CONTENTS 1. Cover Letter 2. Multiple Activation Bypass System 4 3. PBL Flow Chart | 4, Multi-Functional Applications 5. Operational Information & Specifications 6. Testimonials | P.O. Box 30576, Dubai, United Arab Emirates Heh Hig Tel: + 971 4 8839711 Fax: + 971 4 8839713 L Website: www.dsi-pbl.comINTRODUCTION TO THE PBL MULTIPLE APPLICATION BYPASS SYSTEMS Drilling Systems international (DSI) is pleased to introduce the Multiple Activation Bypass System for driling, completion and workover operations. The Bypass system is a simple reliable tool enabling increased BHA circulating rates when required, Attached is information regarding the tools enhanced applications. Primarily the PBL Bypass System was developed to enable the pumping of aggressive LCM pills and to increase circulating rates when drilling small holes. Alternatively the Bypass System has found a niche in completion and workovers applications, proving most effective when its imperative to have a clean well bore. ‘THE BYPASS SYSTEMS HAS NUMEROUS APPLICATIONS TO ENHANCE & AD: A. Lost circulation ‘Workover and completions Horizontal driling Horizontal acdising & stimulation Under balanced drilling Special application coring techniques Fixed cutter/bi-centre bits or hole enlargement applications Sub sea riser/B0P jetting Tripping dry pipe ee THE TOOL CAN BE CYCLED A NUMBER OF TIMES IN ANY OF THE ‘ABOVE MODES. ‘The unique P8L Multi-Functional Bypass System has the flexibility to assist you in substantially reducing driling costs associated with lost ciculation and limited flow rate problems. The tool has efficiently supported operators throughout numerous campaigns worldwide. This is a general overview of the services provided by Drilling Systems International and we hope the information furnished is helpful. if you require further information or assistance please do not hesitate to contact us, or our appointed marketing agents allocated to various regions world-wide ave sir JANE MASCARENHAS JAY BELAMY Moble: +e 7880857547 Meble: 4371 506518527 Mobile: +1 337 7395644 TelFax a2 1228 852209 Tek 4971 48399711 Fax +971 48969713 Fax +1 337 269 0232 mak DaweSith@dsipolcom Ema JoneMscarechas8ds pl com ‘TONY GRANNY [MARTIN GONZALEZ enquiesis-pl com Mobie: #971 505526108 Mobie: +1 9152762826 tec support bl com Ema Tonycramy@dspbicom Teac +1 9158552584 ‘websted com malt MatinGenzlec comMULTIPLE ACTIVATION BYPASS SYSTEM PBL Drilling Tools Ltd. introduces the Multiple Activation Bypass System for drilling, completion and workover operations. The Bypass System is 2 simple, reliable tool for increasing BHA circulating area “at the drop of a ball”. KEY FEATURES AA standard tool configuration includes 6 open and close cycles. ‘A. Drill with optimum hydraulics, use motors, MWD'S or core barrels and maintain the ability to pump aggressive LCM pills, The Bypass sub saves you that trip for open ended drill pipe A Reduce friction losses and increase circulating rates in deep liner clean-out applications. Don't circulate at 4 BPM when the Bypass sub ‘can give you 30 BPM using specialised dual or triple ported tools ‘A Proven reliable performance. Regularly in use worldwide for over twelve years. DRILLING APPLICATIONS Lost circulation means lost time and money to any Operator. Whether it’s a shallow onshore well or a deep offshore multi-well project, all operators want to deal with lost circulation problems in a fast and effective manner. The Bypass System provides your field personnel with the equipment to get that job done. Drill with the hydraulics and specialised tools you need to make hole, and keep the Bypass System on standby in the drilstring for when you encounter lost circulation. OPERATIONS A. Drop the vinyi/torion ball into the drillstring, displace it to the tool and open the circulating port. ‘A. Mix and pump an aggressive LCM pill that will hal the losses, and save you the trip for OEDP. The Bypass sub will accommodate anything your Tig crew can mix and pump. ‘A When the losses are healed up, simply drop a stee! ball into the string, displace it to the tool, pressure up and close the circulating port. A. The procedure can be repeated up to six times before you need to trip. Reduce your mud losses and wasted rig time by allowing your field personnel to act aggressively and heal losses the fist time PBL Drilling Tools has marketed the Bypass System and dealt with lost circulation problems worldwide for over twelve years. Our equipment has made thousands of successful runs. We are ready to assist you in reducing costs associated with lost circulation and limited flow rate problems in completions and workovers.CIRCULATING AND PRESSURE LOSS APPLICATIONS Although not originally designed for this application, the Bypass System has found a niche in completion and workover operations which is saving North Sea Operators substantial time and money, BACKGROUND Typically when the Bypass sub is opened there is a significant drop in pump pressure as a result of the increased flow area through the circulating port (up to 2° diameter). This increase in flow rate has been used by operators of deep platform wells to reduce the time in which a clean-out operation can be completed. What used to take 24 hrs to complete can be accomplished in 8 hrs using the Bypass System. That translates into big, measurable cost savings for these operators. This is a low risk, programmable application which has also been used by operators of onshore wells with dayrates far below those of offshore platforms. Our low dayrates are justified with fractions of rig hours saved. This is the fastest growing application of the Bypass System and operators can. measure the cost savings OPERATIONS [A Position the Bypass sub on top of the small tubulars Used to get inside your liner. A Run in and circulate the liner until all debris is raised above the Bypass sub, A Drop the plastic ball into the dillstring, displace it to the tool and open up the circulating port. A Increase the pump rate (2-3 times) and proceed to effectively clean the large annular area with an appropriate AV. A Rotate and reciprocate the Bypass sub to avoid casing wear and enhance hole cleaning AWhen the hole has been cleaned (and/or displaced), simply drop the steel ball into the string, displace it to the tool, pressure up and close \ circulating port A The procedure can be repeated up to six times before you need to trip. PBL Bypass Sub = MWDADs THE PBL BYPASS SYSTEM The PBL Bypass System was designed to allow displacement of larger particles of loss circulation nineties material (LCM) without affecting peak driling efficiency, tomse TO ACTIVATE THE BYPASS SYSTEM Break the drill string and drop a ball down it. When the ball reaches the Bypass Sub, it will open port. Balls may be pumped part way to the sub in order Si? to speed up the procedure; however, pumping should be stopped two barrels before the ball reaches the sub. With ball in place apply pump ‘wing pressure causing spring loaded sleeve to compress. With the port open, LCM is displaced directly into the annulus. The dril string should be rotated or reciprocated to avoid sticking. Once drculation has been regained and all the LCM has been displaced, the tool may be deactivated, itis important that all the LCM is displaced in order to EES" prevent plugging of the bt jets ‘TO DEACTIVATE THE BYPASS SYSTEM Drop a steel ball. The steel ball wil restrict the flow ut of the port. When the pump pressure reaches ‘SS55" the ball shearing pressure, the plastic ball will blow through the sleeve, the spring will reset the sleeve and the steel ball will fall through into the ball catcher sleeve. This procedure can be repeated upto six times without effecting flow. NOTE: Balls maybe removed from the ball catchers Sub by breaking the top connections on the Sub and removing the Sleeve NOTE: Once surface tested, never run the PBL Bypass System in holes with ball in the all catcher. ON SS SS SS S UThe PBL Auto Lock Bypass System is totally balanced and hydrostatic pressure doesn't effect it The ball shearing pressure can be set to suit operators preference. There are numerous applications for Auto Lock Bypass Sub: A Conventional Drilling A riling with ¢ down hole motors A Coring ‘A Above. any down hole equipment with restrictions (e.g. MWD) A Increasing flow rates to aid in hole cleaning during work overs and driling ‘The Bypass Sub is useful in controlling extreme loss of circulation by treating the thief zone uickly with the highest concentration of LCM that your surface equipment can handle. When returns are satisfactory you may close the tool and continue driling. f another zone is encountered, just repeat ‘the operation ‘The Bypass Sub may also be tested at any time on surface or in the hole, 1) DRILLING 2) OPEN POSITION 3) PRESSURING UP 4) DRILLING POSITION STEEL BALL PLASTIC BALL SLIDING SLEEVE ‘SPRING BALL CATCHER SLEEVE BYPASS SUB OUTER SHELLA BY-PASS SYSTEM FLOW CHART Ce Drilling Mode Vinyl Ball Seated ‘Open Position FLOW to BIT FLOW THRU PORT i De-Activation Balls Sheared Drilling Mose Ball Dropped ‘Through Seat Flow to BitPBL MULTI-FUNCTIONAL BYPASS SYSTEMS LOST CIRCULATION: The PBL Multifunctional Bypass System was developed to aid operators in dealing with lost circulation problems. With the tool run as low in the BHA as possible it can be opened (activated) by simply dropping a ball. When the tool opens operators are not limited in the size or concentration of LCM they can pump. With the Bypass System in the hole the limitations rest with the surface equipment. With the tool open and circulation regained the tool can now be closed. Simply drop another ball to close the tool and drill ahead. If the problem is encountered again there is no problem because the PBL Multi-Functional Bypass System can be opened and closed up to six times a bit run Although the tool was designed to correct lost circulation once it gained more Utilisation and exposure it beceme apparent that there were other cosvtime saving advantages for the tool such as workovers and completions along with horizontal drilings WORKOVERS & COMPLETIONS: Circulating rate and pressure loss application, this application proved very effective for operators working in wells with liners on bottom. itis utiised to bypass small working strings inside liners. With the tool positioned directly above the slim hole string in the liner it can be opened to bypass the friction loss associated with the slim hole working string. Increased flow rates can be as high as five times that of the rate achieved while circulating through the slim hole sting. HORIZONTAL ACIDISING & STIMULATION: In multilateral horizontal wells itis necessary to find the lateral leg which requires stimulation. For this reason itis necessary to run expensive MWD Tools. With the PBL tool run directly above the MWD tool, stimulation can be achieved with no adverse effects on the MWD tool. All acid can be pumped through the PBL Tool land the PBL Tool can be opened and closed so that the operator can regain signals from the MWD Tool. HORIZONTAL DRILLING: With increased activity and demand for horizontal driling it became apparent that there were yet more applications for the tool in this specialised area. One of the more interesting applications is using the tool to break circulation while running in the hole with downhole motors. This application allows operators to break circulation through the PBL Bypass system when running in the hole. This is an advantage when running motors with bent housings and PDC bits it eliminates motor and bit rotation preventing bit wear and tear as well as casing wear. With the BHA on bottom the Bypass System can be closed to commence with driling. ‘These three applications for the PBL Multi-Functional Bypass System have proven effective to operators in some of the most extreme environments worldwide.UNDER BALANCED DRILLING The tool can be used for this application, most commonly the tool is run in the vertical section of the well. The tool is used so that the open hole, the horizontal well bore, is not exposed to any other fluid but native crude. The tool can be ‘opened up to allow the displacement of weighted material in the vertical part of the well bore for safer tripping of the pipe or for well control operations. For this application the ball catcher can be run down the string just above the MWD or Ron-mag tools this will allow free point and back off operations to be performed 2s low in the hole as possible FIXED CUTTER/BI-CENTRE BITS OR REAM WHILE DRILLING TOOL (RWD) APPLICATIONS, When these above mentioned tools are run in conjunction with down hole ‘motors some operational problems can be eliminated with the use of the Bypass System, Pumping through driling motors with the above mentioned tools is not recommend as the OD of the bi-centre bits and the RWD tools is very close to the 1D of the casing. In most cases itis not recommended to turn these bits inside the casing with the motor. The Bypass System can solve this problem as follows: Before running in the hole: ‘With one of the above mentioned assemblies, put the activation ball, preferably with a dart combination into the Bypass System. With the ballin place in the tool circulation can be achieved when desired with the flow going out of the PBL Bypass System and not through the motor or MWD. When the dil string enters the open hole the Bypass System can be deactivated to close the Bypass System and allow for circulation through the MWD and motor. Before coming out of the hole: Drop the activation ball and circulate bottoms up through the tool. Leave the ball in place and come out of the hole, this will allow the drill string to be tripped dryer. The weight of the trip pill will effect the speed of the drill sting drainage. This will also allow circulation while coming out of the hole with out the bi-centre bit or RWD turning in the casing, SUB SEA RISER/BOP JETTING The PBL Bypass System can be utilised to jet BOP's and risers during driling and completion operations. The jetting application can be performed by opening and Closing the Bypass System without the need for tripping jetting tools in and out of the hole. Jetting your sub sea BOP will clean shale and debris out of the cavities in the sub sea BOP stack greatly enhancing safety. Jetting the riser will effectively clean the riser during completion operations. Utlising the PBL Bypass System for jetting sub sea BOP's and risers will greatly reduce rig time. By having the tool as a component of the BHA, this jetting operation can be performed during each trip as and when required‘TRIPPING DRY PIPE: ‘The PBL Bypass System is also effective in helping operators trip more dry pipe. ‘The procedure for thisis as follows 1) Drop the activation ball or ball dart combination into the dil string. 2) Open up the bypass system and circulate bottoms up through the tool 3) Itis recommended to pump a weighted pill down the diil string. This pill wll help to add differential to over come the force of the spring and sleeve allowing the port in the tool to open. The required pressure differential acting ‘on the ball and sleeve is between 100 psi - 130 psi to open the port. 4) When the tool is on surface dropping a steel ball and going through the standard deactivation procedure to reset the tool. OR The tool can be broken at the ball catcher and the ball or ball dart combination can be manually tapped out of the tool. This can be done by inserting a bar through the pin end of the tool and tapping the ball out through the box end. Of the tool, Its also recommended to tap the sleeve as well to make sure itis in the fully closed position. 5) With the balls removed from the tool and the sleeve taped back to the fully closed position and torqued up to the ball catcher sub, the tool is ready to be tun in the hole again. This above-mentioned application will have very positive results when operators are running bi-centre bits or rearn while drilling tools in conjunction with downhole motors. With the combination of these tools in the dril string itis not recommended to circulate while the bi-centre bits or MWD tools are in the casing. The PBL Bypass System will allow operators to circulate at any time thus eliminating wear and tear to the casing, as well as the bit or tools in the dil stringOPERATIONAL INFORMATION A) THE TOOL AND ACCESSORIES: The tool will be sent complete with the following Viny| balls - used to activate the tool Vinyl balVdart combination - used to activate tool for high mud weight applications. Steel balls - used to deactivate the tool One Steel Emergency ball - which is painted red and is the same size as the vinyl activation balls. This ball is used as a last resort to open the tool (Once dropped the tool cannot be de-activated and the dril string will have to bee pulled to recover it The tools are dressed for standard temperatures up to 200 circulating temperature. For temperatures greater please refer to “Effects of High Temperature Conditions on Seal” in this manual B) MAKE UP PROCEDURE: The circulating sub with 1 2 * or 1 34" port on the side is made up on top of the ball catcher sub. ‘Make up torque is as per standard connections on tool used i.e 278" OD tool Connections as per requirement. 3 'f" OD tool 27" PAC, 2 38" HTSL H90 312" OD tool 2.3" IF, 2 7h" SLH9O 434" OD tool BR" IF 6 14" OD - 6 34” OD tool 4” H90, 4 V2" IF, 5" H90, 4 12" XH 8” 0D tool 658" Reg 9" 0D tool 7" 490 9th" OD tool 7 5h" Reg DO NOT OVER TORQUE. Circulating sub: Double check that the inner mandrel is in the closed position by looking through the port on the side. Ball Catcher sub: Ensure ball catcher cage is in the sub, with the bevelled end facing up and no-go on bottom. ©) ACTIVATION PROCEDURE: Before activating the tool check and make note of pump pressure/stroke. This will be referted to upon de-activation of the tool to confirm de-activation. Break the dill string at the floor and drop the vinyl ball (NEVER RE-RUN PBL ACTIVATION BALLS). The vinyl ball can be displaced at a high flow rate for 50% = 70% displacement volume. if balldart combination is used, displace at a high flow rate for no more than 50% of dil string volume. The time it takes to pump the vinyl ball down and seat and open the tool will be affected by the fluid characteristics and volume. “Extreme care to be taken when pumping or landing the vinyl ball into the tool”. Oo not pump at high fluid rates or pressures as this will cause the vinyl ball to be blown through the seat and will result in the procedure having to be repeated. ff this happens, drop the steel de-activation ball to ensure the vinyl ball has blown through the seat prior to dropping another viny ballF) EFFECTS OF HIGH TEMPERATURES AND PRESSURES ON BALL SHEARING AND BALLS With continuous operation of PBL's worldwide, our experience has shown that in high temperatures and high pressures the density of the vinyl balls i slightly affected causing ball shearing pressure to be decreased by 200-400 psi. High temperature balls may be included upon request which withstand 450" Hot hole balls are indicated by yellow colour code. G) EFFECTS OF HIGH-TEMPERATURE CONDITIONS ON SEALS thas come to our attention that on several occasions washing has occurred due to seals failing under high temperature conditions. On customer's request, PBLS will be dressed with high temperature viton seals which can withstand up to 450 °F. Hot hole redress charges will apply. H) Q.A. ON OPERATION BALLS All operating balls are measured using a micrometer, to see if within specifications. INTERNAL DRIFT The drift is the smallest inside diameter of the tool and when the tool has been activated and deactivated and there are balls in the ball catcher cage the rift is eliminated. That is why we recommended running the tool as low in the BHA as possible, J) BALL DART COMBINATION Note: Must be inserted dart end down ‘The use of the ball dart combination is recommended for the following situations, 1) Ifthe drill sting or annulus becomes plugged or packed off it will be hard to get the standard activation ball to the tool to activate it. The ball dart combination will add density to the ball to help the activation ball get to the tool faster. With the tool activated it maybe possible to break circulation through the tool and clean up the annulus. With the annulus clean the too! «an be deactivated to allow the operator to continue driling ahead. I the bit is plugged it will allow the operator to circulate and trip dry pipe. 2) In situations where high mud weights are used the ball dart combination will help to speed up the activation process.3) In situations where there may be a chance that reverse circulating could be an ‘option during completions the ball dart combination will help this situation by ‘adding density to the balls thus holding the ball down in the ball catcher | | assembly while the completion fluid is displaced across the ball catcher assembly. | 44) In the past the PBL Bypass Systems were sent out with an emergency stee! ball ld the same size as the plastic activation balls. This emergency ball was to be Used if the drill string became plugged. It would migrate down the string to | Via the tool through any mud weight even without circulation to activate the tool. The ball dart combination will do the same although if desired the ball dart combination can be blown through the tool deactivating it if desiredWEIGHTS AND DIMENSIONS OF ALL PBL’S TOOL SIZE WEIGHT DIMENSIONS 3 Vs" - COMPLETE TOOL 60 kiLos, 72" x3 We" OD 3 "2" - COMPLETE TOOL, 60 KILOS 72" x3 1h" OD 4.3%" - BYPASS 55 KILOS 36" x 434" OD 43%" - TOP SUB 32 KILOS 24" x44" OD 431" - CATCHER 27 KILOS 30" x 434" OD 6 Nh" - BYPASS 173 KILOS, 54" x6 V2" OD 6 1" - CATCHER 141 KILOS. 48" x6 %2" OD 8" - BYPASS 205 KILOS 48" x8" OD 8” - CATCHER 187 KILOS 48" x8" OD 9" - BYPASS 341 KILOS. 48" x9 12" OD 9 '" - CATCHER 314 KILOS. 48" x 912" 0D BALL SIZES BALLS SIZES STANDARD = BALLDART — STEEL STEEL VINYL COMBINATION. DE-ACT EMERGENCY SHUT OFF. 3:8" Dual rot 1" iB 5a" x2 a 3%" ia 1" 718" ae 3%" 1a" Ver 1 Mer 1 Ma a" 1a" Var 138" Me" 6%" 612" 2" 2 134" 2" at" sa" 2 In" 21a" 136" 2%" PBL BYPASS SYSTEM CONNECTIONS sae 1D DRIFT__DESCRIPTION CONNECTIONS 31" OD 134" Mh" STEEL WITH 34” PORT — 2 78” PAC DSI 31" 0D 144" 15/16" STEELWITH 1” = PORT 2.38" IF 434" 0D 2" 15/16" STEEL WITH 1 Ya" PORT 3:12" IF 6'R" OD 234" Ie" STEELWITH 12" PORT 4 We" IF 634" 0D 234" 11k" STEELWITH 12" PORT 4 12" IF 80D 3%" 1 th* STEELWITH 1 2" PORT 6 Se” REG. 9%" 0D 3%" 11h STEEL WITH 1 "2" PORT 7 58” REG. * OTHER CONNECTIONS AVAILABLE UPON REQUEST.‘PRESSURE DROP ACNOSS PORT 01.25" IN 43/4 BYPASS (MUD DENSITY « 10905) ano so imi) PRESSURE DROP ACHOSS PORT O1.5" IN SLEEVE 6 348 (MUD DENSITY = 10509) ‘im ininy moo s| alle =| 8) 8/8 a] BEAL a He iii glal aalald gla! alae gig Ala] a ang g/g a] a| 8 al2/3 ail gE Sala BIE