At the recent DRILL24 conference, IPI Packers engineering director Francis Ford shared insights into cutting-edge advancements in packer technology and how these tools are reshaping the drilling industry.
Packers, essential hydraulic tools used in drilling operations, are designed to expand, creating seals or anchors in boreholes to tackle various challenges. Francis explained that their design process starts with understanding the client’s objectives. “Knowing what the client wants to achieve helps guide the design. Next, we determine the operating and dimensional parameters, which define the constraints on the operational sequence, available space, and activation mechanisms.”
While the company has formalised procedures within its quality management system (QMS), the design concept always focuses on making tools that match the packer to drive performance. Packer modelling software plays a key role in speeding up the design process.
Francis pointed out that challenges often arise around time constraints, supply chain issues, and unforeseen events during qualification testing. “Unpredictable situations, especially with new designs, can slow down delivery. Also, when client requirements are broad and undefined, it becomes harder to meet the design brief. That’s why understanding the tool’s purpose is crucial.”
One of IPI’s standout innovations is our grout-free expandable standpipe technology, which offers significant time savings and enhanced safety. “This technology eliminates the need for cement, grout, or resin to anchor standpipes, allowing for efficient high-pressure grouting and fluid control. However, introducing new technology into an industry that’s long relied on standard practices requires a significant marketing effort,” Francis noted. He credited colleagues Joel Adams and Ivan Kosorok for leading the effort, gathering case studies that highlight the system’s time savings and operational benefits.
IPI’s grout-free expandable standpipe is also being studied for use in pile foundations. This innovation builds on swage patches—metal cylinders expanded by a packer to patch corroded areas in casing. IPI also supplies these patches and packers for swaging operations.
Looking to the future, Francis highlighted how packer technology is evolving to meet the demands of industries such as renewable energy and critical minerals extraction. “We’re chasing higher pressures, larger expansions, and higher temperature tolerance.
The foundation for this is elastomer development—we need materials that can elongate and maintain strength at required temperatures.”
In block-caving operations, packer technology has progressed from designs capable of handling 6,000 psi to recent tests withstanding 20,000 psi. This allows clients to maximise the lifecycle and value of the tools in deeper, high-stress environments.
Although IPI has mainly focused on geothermal test tools, Francis sees growth potential in this sector. “For lower and medium temperatures, we offer equipment similar to oil and gas applications. For high temperatures, expandable metal technology plays a big role, especially in long-term applications.”
Francis concluded by reinforcing IPI’s dedication to innovation and delivering high-quality, custom solutions. “Whether it’s a standard application or a custom design, we have the technology to make it happen,” he said.
“We’re chasing higher pressures, larger expansions, and higher temperature tolerance.” – Francis Ford, Engineering Director
In his presentation at DRILL24 Francis outlines several key applications of packers, such as their use in water shut-off, well interventions, and borehole repairs.
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Stuart recently joined IPI as the Director of Oil and Gas, bringing with him 15 years of diverse experience in the industry, with a strong focus on inflatable packers. His extensive background encompasses a variety of roles, including field engineering, operations management, sales, and business development. This breadth of expertise, coupled with his international experience in markets across North America, Europe, Australia, and the Middle East, positions Stuart to effectively lead and expand IPI’s oil and gas operations on a global scale. Stuart holds a Master’s degree in Mechanical Engineering from the University of Aberdeen and a Master’s degree in Finance from City University of London. His robust technical foundation and financial acumen uniquely empower him to drive strategic initiatives and foster growth within the company.
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