcher sleeve.
Permanent packer can be set by;
1. With electric Line,
2. With tubing/drill pipes with a proper mechanical setting tool,
3. With tubing/drill pipe with a hydraulic setting tool,
4. With slick line.
Once packer is set, tubing strings with a stinger sub lowered into the well
and stab into the packer. If required, tubing string can be pulled out of the ho
le and re-run into the well and stab again into the packer.
They are recommended for use where,
-Exact location of the packer is critical. In this case it must be set by electr
ic Line.
-High pressure differential is required.
-Large packer bore is required.
-Less frequency of work over, (retrievability is less possible ),
-Maximum dependability is required.
The essential features of a permanent packer are:
A packing element that resists swaboff but packs of securely when the packer is
set, with two interlocked expandable metal back-up rings that contact the casing
creating a positive packing element extrusion barrier.

Two opposed sets of full-circle, full-strength slips, supported by two opposin

gly tapered cones, assures that packer will stay where it is set.
A smooth, continuous I.D polish bore inner mandrel, a outer body, and a ratchet
mechanism.
Setting mechanism:
A relative movement is established between the inner mandrel and the outer b
ody with the help of setting tool. The cone moves against the slips and sets aga
inst the casing wall and packs off the packing elements. A positive pack-off and
anchor is established and maintained by full-circle ratchet.
Tubing-to-Packer connections
There are three methods of tubing-to packer connection:
1. Latched or fixed with an Anchor Tubing Seal assembly. This type of seal
assembly is used where well conditions require that the tubing be landed in tens
ion or where there is insufficient tubing weight available to keep the seal asse
mbly in the packer bore.
2. The Anchor Tubing Seal assembly is latched to the packer, enabling the t
ubing string to be landed in tension in order to counter expansion during produc
tion. This has the advantage of preventing helical buckling if sufficient tensio
n is applied, resulting in easier wire line work. Because there is no movement b
etween packer and tubing, the risk of leakage is reduced.
There are three types of anchor tubing seal assembly.
-The snap in, snap out stinger
-The snap in, rotate out stinger,
-The rotate in rotate out stinger
Landed or provided limited movement using a Locator Tubing Seal Assembly. Like a
ll Locator seal assembly, it should be landed with sufficient set down weight to
prevent seal movement. This type of seal assembly will give long service even i
f movement occurs.
“Stung in” or allowing considerable free movement, by using a Locator sub with a lon
g seal assembly.
THE PACKER-TO-TUBING SEAL
The different well environments and completion practices require different tubin
g-to-packer seal systems, No single seal system works best under all conditions.
 All will work their best if seal movement is prevented. If movement cannot be p
revented, avoid allowing the seals to leave the seal bore. If the seals must lea
ve the seal bore, use of bonded seals is highly recommended.

TUBING SEAL SYSTEM

To select the proper tubing seal assembly for any well completion, careful consi
deration must be given to present and future well conditions Factors which must
be considered are:
- Maximum pressure differential
- Maximum and minimum temperature
- Well fluids (H2S,CO2,or other corrosive and inhibitors)
- Seal movements
These environmental considerations will determine the best combination of seal (
elastomer), accessory material (steel) and accessory type (locator, anchor or ot
her) for use in each case.
STEEL SELECTION
All metal parts heat- treated to a maximum hardness of 22 RC, subjected to a t
ensile load conform to NACE standard MR-01-75 for H2S service. Differential pres
sure should not exceed 10,000 psi.
Alloy steel heat- treated to a maximum hardness of 36 RC. For pressure differen
tials not exceeding 15,000 psi.
410 stainless steel heat-treated to a maximum hardness of 22 RC .Conforms to NA
CE standard MR-01-75 for H2S or CO2 service. Differential pressure should not ex
ceed 10,000 psi. Use where corrosive environments will be encountered.
SEAL SELECTION
Standard seal stack
Standard Seal Sacks are made up of Nitrile chevron seals and steel spacer rings
. It is suitable for normal service and not exceeding 325 degree F This type of
seal stacks are not recommended low temperature gas wells (less than 120 degree
F) The seal stack should not be allowed to leave seal bore in service.

V-RYTE SEAL STACK

V-Rite-Seal Stacks are made up of Viton chevron seals with Teflon and Ryton back
-up rings, and Ryton front –up rings. This types of seal stacks are suitable for a
ny well fluids except amine based inhibitors. These seals have been tested at 40
0 degree F , with 10,000 psi differential under dynamic conditions and 15,000 ps
i under static conditions. Should not be allowed to leave seal bore in service.
BONDED SEAL STACK
Two nitrile or viton seals are bonded to each metal insert with a inner O-Ring
and these inserts are separated by spacer. This type of seal stacks are used wh
ere seal movement out of the seal bore cannot be prevented. Nitrile seal units a
re suitable for normal service and up to a temperature of 350 degree F. Viton se
al units are suitable for sour service ,in all well fluids except amine based in
hibitors, and up to a temperature of 250 degree F.
K-RYTE SEAL STACK
A Baker Packer development consists of Kalrez chevron seals, backed-up by Teflon
and Ryton back-up rings, and Ryton front-up rings. This type of seal stack resi
sts the effect of H2S, CO2, amine inhibitors and highly corrosive treatment flui
ds. Baker has tested these seals at 450 degree F and 15,000 psi differential und
er static conditions and 500 degree F and 10,000 psi differential under dynamic
conditions, Seal movement should be kept to a minimum and seal should never leav
e the seal bore.
The basic seal units include two seal stacks and each stack consists of ten
number of chevron seals. Any number of seal units can be screwed together to in
crease the length.
It is not recommended to use a long continuous series of seals in a seal bor
e/seal bore extension, because of excessive seal friction and possible concentri
city problem of the packer bore and seal bore extension. Spacer type seal units
should be considered in this case.
Two debris barrier units, one at the top and one at the bottom in the locato
r will prevent debris from entering the seal bore and also provide a back-up sys
tem for the working seals. This is a preferred method of handling the various pr
oducing, shut in and treating events likely to occur in the life of the well.
PACKER ACCESSORIES:
1. Millout Extension,
2. Guide for Millout Extension,
3. Connector sub-Millout Extension-to-Seal Bore Extension,
4. Seal Bore Extension,
5. Concentric Coupling,
6. Crossover sub-Seal Bore Extension-Tailpipe
Millout Extension
The Millout Extension is used to provide the length and inside diameter necessar
y to accommodate the mandrel and catch sleeve of a standard Milling Tool, for th
e packer that will eventually be milled out. It has a larger I.D than the packer
I.D. It has a threaded pin x pin connection. The Millout Extension is connected
with the packer at the top through a guide and at the bottom with the seal bore
extension through a cross over connecting sub. Standard Millout Extensions util
ized API tapered threads.

Guide for Millout Extension

Guides are threaded bottom subs for seal bore packers and an integral part of th
e packer. They are available as API tapered threaded box down to accommodate Mil
lout Extention.
Connector Sub-Millout Extension-To-Seal Bore Extension
It is a crossover sub to connect Millout Extension and Seal Bore extension. It
has a API tapered threaded box connection at the top to connect Millout Extensi
on At the bottom, it has a matching straight threaded connections with a O-Ring
to connect Seal Bore Extension.
Seal Bore Extension
A Seal Bore Extension is used to provide additional sealing bore when a long sea
l assembly is run to accommodate tubing movement. The seal bore extension has th
e same ID as the packer. It has a straight threaded pin x pin connections with p
rovision to seal with O-Rings Seal bore extensions are available in ten foot le
ngth.
Concentric Coupling
Concentric couplings are used to join two Seal bore extensions. It has a straigh
t threaded box x box connection with two O-Rings to seal the connection. The con
centric coupling has the same ID as the packer
Crossover sub-seal bore extension-to-tail pipe
Using this sub tailpipe or other accessories can be run below seal bore extensio
n as required.

ADVANTAGES OF THE PERMANENT PACKER

1. Solid, slim-lined construction and a packing element system will resist
swab-off.
2. Can be run and set faster compare to other packer due to more clearance
between packer and casing ID.
3. It can be set with precise control of the setting depth with electric wi
reline.
4. Offers a wide variety of packer internal diameters and tubing-to-packer
connections.
5. As the seals can easily slide up and down inside the packer polished bor
e, these packers are especially useful when extensive tubing movement is expecte
d.
6. A nipple in the tail pipe below the mill-out extension will allow for zo
ne isolation before pulling out the tubing.
7. The tubing can be retrieve easily. It is ideal for wells subject to freq
uent work-over.
LIMITATION OF THE PARMANENT PACKER
1. Available in single string configuration only.
2. This type of packer once set, can be regarded as part of the casing and
can only be removed destructively by milling/drilling.
3. The reliability of the retrieving tool, which can lead to multiple tubin
g run to retrieve the semi-permanent packers.
4. If no tubing movement occurs for a long period of time the seals may sti
ck to the polish bore surface, thus causing a tubing retrieval problems.
5. It may be difficult to run in a highly deviated and crooked hole, if tai
l pipe weight is not sufficient.

POLISHED BORE RECEPTACLE PACKERS (PBR)

To over come problems of packers sticking and to allow for a maximum packer bore
where the casing diameter is limited (deep high pressure wells) a new tool has
been developed: the polish bore receptacle packer, which consists of a flow tube
moving in a polish bore receptacle. The latter could be incorporated in the cas
ing string as a nipple or tied to a liner (type) top extension.
CASING SEAL RECEPTACLE
The Casing Seal Receptacle is a casing sub containing a seal bore and left-hand
squire thread both of which are compatible with standard Packers tubing seal ass
emblies. It is run as an integral part of the casing string usually as a crossov
er between casing sizes. hen cementing or doing remedial work inside the casing,
a sleeve is inserted in the Polish Bore Receptacle to protect the bore,
The tubing string is run with standard tubing seal assembly attached with wi
re-line accessories. The Shear-Out Anchor Tubing seal assembly is released by ei
ther tubing rotation or sufficient pull to shear loose. If heavy mud is left in
the annulus, a Locator Seal Assembly may be required.

RETRIEVABLE PACKER BORE RECEPTACLE.

The Retrievable Packer Bore Receptacle is design to be anchored into th
e top of a retainer production packer or a liner hanger by means of an anchor .T
he PBR seal assembly can be shear-screwed in place in the PBR. The PBR ass
embly with its anchor seal assembly can then be latched into the hydraulic set r
etainer production packer and entire completion string is run in and set on the
tubing string in one trip.
The anchor seal assembly can be latched in latched out or latch in rotate o
ut type. A retrieving tool is required to retrive the PBR after pulling out
of the tubing strings.
ADVANTAGES OF POLISH BORE RECEPTACLE PACKER SYSTEM.
• PBR can be designed to provide maximum bore.
• The completion string can be set in one trip and save considerable rig time.
• Combination of packers and PBRs can be possible.
• Polished bore and sealing elements allow movements of up to 40 feet.
• The seal resistance to two types of fluids (packer fluid and produced fluids) is
overcome by using two types of sealing materials
• Floating device which effectively eases work-over problems
• The liner hanger is protected from the pressure differentials induced from the t
op (in the case of upper zone stimulation for instance).