New Family of Setting Tools for Ultra Deep and High Temperature Well Condition

Abstract

A new generation electro-mechanical downhole power unit for setting and retrieving packers, bridge plugs, whipstocks, subsea tree plugs, and other downhole devices has been recently developed and deployed. The new Downhole Power Unit - Intelligent, DPU-I® is designed to operate at high temperatures and extremely high pressures (400°F, 30K psi) and to provide up to 100K lbf setting force. The high force for either setting or retrieving downhole devices is independent of hydrostatic pressure and provides an alternative to jointed pipe or coiled tubing interventions, which were previously required to obtain high setting forces. New to the industry is the ability to monitor the downhole line tension, stroke length, setting force, the rate at which the force is being applied during the setting operation, and force at which the DPU-I detaches from the downhole device in real time at the wellsite or remotely by means of global satellite communications. This new functionality enables well completions experts to remotely monitor the setting or retrieval operations 24 hours per day, seven days per week. It also provides a record of the setting operation for risk mitigation, and for developing and improving best practices. This new downhole power unit conforms to our digital workflows used to model, measure, and optimize customer assets. The slow controlled setting operation enables the slips or other anchoring mechanisms in the device to be set and to fully engage the casing/tubing and for the elastomer sealing elements to conform to the casing or tubing ID. This function is extremely critical in highly deviated well conditions and when using casing or tubing with high Rockwell hardness. Unlike setting devices that use explosives, military or governmental escorts are not required. In addition, single lift heli-operations can be used. This tool does not require radio silence operations, and there is no nonproductive time associated with tool re-dressing between runs. Tool sizes are available for well intervention in 2 3/8 in. tubing through 13 3/8 in. casing and can be tractor-conveyed in high angle or horizontal wells. Introduction Traditionally, the method of choice for setting packers, bridge plugs, and similar wellbore devices consisted of conveying an electrically-activated explosive-charge setting tool to the required depth on electric line and activating the explosive train (deflagration) by applying voltage or current to the e-line. Although this explosively activated setting tool has been used in the industry for many decades, it has many limitations and safety issues:Requires explosive activation • Requires special explosive transport and rig/well site explosive storageRequires radio and telecommunication silence on the rig during operationsRequires personnel trained to use explosivesSetting force decreases with increasing hydrostatic pressureSetting force is rapidly applied over a few seconds, which may not be sufficient time for slips and elastomers to conform and engage in the casing/tubing.High temperature operations can be more difficult to perform reliablyNeed to re-dress between runs