A new-generation electro-mechanical downhole power unit for setting and retrieving packers, bridge plugs, whipstocks, and other downhole devices has been recently developed and globally deployed. The new downhole power unit – Intelligent (DPU®-I system), is designed to operate at high temperatures and extreme high pressures (400°F, 30 Kpsi), while providing up to 100 Klbs of setting force. The high linear force for either setting or retrieving is independent of hydrostatic pressure and provides a cost-effective alternative to jointed-pipe interventions, which were previously required to obtain high setting forces. The e-line-conveyed DPU-I system, with its high setting force, has been successfully used numerous times in deepwater wells and has shown to save in excess of one day’s rig time for setting sump packers or other devices in ultra-deep well conditions compared to jointed-pipe intervention. New to the industry is the ability to monitor in real time at the wellsite and remotely via satellite communications the downhole line tension, tool acceleration, stroke length, the setting force, and the rate at which the force is being applied during the setting operation as well as the force at which the DPU-I system detaches from the downhole device. This allows well-completion experts to remotely monitor the setting or retrieval operations 24/7 and provides a record of the setting operation for risk mitigation and developing and improving best practices.

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 elastomer sealing elements to conform to the casing or tubing ID, which is extremely critical in highly-deviated well conditions and when casing or tubing with high-rockwell hardness is used. Unlike setting devices that use explosives, military or governmental escorts are not required. Single-lift, heli-operations can be used. Radio silence operations are not required, and there is no non-productive time associated with tool re-dressing between runs. Tool sizes are available for well intervention from 2–3/8–in. tubing through all casing sizes and can be tractor conveyed in high-angle or horizontal wells.

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