PRODUCTION ENGINEERING-I
(Course code: PE0405)
Topics to be covered: Packers, tubulars, and flow lines and Flow control devices
PRODUCTION SYSTEM
•Reservoir
•Wellbore
•Completion String
•Production Tubing
•Artificial Lift System
•Wellhead
•Christmas Tree
•Flowline and Gathering System
•Surface Production Facilities
•Storage and Export System
PACKERS
• A production packer is a downhole device that
provides a seal between casing and tubing annulus.
Functions of Packers
Supports some weight on tubing
Holds well servicing fluids in casing annulus (kill fluids)
Prevent downhole movement of tubing string
Separate producing zones and prevents fluid
contamination
Aid in forming the annular volume required for gas lift or
subsurface hydraulic pumping systems.
PACKERS COMPONENTS
SLIPS PACKING ELEMENT
Metallic components with Made of elastomeric material
hardened teeth. Expands radially when the
Anchor the packer firmly to the packer is set to create pressure
casing wall. seal
SLIP CONES MANDREL
Tapered surfaces that force the The main structural
slips outward. component of the packer.
When axial force is applied, slip Houses all internal mechanisms
cones convert it into radial and provides the flow path for
gripping force. fluids.
TYPES OF PACKERS
Special Packers
• Seal bore Retrievable
• Open hole Packer
• Inflatable Packer
• Dual string packer
• Swell packer
• Expandable Packers
• ESP Packer
• Multi zone packer
PERMANENT PACKERS
These are for long term installations
and can be removed only by milling
•High performance under high temperature
and pressure
•Reliable due to simple, robust design
•Slim OD allows passage through tight
wellbores and supports larger tubing ID Advantages
•These can remain in place during workovers
•Removal is destructive. Seal wear due to tubing
Disadvantages movement or long-term adhesion
•High intervention cost if removal is required
•Unsuitable for frequent removal applications
RETRIEVABLE PACKERS
Applications
• Short life completion.
• Multi-zone completions for zonal segregation.
• Cement Squeeze
• Casing leak detection
• In relatively mild well conditions.
Advantages Disadvantages
•Can be retrieved without destroying the •More expensive than permanent
packer packers
•Saves drilling rig time and replacement •May get stuck and cannot always be
cost retrieved with conventional tools
•Can be redressed and reused if in good •Takes longer to mill than permanent
mechanical condition and not corroded packers due to harder slip material
SEAL BORE-RETRIEVABLE PACKERS
These packers are retrievable and have performance
characteristics similar to those of permanent packers.
Applications
• Hydraulic Fracturing: Seals off zones during stimulation
and fracturing operations.
• Gravel Packing: Holds gravel in place as part of sand
control systems.
• Water/Gas Injection: Provides zonal isolation for pressure
maintenance and enhanced oil recovery.
• Open Hole Completions: Acts as a hanger packer in
horizontal and open-hole wells.
• Extended reach wells
MECHANICAL SET PACKERS
Mechanically set : The packer is set using mechanical forces like rotation or tubing
Tension set weight/pull
The tubing is rotated to unlock the J-slot, followed
by a deliberate upward pull (tension). The upward
force draws the slips onto the cone to anchor the
tool and compresses the packing element, creating
the seal.
Compression set
The tubing is rotated to the setting position, and
the tubing weight is lowered (slacked off) onto
the tool. The downward mechanical weight drives
the slips into the casing and squeezes the
packing element outward to form a high-pressure
seal.
a) Retrievable tension Packer b) Retrievable Compression
Packer
Reference video: [Link]
MECHANICAL SET PACKERS (CONTD.)
Packer
Advantages Disadvantages
Type
• Ideal for shallow
wells where
• Thermal
insufficient set-down
Tension expansion of tubing
weight is available
Set can generate forces
• Injection-friendly,
Packer that may lead to
pressure from below
unsetting
helps maintain the
seal
• Handles pressure
Compre from above effectively • Requires sufficient
ssion • Tubing weight helps tubing weight; not
Set maintain the seal suitable for shallow
Packer under higher pressure wells
above the packer Mechanical Packer
HYDRAULICALLY SET PACKERS
Mechanism:
Hydraulic pressure applied
inside the tubing acts on a
setting piston, generating
axial force that
compresses the sealing
element and drives the
slips outward to anchor the
packer against the casing.
HYDRAULICALLY SET PACKERS
Characteristic Advantages Disadvantages
Less suitable for simple vertical
Ideal for highly deviated and horizontal wells
Well Suitability wells where mechanical packers
where tubing manipulation is difficult
are sufficient
Set by tubing pressure; no rotation or vertical Requires a plugging device below
Setting Mechanism
movement required the packer to apply pressure
Can be run with production tubing in a single Installation is more complex due
Installation
trip, saving rig time to hydraulic system requirements
Improves operational efficiency in complex Higher initial cost compared to
Cost & Maintenance
wells mechanical packers
Requires careful system integrity
Multi-zone Ideal for multi-zone and stacked packer
management in complex multi-
Completions installations with sequential setting
packer setups
SPECIAL PACKERS
Swellable Packer
Feed through Packer
Inflatable Packer
Service Packer ESP Packer
Open hole Packer Straddle Packer Dual string Packer