Featured in Australasian Drilling: IPI unpacks packer technology

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. ā€œUnpredictable 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 toolā€™s purpose is crucial.ā€

One of IPIā€™s standout innovations is our grout-free expandable standpipe technology, which offers significant time savings and enhanced safety. ā€œThis 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 thatā€™s long relied on standard practices requires a significant marketing effort,ā€ 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.

IPIā€™s grout-free expandable standpipe is also being studied for use in pile foundations. This innovation builds on swage patchesā€”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. ā€œWeā€™re chasing higher pressures, larger expansions, and higher temperature tolerance.

The foundation for this is elastomer developmentā€”we need materials that can elongate and maintain strength at required temperatures.ā€

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.Ā 

Although IPI has mainly focused on geothermal test tools, Francis sees growth potential in this sector. ā€œFor 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.ā€Ā 

Francis concluded by reinforcing IPIā€™s dedication to innovation and delivering high-quality, custom solutions. ā€œWhether itā€™s a standard application or a custom design, we have the technology to make it happen,ā€ he said.Ā 

ā€œWeā€™re chasing higher pressures, larger expansions, and higher temperature tolerance.ā€ Ā – 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.

Read the full magazine now: Australasian Drilling Dec-Jan 2024-25… – Flipsnack

 

You May Also Like

Made Differently,
Perform Better

Discover why we’re the market leader for Inflatable Packers across a variety of industries.Ā 

Stuart Brown

Director

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 IPIā€™s oil and gas operations on a global scale. Stuart holds a Masterā€™s degree in Mechanical Engineering from the University of Aberdeen and a Masterā€™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.

Masoud Jangani

Director

Masoud joined IPI Packers in 2022 as the Oil & Gas Region Manager for the Asia Pacific, bringing over 20 years of experience across operations management, technical sales, and business development in the resources sector. His diverse career spans both the mining and oil & gas industries, where he has held key leadership roles at global companies. In 2024, Masoud was appointed Director of the Mining, Water, and Geotech product lines (MWG), driving strategic growth and expansion across these sectors. Masoud holds a bachelor’s degree in engineering and graduate certificates in finance and business law.

Garry Taylor

Dave Knell

Director

David (Dave) Knell has been involved with the manufacture and application of inflatable packers for over 35 years. He started his career as an apprentice aged 15, and within a year, was running packers offshore, in Western Australia. Dave was the first employee of IPI and has been instrumental in the development of IPIā€™s manufacturing facility and capabilities. His knowledge of building packers is backed by extensive experience in the field, an innate understanding of real-world applications, and a fierce attention to detail. Dave is currently focused on expanding IPIā€™s ISO9001 certified manufacturing operations on a global scale, to better serve customers and to foster the continued growth of the company.

Francis Ford

Director

Francis joined IPI in 2005, based in Perth, Western Australia, as an apprentice. He developed his skills in manufacturing, tool and packer design and field operations across multiple industries ā€“ mining, water, civil/construction and oil & gas. His level of expertise and understanding enabled him to progress into leading IPIā€™s R&D efforts as manager. This included leading key custom / OEM designs and their practical developments, for multiple clients as well as continuing to progress the design and development of IPIā€™s unique systems. Now as engineering director, he is developing IPIā€™s engineering team to better support clients by improving our predictive packer modelling and fostering the continuous improvement of our packer tools and technology. A member of the Society of Petroleum Engineers and author of several technical papers, he is credited in several industry patents.

Joel Adams

Director

Joel Adams is a hydrogeologist, turned packer expert who has spent 30 years applying inflatable packer technology to complex downhole problems. His experience includes well testing for nuclear waste site characterization, water resources, water rights, rock stress testing, water well rehabilitation, and plug and abandonment (P&A). Joel has been leading the team as Director – North America since 2007 and has been associated with IPI, either as a key customer, agent or employee, since its founding in 1999. He led the introduction of IPI packer technology to P&A work, offshore in the Gulf of Mexico, and the establishment of DuraFRACĀ® packers as the market leader in the water well hydrofrac market. With numerous publications and presentations, Joel is a recognized expert in well testing and custom packer system design.

Howard Kenworthy

Director

Howard joined IPI in 2005 as commercial manager when IPI had 5 staff and was making customized product to order. His prior career was with UK public companies in retailing and financial services, leading operating companies. He holds an MBA which he took a few years after his degree from Oxford (Philosophy, Politics and Economics). He has led IPIā€™s distribution development with standard products and established most of IPIā€™s international operations as part of his role in business planning, finance and strategy. This included joint ventures in the USA, Chile and Indonesia. He was based in South East Asia 2015 to 2022, prior to relocating to Sharjah in the UAE, from where, as Commercial Director, he continues to develop and co-ordinate planning and strategy, the groupā€™s global distribution and financial operations.

Clem Rowe

Founder and Executive Chair

Born and bred in Western Australia, Clem is a Curtin University graduate with a degree in mechanical engineering. Early in his career, Clem worked on offshore engineering projects in Western Australia and France. While working offshore, Clem was first exposed to inflatable packers, manufactured by a small Australian company that he subsequently joined in 1988 as Engineering Director. Clem established IPI in 1999 and has grown it from a small Western Australian manufacturing operation, to the world-wide manufacturing and distribution organization that it is today, by carefully selecting a competent team, that shares his values of quality, innovation and customer service. Clem is a member of the Society of Petroleum Engineers, the Institute of Hydrogeologists and the Institution of Engineers, Australia. He is the author of multiple articles and papers on inflatable packers and their application and has several international patents to his credit.

Our Industries