REX: 18” VERSAFLEX (BIG BORE)

LINER HANGER SYSTEM RUN ON

TARIF DEEP 1.T1

Rig EDC 56 – Tarif Deep-1 – EGYPT

November 2017
 AGENDA

● General Information

● Preparation

● Operational execution

● Recommendation & Lessons learnt

18’’ VERSAFLEX LINER HANGER. TARIF DEEP-1. TOTAL EGYPT. NOVEMBER 14, 2017
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GENERAL INFORMATION
Title of FEEDBACK : WHY 18” VERSAFLEX liner hanger
Well : Tarif Deep-1.T1
Affiliate : TOTAL E&P EGYPT
Environment : HPHT Exploration Onshore
Rig : EDC 56 HP land rig
Spud Date 30th April 2017
End Date 3rd of November 2017
CONTACT
Marc LEFRANCQ (Author) Marc.lefrancq@external,total.com

Executive summary
This FEEDBACK presents the explanations why 18” VERSAFLEX liner hanger system run
on Tarif Deep-1. The following points will be explained on this slides.
- Why 18in Big Bore Versaflex system?
- Versaflex system versus Conventional system
- 18in Versaflex Big Bore particularities
- Job challenges and recommendations
- Cost implication

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 PREPARATION

● Why 18in Big Bore Versaflex system?

● Versaflex system versus Conventional system

● 18in Versaflex Big Bore particularities

● Job challenges and recommendations

● Cost implication

● Contacts

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 WHY 18” BIG BORE VERSAFLEX?

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 WHY 18” BIG BORE VERSAFLEX?

● Exploration HPHT Well:

- Deepest well in block NEMO
- Well was targeting Mesozoic Carbonate
(has never been reached in NEMO block)
- Challenging geology throughout the well
- Losses and bore hole degradation was expected
- High likelihood for using contingencies string.

● Well architecture (heavy architecture)

- 30” x 22” x 18” x 14” x 11¾ x 9⅞ (dry case)
- 30” x 22” x 18 x 14” x 11¾ x 9⅞ x 7” x 4½” (success case)
- 16” liner , 7⅝” Exp as contingencies

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 WHY 18”BIG BORE VERSAFLEX?

● Wellhead Cameron:
- Only three full casing strings are available in surface wellhead
- No landing string available in 22” casing.

● Purpose of 18in liner in well architecture

- Isolate reactive shale of Kafer ELanding stringhikh and water / gas
bearing formation in Qwasim.
- Obtain enough shoe strength in the claystones of Sidi Salim formation to
be able to increase Mud weight to drill through Sidi Salim potential
pressure ramp.

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 WHY 18”BIG BORE VERSAFLEX?

● Initial choice for 18in Versaflex Liner:

- Only 18” size in market
- Planned equipment manufacturing time frame in line with project schedule
- No landing sub available in 22” casing
- Liner HGR Expandable material is 110 grade / non-expandable material
125 grade.

- Good commercial deal with Halliburton – all equipment on consignment

bases

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 VERSAFLEX SYSTEM VERSUS CONVENTIONAL SYSTEM

● Main Versaflex features

- Used expandable technology
• Simple operational procedures (no HGR then PKR to set)
• No dogs to set hanger (no slip damage to casing)
• Elastomers providing both sealing & hanging capacities
- No rotation to set or release tool
- Emergency release by shearing contingency pins
- More applicable in tight tolerance string
- Minimal mechanical parts (hydraulic energized)
- Redundant sealing elements
- Less induced damage and more stress distribution to supporting casing

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 18” BIG BORE VERSAFLEX PARTICULARITIES

● Liner Accessories
- 18” Float shoe: Auto-fill type

Type “RPT” Reamer shoe, 4.1/4” Super seal II valve, 19” Max OD

(18.1/4” Body OD). With tapered composite nose & down jets.

- 18” Float Collar: Auto-fill type

Single float valve, 4.1/4” Super Seal II valve, 18. 098” OD.

- Centralizers:`

18” Centek TUR non-rotating centralizer , 22.50” Max OD,

Compressed to 19.12” OD. In addition to Pro-Tech 19” fixed centralizer

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 18” BIG BORE VERSAFLEX PARTICULARITIES

● Liner System
- Plug Systems:

Bottom & Top Dual SSR II plug system, released by foam darts.

• Bottom plug launched actually at 2000 psi, rupture at 850 psi,

• Top plug launched actually at 1350 psi

- Plug Launcher & Equalizer Swivel:

To prevent damaging and/or releasing the cement wiper plug

prematurely due to pressure trapped above the plug

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 18” BIG BORE VERSAFLEX PARTICULARITIES

- Setting tool:

Equipped with 3” setting ball seat, Pressure is then applied to

the entire landing string to push the expansion cone downward

to expand & set the elastomers. End of expansion is known

when pressure bleeds off (no need to shear ball seat to circulate

after tool releasing).

- Commander 1000 Cement Head:

CMT Head is used to accommodate two foam wiper dart and

support 2,000 klbs (tensile load) with integral swivel design

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 18” VERSAFLEX BIG
BORE PARTICULARITIES
- Liner Schematic
Assembly from bottom to top:
 Float shoe, float collar & landing
collar, 5 jts shoe track
 187 Jts of 18” P110 105ppf
VAM Bolt liner.
 18” Cross over (TSH-511 box x
VAM bolt pin)
 18” Liner HGR assembly
 18” Liner HGR setting tool
 Cross over HT-55 box x 6.5/8
FH pin
 5.1/2” HT-55 handling pup jt
 5.1/2” HT-55 Landing string
 Cmt stand (cmt head, FOSV,
X/O’s)
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 18” BIG BORE VERSAFLEX PARTICULARITIES

● Highlights
 Good alternative to casing hanger subs.

 No restriction inside the supporting casing

 Liner could be set at any depth (as long as TOL is not at collar depth)

 Minimum rathole

 No constraint on deviation

 Hydraulic set

 Less mechanical parts.

 Setting tool has contingency releasing mechanism (shear screws)

 It is compatible with LOD line pipe. No need for internal weld cap grinding

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 18” BIG BORE VERSAFLEX PARTICULARITIES

● But...
 However cement job has to be completed before releasing running tool, which

added more risk to bring the cement above top of liner

 Hanger could be set in a collar depth if there is any mistake in the tally.

 Post expansion pipe properties could be limiting

 No tie back available for the big bore sizes

 High force is generated during cement job as the hanger is only set after

performing the cement job.

 Few QA/QC issues were noted on Versaflex team in Egypt as next......

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 18” BIG BORE VERSAFLEX PARTICULARITIES

● QA/QC feedback
 Versa-Flex Liner Hangers successfully RIH not all without incident.

 Communication issues did improve as project went on.

 QA problems when building the 18” Big Bore System. Various parts of running tool failed in house inspection

and delayed build if Total operations had not slipped Halliburton would not have been able to deliver on time.

 Excessive time to build and complete 18” System.

 Not a one stop facility to build Versa Flex. (Unable to torque Running Tool).

 Plug system problem should have been captured if they had followed latest In House Hall World instruction.

 CMT Head testing of FOSV correctly they were unaware of which was an eye opener and Total QA had to

advise.

 As per other vendors paid little or no attention to 15 day look ahead and last minute.com.to have equipment

ready for load out.

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 18” BIG BORE VERSAFLEX PARTICULARITIES

● Calculations
Estimated Actual
Liner string weight 630 klbs 665 klbs
Landing string weight 113 klbs 120 klbs
Top Drive weight 45 klbs 45 klbs
Total String weight 788 klbs 830 klbs
Calculated reduction in wt due to CMT 463 psi 117 klbs 117 klbs
Total String weight after cementing 671 klbs 713 klbs
Hanger Setting pressure 5460 psi 3700 psi
Piston Force (only inside LS) 68.64 klbs 46.5 klbs
Bumping Top Plug 500 psi 0 psi
Piston Force (inside 18" liner) 111.9 klbs 0 klbs
Min required LS tensile 854.9 klbs
5.1/2" HT-55 LS tensile rating 1170 klbs

Higher landing string tensile rating required to

set & cement Versaflex liner HGR

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 OPERATIONAL EXECUTION

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 JOB TIME LOG AND OPERATIONAL NPT

18’’ Versaflex Liner running &

setting time overview 1.5 2 3
1.5

Rig up/down
Running
Liner Jts running
Duration:
1 10 40 hrs
10
Running on
landing string
Circulation 7.5 32
Total Job
Cementing M/U Shoe Track Run 187 jts
Duration:
M/U lnr HGR M/U SSR plugs
Liner Setting
83.5 hrs
12 Change WFD Equipment

JOB NPT:
40 • 2.0 hrs to change out leaking
500 ton RMS-2000.
• 1.5 hrs to m/u 18” SSR plugs to
equalizer swivel
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 JOB TIME LOG AND OPERATIONAL NPT

NPT Executive Summaries

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 JOB TIME LOG AND OPERATIONAL NPT

NPT Executive Summaries

1.5 hrs were spent while making

up Dual 18” SSR plug assembly to
the equalizer swivel.

One swivel got damaged and the

back up one was used.

It’s highly recommended to make

up such big plug sizes in the work
shop to save rig time and avoid
equipment damage at rig site.

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 RECOMMENDATIONS & LESSONS LEARNT
● Long String

• High tensile rated landing string was selected to handle string weight and piston force while cementing & setting.

• Reamer shoe with down jets used to help passing thru any tight spots

• Rotation initiated while circulation to clear any debris before cementing

• High torsional drag was experienced with such long string, 2 attempt were performed to rotate sting at 2226 m MDRT with

max torque of 27klbs.ft, however rotation was established on bottom with initial torque of 35klbs.ft (dropped to 22klbs.ft)

● Losses

• Control running speed to avoid surging formation

• Planned for Autofill float system, however it was converted before running....

● Potential foam dart stuck below cement head

- Routine check for equipment, sub , X/O’s during QAQC inspection – crossover below cement head was changed in

workshop due to square shoulder in 6.5/8” FH box connection.

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 RECOMMENDATIONS & LESSONS LEARNT

● Risk of accidental release of SSR plugs

- Adding equalizer swivel between setting tool & plugs to avoid premature plug release.

- Stage up / Stage down circulation carefully

● Risk of accidental shear of running tool

- Installed 4 x 12 Klbs emergency shear pin screws to increase required releasing force

- Do not allow more than 30 Klbs slack while running

- Calculate buoyancy effect while cementing and compensate if necessary

● Risk of setting tool stuck (after cementing)

- Ideally to accommodate more liner overlap to allow bring cement inside previous shoe without getting cement above TOL

- Enough thickening time for lead cement slurry (15 hrs thickening time – with +/- 5 hrs safety margin)

- Contingency releasing mechanism in the setting tool as backup

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 COST IMPLICATIONS

● Cost Cost breakdown for 18” Versaflex liner HGR

Item Realized Planned
Liner cementing accessories $ 96,170.00 $ 96,170.00
18" Liner joints (187 jts + 5 jts + Pups) $ 883,144.00 $ 883,144.00
18" Versaflex Liner HGR assembly (Purchased) $ 388,031.00
Landing collar $ 18,626.00
TSH 511 x VAM bolt X/O $ 35,000.00 $ 388,031.00
Liner HGR assembly $ 321,491.00
Dual SSR 18" wiper plugs (inc. foam darts) $ 12,914.00
18" Versaflex Liner HGR Running tools (Rental) $ 67,075.00
Versaflex liner setting tool $ 32,075.00 $ 37,325.00
Equalizer swivel $ 35,000.00
Personnel $ 152,865.00 $ 66,600.00
Total Liner String $ 979,314.00 $ 979,314.00
Total Liner HGR System $ 607,971.00 $ 491,956.00
Grand Total $ 1,587,285.00 $ 1,471,270.00
Note: Difference between planned & realized cost because of
additional days due to well sidetrack
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 VERSAFLEX BIG BORE PORTFOLIO

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 VERSAFLEX BIG BORE PORTFOLIO

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 CONTACTS
● TOTAL E&P, Egypt

- Aurelie QUINCHARD / Romain DESSOLY – Drilling Engineer

- Marc LEFRANCQ – Drilling Superintendent

- Krish RAGHAVAN / Stephane L’HOSTIS – Fluids Superintendent

- Ronaldo Slootweg / Edward Prohl – Drilling Supervisor “RSES”

- Emad BADR / Mohamed ELSAYED – Night Drilling Supervisor

- Wayne Breaux / Charles Collie – QA/QC Supervisor

- Larbi BOUZIANE – Drilling Manager

● Halliburton Versaflex

- Mohamed Khedr – VersaFlex iner Hanger Engineer <[email protected]>

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