OILFIELD TECHNOLOGY MAGAZINE

VOLUME 06 ISSUE 06-JUNE 2013

JUNE 2013

Advancing Directional Technologies

www.energyglobal.com
MicroCORE
Simple two in one innovation

Improved geological
insight while drilling faster
The MicroCORE Drill Bit improves ROP by up to 35%, while delivering
high quality undisturbed cuttings, generating crucial geological
information and giving operators the ability to analyze a continuous
flow of valuable formation material.*

TOTAL patented technology

www.terceloilfield.com
*Dependent on bit size
 June 2013 Volume 06 Issue 06

contents
ISSN 1757-2134

10

| 03 | EDITORIAL COMMENT | 35 | NOT ALL ARE CREATED EQUAL

Tyler Cobb, Baker Hughes, USA, reiterates the importance of selecting
the correct drill bit from the perspective of operators and contractors.
| 05 | WORLD NEWS

| 41 | DRILL BIT DEVELOPMENTS

| 10 | OIL AND GAS: FROM RUSSIA WITH LOVE?
Todd Bielawa and Jack Castle, Century Products, Inc., USA, outline
Louise Taggart, AKE, UK, looks at how the upstream oil and some recent developments in drill bit technology that are helping
gas industry functions in Russia, and considers challenges and operators continue to get the job done in ever-harsher conditions.
opportunities inherent in operating in the country.

| 45 | GETTING A BIT MORE

| 13 | MIND THE GAP
Cary Maurstad, Varel International, USA, takes a look at some of the
Simon Drysdale, BP, UK, explains how investing in current talent is latest advances in drill bit technology that are helping oil producers drill
helping to bridge the skills gap in the global oil and gas industry. faster and further.

| 18 | MANAGING THE HUMAN RESOURCE | 49 | MOVING ON WITH MWD

Laura Drysdale, Change International Recruitment, UK, explains Steve Krase, Ryan Directional Services, USA, gives us a look at a
how the growth in demand for hydrocarbons has fuelled a boom in unique approach to MWD for unconventional wells.
the deepwater market, which is stretching the limits of manpower
availability.
| 54 | PUTTING UP BARRIERS
Paul Hazel, Welltec A/S, UK, explains how improved annular barriers
| 24 | OPENING UP THE ARCTIC
lead to better completions.
Matt Corbin, Aker Solutions, UK, provides an overview of the
development of a subsea gas compression system that could pave
the way to easier operations in the Arctic. | 60 | KEEP ON YOUR TOES
Stephen J. Chauffe, TEAM Oil Tools, USA, examines a new hydraulic
toe valve designed for a cemented environment.
| 27 | MAPPING OUT THE ARGUMENTS
Cyril Widdershoven, TNO, the Netherlands, shows how the arguments
for and against the production of shale gas in the EU are mapped out, | 65 | SEAL THE DEAL
and explains the political-economic decisions that need Sean Hollis and David Brown, CSI-Technologies, USA, show how
to be made. common well repair problems can be overcome with an engineered
sealant.
| 31 | CABLE FREE COLLECTION
Doug Crice, Wireless Seismic, USA, examines the growing range of | 69 | FOAM-FREE CEMENTING
cableless seismic systems available to operators, and compares these Amir Mahmoudkhani, Kemira, USA, explores the advantages of green
with traditional cable-based systems. innovations in defoamers for cementing applications.

On this months cover >>

Drilformances PDC drill bits and innovative downhole tools deliver consistent high performance. Operators turn to
Drilformance when speed, directional control and a quality wellbore are fundamental to achieve project economics. The
companys innovative design methods continue to deliver advances in drilling technology that result in optimal economic
returns for operators.

Oilfield Technology is audited by the Audit Bureau

of Circulations (ABC). An audit certificate is
available on request from our sales department.

Copyright Palladian Publications Ltd 2013. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted
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All views expressed in this journal are those of the respective contributors and are not necessarily the opinions of the publisher, neither do the publishers
endorse any of the claims made in the articles or the advertisements. Printed in the UK. Images courtesy of www.bigstockphoto.com.
 PLUG AND ABANDONMENT

Overcoming conventional
P&A failures gave this operator
a resin to celebrate.

Case History:

OPERATOR CHALLENGE
OFFSHORE
Costs were mounting for an offshore
operator trying to abandon a well.
Conventional decommissioning
operations failed to stop a continuous
high-pressure bubble stream.

HALLIBURTON SOLUTION
The low yield point of Halliburton
WellLock resin enabled inltration
of the leak. The three-dimensional
polymer network not only resisted
gas channeling, but effectively
displaced seawater and wellbore
uids, achieving a competent
plug bond.

SOLUTION RESULTS
Testing after the plug set
demonstrated a competent
seal compliant with regulations.

Whats your plug and abandonment challenge?

For solutions, go to halliburton.com/welllock

Solving challenges.

2013 Halliburton. All rights reserved.

 comment
Anna Scordos
Editor

T
he UK will be a place for shale gas companies to see,
and be seen, over the next few years. IGas is a leading
onshore hydrocarbon producer in the UK, delivering
natural gas and crude oil to Britains energy market and has
recently announced that it has previously underestimated
the volumes of its gas resources in northwest England. The
company has now predicted that its licensed sites in Cheshire
hold approximately 102 trillion ft3 of shale gas. These volumes
of reserves could meet British gas consumption demands
for many years to come. In an interview with the BBC,
Andrew Austin, the companys Chief Executive, said, We
[Britain] import around 1.5 trillion ft3, we consume around
3 trillion ft3 a year. Assuming you could recover technically
something like 10 to 15% of the shale gas in place, then it
could move import dependency out for about 10 to 15 years.
The company will start drilling this year.
Many O&G players in the UK have strong hopes that
the country will, at some stage, manage to replicate the
success of the USA in harnessing the resource. Development
of shale plays in Europe is slow, but the regions markets
are still affected by the huge shale exploitation in the US;
last year LNG cargos were diverted from the US to Europe,
which made gas from Russia expensive in comparison. But
Gazprom is insisting that its gas is competitive now, and
expects European exports to rise by 9.4% this year. The
state controlled energy group is nothing if not condent. A
recent Financial Times article quoted Alexander Medvedev,
Gazproms Deputy Chief Executive, as saying Gazprom
will continue to play a leading role as a gas exporter. As
The Beatles sang, All you need is gas. Inaccurate song
quotes aside; European gas demand is actually on the
decline, as, over recent years, Europe soaked up the
surplus US domestic coal supplies sidelined by the shale
phenomenon.
Oil & Gas UK, the leading representative organisation for
the UK offshore oil and gas industry, released a statement
last month revealing that companies delivering drilling,
completion, testing and maintenance for oil and gas wells
generated gross revenue of 1.9 billion (US$ 3.05 billion)
in 2012, apparently the highest since records began in
1996. Spending on equipment and technology rose by
approximately 5% from US$ 178 million to US$ 186 million.
Well services contractors spent up to 90% of their annual
capital investment on developing new technologies. The
Rt Hon Dr Vince Cable, Secretary of State for Business,
Innovation and Skills, acknowledged The Long and Winding
Road ahead for the UK O&G industry, saying: These gures
show just how valued the UKs expertise in the oil and gas
sector is across the world. They also emphasise the value
and potential growth of the industry to make a stronger UK
economy. We want to continue to attract investment into the
supply chain so that we can compete internationally. The
UK will clearly be working Eight Days a Week to maintain its
competitive edge on the international O&G stage. O T

es Little
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June 2013 3
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// BP // US$ 1 billion Alaska expansion planned
BP has revealed plans for US$ 1 billion
of investment in its Alaskan operations
over the next five years, including the
addition of two new drilling rigs to its
North Slope fields. The new rigs will
push BPs Alaskan total up to nine.
According to BP, the plans will call
for an increase in drilling and well work
activity, the upgrading of existing
facilities and the addition of up to
200 new jobs in the state, giving a
boost to both the companys operations
and the states economy.
The company has also secured
support from the other working interest
owners (ExxonMobil, ConocoPhillips
and Chevron) at Prudhoe Bay to
begin the evaluation of an additional
US$ 3 billion worth of development
projects. These projects would continue
for almost a decade. They are likely to
involve the construction of new drilling
pads and the drilling of more than
// Russia // 2013 oil
production record hit
Russias oil output in May rose slightly
(a 0.1% increase) bringing the figure to
10.48 million bpd, partially supported
by the countrys top producer, Rosneft,
which had been further ramping up its
output.
This figure matches Russias
November 2012 output, but still falls
just short of the countrys post-Soviet
record of 10.50 million bpd. Rosneft
pushed its overall production up by
0.15% as a result of growing output
from its recently acquired Vankor field
(which was obtained after the company
bought out TNK-BP for US$ 55 billion).
The companys total output is
4.6 million boepd.
The countrys gas production
fell by 1.7 billion m3/d, as a result of
Gazproms output declining by 11%.
world news
110 new wells.
Janet Weiss, BPs regional president
said, Our announcement today should
make it abundantly clear that BP is
committed to being a part of [Alaskas]
future and to continuing to extend the
life of North Americas largest oilfield.
BP has claimed that the decision
behind this new wave of investment in
Alaska was a result of recent changes
to the states tax law. The states tax
laws changed in April, and have made
oil and gas operations more appealing
to investors. Changes included a 20%
reduction in taxes collected on new oil
production, and a new flat tax of 35%
on profits.
Weiss explained that, Now an
improved tax structure is in place, oil
and gas projects can once again move
forward, keeping Alaska competitive in
the midst of Americas recent energy
renaissance.
// OPEC // Cap to
stay at 30 million bpd
The international oil cartel, OPEC, has
decided to maintain a production cap
of 30 million bpd; this decision had
been widely expected, but according
to some sources, the ongoing shale
oil boom in the US has begun to raise
concerns.
Sources claimed that the countries
that had been hurt most by shale
oil had asked the group to look
into ways of resolving the situation.
However, OPECs Secretary General,
Abdalla Salem el-Badri said that
although a review into the impact of
shale oil would be launched, it would
be down to member countries to find
their own solutions.
Several countries have already
begun to seek alternative markets
outside of the US.
inbrief
ARGENTINA
The Argentine government has
signed an agreement with the Federal
Organisation of Hydrocarbon Producing
Provinces that aims to guarantee
the fulfilment of the objectives in the
hydrocarbon sovereignty law. The law in
question is designed to make Argentina
self-sufficient in hydrocarbons within as
little as four years.
The ambitious law could face
significant hurdles in the form of a lack
of drilling rigs and other equipment, as
well as concern from foreign companies
over the safety of their investments
in Argentina in the wake of the
nationalisation of Repsols YPF.
POLAND
Wlodzimierz Karpinski, Polands
treasury minister has stated that
despite setbacks in its development,
successfully utilising the countrys shale
reserves will remain a priority.
The pressure on companies
to invest in this area will certainly
not be smaller, it could even be
bigger, because this is a matter of
national interest, Karpinski was
quoted as saying. Poland is believed
to hold recoverable reserves of
346 - 768 billion m3.
IRAN
According to the Financial Times, Irans
oil output has fallen to a 25 year low as
Tehrans major Asian customers have
cut their imports in response to US
sanctions.
China, India, Japan, South Korea
and others have all dramatically
reduced their imports of Iranian oil,
purchasing just 750 000 bbls between
them this April - down 30% on the
figure for March. The US has provided
180 day waivers to allow time for Iranian
customers to find new suppliers.
OILFIELD TECHNOLOGY
June 2013
05
world news

diarydates // Syria // Production // Lundin // Sverdrup

5% of pre-war levels appraisal well complete
3 - 6 September
Offshore Europe The Syrian oil minister, Suleiman Abbas Swedish company, Lundin Petroleum
Aberdeen, UK has revealed that the countrys oil has completed another appraisal well
E: oeteam@reedexpo.co.uk output has fallen by 95% from pre-war at the Johan Sverdrup field offshore
www.offshore-europe.co.uk levels to just 20 000 bpd (down from a Norway and has found additional
figure of 380 000 bpd). resources.
22 - 27 September The Syrian government had been The well encountered an oil
SEG International Exposition and 83rd dependent upon oil as its main source volume of approximately 12 m,
Annual Meeting of revenue until the EU imposed an which was described by the
Houston, USA embargo as punishment for attempts to Norwegian Petroleum Directorate as
www.seg.org/web/annual-meeting-2013 suppress the uprising. Production took having very good reservoir quality.
a significant hit after the government The companys CEO and President
lost control of most of northern and said, The latest [...] appraisal well
30 September - 2 October
eastern Syria, where the majority of the provides a further important data point
SPE ATCE
countrys oilfields are located. and will be incorporated into the latest
New Orleans, USA
The EU had recently agreed to reservoir model, which will be used to
E: meetings@spe.org
allow the purchase of oil from the update resource estimates later this
www.spe.org/atce/2013
Syrian opposition. However, extensive year.
smuggling operations and the influence The well, located in water 112 m
29 - 31 October of powerful local tribes will likely mean deep and drilled to a total depth
OTC Brasil that the opposition will be unlikely to of 2045 m, was drilled by the rig
Rio de Janeiro gain full control of the facilities. Bredford Dolphin.
E: otcbrasil@ibp.org.br
www.otcbrasil.org/2013
// Petrobras // Domestic production
on the rise; new pre-salt record set
webnews Brazils state giant, Petrobras, has reported that domestic oil
highlights production rose by 4.2% in April to a total of 1.98 million bpd.
The companys total hydrocarbon production including natural
gas rose by 2.6% to 2.55 million boepd.
IGas announces significant rise According to Petrobras, The output increased primarily
in gas-in-place at UK shale basin due to the resumption of production on platforms P-09,
PCE-1 and P-54, in the Campos Basin, following a scheduled
Northcote Energy - highly positive shutdown in March, and the ramp-up in production on
frac update FPSO Cidade de Itaja, in Bana Field, Santos Basin. Aprils
most significant scheduled shutdowns happened on FPSO
Challenges for oil and gas Esprito Santo, in Parque das Conchas, operated by Shell, and
development in the Western Pacific on FPSO Brasil in Roncador Field.
The company also added that, It is also important to note
the increasing contribution of pre-salt areas, which have been
To read more about Scan for the
ENERGY GLOBAL adding to consolidated output results. A new pre-salt output
these articles and for iPhone/iPad App record of 311 000 bbls of oil was set on 17 April. In addition to
more event listings go to: the daily record, Petrobras set a monthly record of 293 800 bpd
in the pre-salt.
Brazils pre-salt fields are believed to hold significant
Get the free mobile app at
http:/ / gettag.mobi amounts of oil and could pave the way for Brazil to become a
major hydrocarbon exporter.

OILFIELD TECHNOLOGY
06 June 2013
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 world news
// Total // To partner with others in South Sudan
Total has announced that it will partner
with ExxonMobil and Kufpec in order to
search South Sudans Jonglei state for oil.
Total has held in a majority interest
in the 120 000 km2 Block B in the region
since the 1980s, but the long civil war
between Sudan and the newly emerged
South Sudan prevent the company from
going ahead with exploration.
It was announced by the
South Sudanese government last year
that, in order to speed up development
of the region, negotiations were taking
place in order to split the block. The
chairman of South Sudans parliamentary
committee on energy and mining,
Henry Odwar, announced that the block
would be split into three: B1, B2, and B3.
Odwar was quoted as saying that,
// US // Shale boom
reduces hurricane threat
As well as bringing about a significant
upturn in domestic oil and gas
production, the US shale boom may have
the unexpected advantage of making
the oil and gas industry more resilient to
hurricanes.
According to the EIA, the shift of the
industry towards inland operations (away
from exposed offshore facilities) will likely
mitigate the overall impact of hurricanes
on oil production. In the four years
leading up to 2011, production in the
Gulf of Mexico (GoM) accounted for more
than a quarter of the US entire output; in
2012, this figure had dropped to 19%.
The EIA reports a similar scenario for
natural gas, with 26% coming from the
GoM in 1997, but accounting for just 6%
last year.
Hurricanes however, are still liable to
cause significant disruption if they make
landfall; Hurricane Isaac (2012) caused at
least 1.3 million bbls of production to be
shut in.
OILFIELD TECHNOLOGY
08 June 2013
Now Total has gone ahead and, with a
nudge from the ministry, engaged certain
partners. ExxonMobil and Kufpec have
been brought in to be partners in Block
B1. According to Reuters, a source
with inside knowledge of the deal has
confirmed that B2 is likely to be managed
by the same partnership, and that the
government has yet to decide on B3.
South Sudan has only recently
resumed production from its fields after
a 16 month hiatus brought about by a
diplomatic spat with Sudan; at one point,
the two countries were perilously close
to all out war. Even since the resumption
of production, tensions between the two
nations are still high; recent attacks by
militants on the border have only served
to fuel suspicion.
// PDVSA // US$4billion
loan signed with China
Venezuelas PDVSA has agreed a
US$ 4.02 billion loan with Chinas
Development Bank Corp. (CBDC), the
proceeds of which will go towards
ramping up production in the Orinoco
belt. The deal was signed by PDVSAs
President, Rafael Ramirez and CDBC
Vice President Wang Yongshen.
Specifically, the money will be used
to boost production at the Sinovensa
field from 140 000 bpd to 330 000 bpd.
PDVSA holds a 64.25% stake in the field,
with China National Petroleum Corp.
holding the remaining 35.75%. Increasing
production at the field falls under
PDVSAs 2013 - 19 business plan, which
is targeting at increasing Venezuelas
total production to 6 million bpd (up from
2.91 million bpd at the end of last year).
Chinese companies including CNPC
have signed various agreements with
PDVSA, which are designed to see
each company boost its production by
1 million bpd by 2019.
// Kodiak // Acquires
North Dakota assets
Kodiak Oil & Gas Corp. has announced
that it is going to spend US$ 660 million
on assets in North Dakota, which were
previously owned by Liberty Resources.
The acquisition covers 42 000 acres
of both producing and undeveloped
assets across the Williston basin, with
coverage in both the Three Forks and
Bakken plays. This will bring Kodiaks
total holdings in the Williston basin to
196 000 acres. The acquired acreage
produces approximately 5700 bpd at
present.
The Bakken and Three Forks
formations are believed to hold a total
of approximately 7.4 billion bbls of
undiscovered, but technically recovered
oil. North Dakota is now the second
largest oil producing state in the US.
// Statoil // New nd
near the Vigdis eld
Norwegian state player, Statoil has made
a new oil discovery near the North Sea
Vigdis field, however, after disappointing
results, the commercial viability of the find
remains in question.
According to the Norwegian
Petroleum Directorate, The objective
of the well was to prove petroleum in
Lower Jurassic reservoir rocks (the
Cook formation), as well as to collect data
in order to assess further development of
the area.
The well proved a 24 m oil column
in the Cook formation with somewhat
poorer reservoir quality than expected.
The size of the discovery is being
evaluated regarding whether or not it may
be commercially interesting.
The well, which was drilled from a
template at the Vigdis field, reached a
total vertical depth of 2546 m, in water
some 292 m deep. The drilling vessel
was the Fred Olsen Energy-owned
Bideford Dolphin.
 he upstream oil and gas business is vital to the Russian
T economy. Last year, revenues from the hydrocarbon
sector contributed approximately 50% of GDP and they
will remain even more vital as the government looks to pump
more public money into military reform and social spending.
Data from the Energy Ministry indicated that Russias level of
oil output was the highest in the world last year, ahead of even
Saudi Arabia. Output was edged up by increased production at
Rosneft to a post-Soviet high of 10.4 million bpd, an increase of
PU:PILYPH([[YHJ[PUNPU]LZ[TLU[[VUL^LSKZ^PSSILRL`PM
Russia is to maintain its oil output levels in the longer term and
M\SSP[ZHTIP[PVUVMRLLWPUNJY\KLWYVK\J[PVUH[UVSLZZ[OHU
10 million bpd until 2020. In order to attract further investment,
however, issues such as changes to the tax regime and
corruption will have to be addressed so as not to hinder further
growth in the upstream sector.
Production
1.1% on 2011 levels. However, future output may be constrained 5H[\YHSNHZV\[W\[PU9\ZZPHMLSSMYVTSHZ[`LHYZN\YLKV^U
I`[OLJV\U[Y`ZPUJYLHZPUNS`TH[\YPUNLSKZWHY[PJ\SHYS` to 655 bcm, attributed in part to a drop in production of 5.1%

10
 Louise Taggart,
AKE, UK, looks at
how the upstream
oil and gas
industry functions
in Russia, and
considers the
challenges and
opportunities
inherent in
operating in the
country.

(26 bcm) at Gazprom. Gazproms position has also been weakened
abroad, with exports constrained by continued stagnation in the
European export market and by growing hostility towards its pricing
structure, which pegs gas prices to oil indexes. Independent
producer Novatek saw its own production levels rise 7.1% and
such independent companies are expected to increasingly
challenge Gazproms dominance in the coming months and years.
However, the gas sector remains dominated by the Gazprom
monolith. Although the downstream sector could be opened
up, with discussion continuing over the possibility of liberalising
35.L_WVY[Z[VV[OLYYTZHSSV^PUNMVYHT\JOTVYLJVTWL[P[P]L
domestic market, the upstream market is likely to remain dominated
by such domestic giants in the short term.
Exploration
Offshore exploration in the key Arctic region remains dominated
by Gazprom and Rosneft, which hold the rights to some 80% of
Arctic sections. The right to work on the continental shelf belongs
only to companies with more than 50% state ownership; private
companies are limited to entering only as junior partners without a
stake in the operating licence. The government has also outlined
plans to suspend the development of reserves in 20% of the

11
Arctic shelf, ostensibly in a further bid to halt private access to
reserves. In May, the government awarded four exploration licences
for the Barents Sea to Gazprom without the need for an auction.
Although some foreign companies have begun to secure
upstream access in the Russian Arctic in the form of partnerships
with Rosneft and Gazprom, the government will remain reluctant
to open up these natural resources to foreign or private investors,
except as junior partners brought in to provide technological
L_WLY[PZL/V^L]LY[OLKPMJ\S[PLZMHJLKI`MVYLPNUJVTWHUPLZ
Z\JOHZ)7^OPJOZH^P[ZLMMVY[Z[VKL]LSVWVMMZOVYL(YJ[PJLSKZPU
JVUQ\UJ[PVU^P[O9VZULM[Y\UPU[VKPMJ\S[PLZYLZ\S[PUNPU[OL
widely-publicised exit of BP head Dudley, will make foreign
investors wary of entering the market as a junior partner with limited
oversight.
Boosting investment
+LZWP[L[OPZTHU`VM9\ZZPHZJ\YYLU[VWLYH[PUNLSKZHYLTH[\YPUN
and changes will need to be made to encourage investment in the
TVYLKPMJ\S[LSKZHZJ\YYLU[WYVK\J[PVUTH[\YLZ;OLNV]LYUTLU[
is coming under growing pressure to loosen regulation and taxation
[VIVVZ[PU]LZ[TLU[PUNYLLULSKWYVQLJ[ZPUHYLHZUV[HIS`[OL(YJ[PJ
which have much higher exploration and extraction costs associated
with their reserves. Russias tax system has undergone various
changes in recent years, hampering oil companies efforts to make
long term investment plans, with operators calling for a more stable
and clear tax regime. The Finance Ministry has indicated it may
move to gradually phase out oil export duties whilst simultaneously
increasing the rate of mineral extraction tax (MET). The ministry is
expected to announce its proposals on lowering the export rate by
2 3% annually in May. The proposal is expected to lower the crude
export duty rate from the current 60%, and would also lower rates
MVYYLULKWYVK\J[Z^OPJOHYLJHSJ\SH[LKHZHMYHJ[PVUVMJY\KL
However, in a bid to offset any losses in revenue, it would also intend
to raise the MET. The MET increase could be as much as 5%.
The proposal has already attracted criticism from upstream
operators and the tax is widely seen as a brake on investment
needed to increase oil production. Russian oil companies have
voiced concerns over the latest proposals, saying they would
lead to a decline in oil output and result in less tax revenue. The
L_[YHJ[PVU[H_^HZH[MVYZL]LU`LHYZ\U[PS[OLH\[OVYP[PLZPUJYLHZLK
it by 6.4% last year. The amount of tax is calculated monthly for
each extracted commercial mineral.
Another hurdle to investment in the upstream energy sector
remains the wider operating and business environment. Russia
has sought to develop a more investor-friendly environment than
some of its other energy-rich neighbours, such as Kazakhstan.
However, a number of issues can still pose a barrier to foreign
investment in the upstream sector, both direct such as taxation
and the regulatory environment, and more latent issues such as
the political environment.
Political environment
Russias political environment has come under increased scrutiny
following the disputed parliamentary elections in December 2011,
^OPJOYLZ\S[LKPU[OLYZ[SHYNLZJHSLVWWVZP[PVUWYV[LZ[ZZPUJL
the collapse of the Soviet Union. The consequent perception
of political instability, which some parts of the Western media
were quick to erroneously label part of the wider Arab Spring,
\UKLYTPULKPU]LZ[VYJVUKLUJLPUWVSP[PJHSZ[HIPSP[`HUK
consequently in the wider business environment. However, for
the medium term at least, the status quo is unlikely to witness
OILFIELD TECHNOLOGY
12 June 2013
HU`ZPNUPJHU[\WOLH]HS7YLZPKLU[7\[PUYLTHPUZYTS`PUJVU[YVS
at the helm of the government and although some changes have
been brought in as a sop to the opposition movement, the political
elite will remain well established. Although this will ensure a
level of political stability, it in itself also engenders further issues.
Political stagnation will ensure the continuation of the entrenched
business elite, along with the implications that it brings for their
vested interests. The business environment remains dominated
by cronyism and widespread corruption. The US 2013 National
Trade Estimate Report on Foreign Trade Barriers reported that
corruption remains the key barrier to foreign investment in Russia.
Although the government has sought to improve the business
climate, corruption was reportedly continually cited as a major
concern in both commercial and bureaucratic transactions. A
number of recent political resignations following allegations of
undeclared assets will do little to reassure investors that any
ZPNUPJHU[JOHUNLZOH]LILLUTHKL[VHKKYLZZZ\JOHULUKLTPJ
problem.
The appointment of the next head of the Central Bank is also
PUKPJH[P]LVM2YLTSPUPU\LUJLV]LY[OLSL]LYZVM[OLLJVUVT`
Putin nominated his chief economic advisor Elvira Nabiullina to
the position, raising concerns over the banks independence in
its future monetary policy given her close links to the Kremlin
and undermining hopes that the Central Bank would seek more
independence.
Government involvement
The government is expected to retain its involvement in the
upstream energy sector in the medium term, given its strategic
importance to the economy. This was evidenced by the Rosneft
[HRLV]LYVM;52)7UHSPZLKPU4HYJO^OPJOZLLZ9VZULM[
take control of assets including Samotlorneftegaz, the largest
production facility in Western Siberia. Rosneft is one of the key
actors in the governments armoury of assets, majority-controlled
by the state holding company Rosneftegaz. A possible partial
privatisation of Rosneft continues to be mooted, with the most
recent reports suggesting that the government could seek to
sell a 19% stake in the company as part of its plans to speed
up the privatisation process. Privatisation has been on the
table for several years, most notably under the presidency of
Medvedev, but has seen little real movement. A renewed sell-off
JV\SKWYV]PKLHZPNUPJHU[^PUKMHSSMVY[OLMLKLYHSI\KNL[^OPJO
has been hit by a fall in tax revenues. The Economy Ministry
has indicated that privatisation of state stakes could raise
approximately RR 320 billion (US$ 10.2 billion) this year. According
to the governments mid-term privatisation strategy, the state
energy holding company should start cutting its 69.5% stake in
Rosneft this year, with a complete sale by 2016.
Future prospects for the upstream sector will remain stymied
by vested government interests, the dominance of state-owned
energy majors in exploration and extraction, and issues that
affect business operations across the board, such as corruption.
However, given the governments reliance on the revenues from
hydrocarbon reserves and the need to boost foreign investment
in newer developments to ensure that production levels do not
tail off in the future, it will at some point be forced to realise that
private and foreign capital is vital for ensuring that the sector
reaches its full operational potential. Technological know-how for
L_WSVYH[PVUH[YLTV[LHUKJVTWSL_LSKZWYVK\J[PVUJHWHJP[`
and investment capital will eventually tip the balance in favour of
sector liberalisation. O T
 he world of oil and gas has changed dramatically over also a need to retain and maximise the capability of the existing

T [OLSHZ[`LHYZ-VY[OLYZ[LPNO[`LHYZVM[OLZ
oil prices rose year-on-year, leading to both increased
investment in existing infrastructure, and an appetite to
workforce.
6PSWYPJLZHIV]L<: IISHSVUL^PSSUV[KLSP]LYZ\JJLZZ"
the industry needs to ensure that the global workforce is in a
look to new frontiers in an attempt to increase production continual cycle of learning new skills and career development.
to meet demand. In the past
10 years BP has been pushing the Simon Drysdale, BP, UK, Bridging the skills gap; why
boundaries of exploration, from are we where we are?
established geographies such as explains how investing in With the constant focus on the need
the Gulf of Mexico to the emerging
such as Angola.
current talent is helping to to bridge the apparent skills gap,
many people within the industry
The uptick in oil prices is driven
in part by the incessant increase
bridge the skills gap in the ask did you not see this coming?
Whether the industry had foreseen
in global demand for energy. global oil and gas industry. the challenge or not, the more
The International Energy Agency important question is why has a
predicts that demand for energy will grow by some 40% by skills gap and subsequent war for talent emerged?
-VZZPSM\LSZHYLL_WLJ[LK[VTHRL\WZVTLVM[OPZ (JVTIPUH[PVUVMOPZ[VYPJZWVYHKPJOPYPUNYLLJ[P]LVM
KLTHUKHUK)7ZV^U,ULYN`6\[SVVRZ\NNLZ[Z[OH[ 
VM[YHUZWVY[M\LS^PSSZ[PSSJVTLMYVTVPSPU
The future looks very bright for the oil and gas industry, but
it certainly faces challenges. Attracting the right talent, with the
appropriate skills, is a cross-sector challenge that has received
an unprecedented level of attention amongst employers and
in the media coverage over recent years. Whilst a great deal of
talk and attention has been given to the need to recruit, there is
[OL\J[\H[PUNVPSWYPJLHSHJRVMLUNHNLTLU[^P[O`V\UNLY
NLULYH[PVUZJV\WSLK^P[OHUL]LYHNLPUN^VYRMVYJLWYVSLOHZ
led to the current skills gap.
The oil and gas industry has a history of hiring and training
the workforce based on the current oil price. Traditionally, when
oil prices have fallen, workers have been made redundant as
projects are delayed and workload drops, and when oil prices
spike, the industry battles to acquire as much resource as
13
Figure 1. A drilling engineer on the Dada Gorgud rig in the Azeri Field, Azerbaijan, which drilled the AZB001 well. Image courtesy of BP p.l.c.
possible as it embarks on a talent acquisition programme. BP
is moving away from this model and looking to invest whatever
is required to ensure the right skills in the right places so that
the company will be ready to adapt to both macro and micro
economic changes.
Whilst planning and economic forecasting have a role to
WSH`PU[OLJ\YYLU[ZRPSSZNHWL_[LYUHSPU\LUJLYZHSZVL_PZ[;OL
last 15 years has seen the rise of graduates going straight to
;OL*P[`^P[OHUL]LYPUJYLHZPUNU\TILYVM:JPLUJL;LJOUVSVN`
,UNPULLYPUNHUK4H[OZ:;,4Z[\KLU[ZJOVVZPUN[VW\YZ\L
a career on a trading platform over a production platform.
;OLZLOPNOS`PU[LSSPNLU[HUKLK\JH[LKPUKP]PK\HSZOH]LZOPLK
away from the oil and gas sector in recent years, and who can
ISHTL[OLT&;OL`OH]LILLUWYVTPZLKSVUNYL^HYKPUNJHYLLYZ
HUKZHSHYPLZ[VTH[JO;OLPUK\Z[Y`OHZYLZWVUKLKWVVYS`H[
engaging and educating tomorrows generation about the critical
role oil and gas plays in the world and the fantastic career
VWWVY[\UP[PLZVUVMMLY;OLPUK\Z[Y`ULLKZ[VNL[IL[[LYH[[OPZ
build understanding of what needs to be done and encourage
sector advocacy.
Need for formal learning
It must not be forgotten that whilst bringing new recruits and
young talent into the sector is of paramount importance,
OILFIELD TECHNOLOGY
14 June 2013
the continual development of the sectors employees is of
equal importance. Huge investment is required to ensure that
LTWSV`LLZJVU[PU\HSS`UKKL]LSVWL_[YHJ[HUKIYPUN[VTHYRL[
LULYN`YLZV\YJLZPU[OLTVZ[ZHMLHUKLMJPLU[^H`
)7PU]LZ[ZV]LY<:TPSSPVULHJO`LHYPU[YHPUPUN
and development. It has developed and implemented global
HNZOPWWYVNYHTTLZZWLJPJHSS`MVY[OLKL]LSVWTLU[VM`V\UN
[HSLU[PUJS\KPUN[OL*OHSSLUNL7YVNYHTTL;OLWYVNYHTTL
THWZV\[[OLYZ[[OYLL`LHYZVMHUPUKP]PK\HSZJHYLLYHUK
allows graduates to sample three differing roles within the
organisation, enabling consistent and structured learning
[OYV\NOV\[,HJO*OHSSLUNLYNVLZ[OYV\NOHJLU[YHSS`THUHNLK
PUK\J[PVUL]LU[^OPJO\ZLZ]PY[\HS[YHPUPUN[LJOUVSVN`;OL
result has been huge cost savings for the business and more
centralised training for recent joiners. A win-win situation.
Additionally, the company has recognised that the
training of new talent needs to be extended beyond these
three initial years and has subsequently developed and
implemented the E&P eXcellence Programme for its staff.
;OLWYVNYHTTLVMMLYZHM\Y[OLYZL]LU`LHYZVMWLYZVUHS
development and aims to offer depth and increased
operational capability.
As previously mentioned, a uniform approach to learning
and development is required to ensure existing staff, from all
areas of the globe, have an ongoing and consistent career
development programme. The BP Upstream Learning Centre
in Houston is an example of this approach. The 65 000 ft2
centre, which is made up of 10 classrooms designed for over
300 students, opened in March 2010 and is viewed within
the industry as being an example of the future of training.
Last year, of the 14 900 people who were trained worldwide
by BP, nearly 6400 passed through the doors of the centre.
Technology is central to the offering with life-sized
simulators, 3D visualisation capability, dual image displays,
video capture and conferencing capability, and purpose-built
broadcast rooms to allow teachers to deliver training in the
LSK
Need for multi-company learning
By its very nature, the oil and gas industry has a history of
being collaborative. Organisations form partnerships on the
overwhelming majority of global projects and they rely upon
and utilise a great number of service companies to ensure the
global workforce remains mobile and adaptable to constant
changes in their clients needs.
The oil and gas industry does better than many others at
facilitating and encouraging learning and development across
multiple organisations, and industry bodies, such as OPITO, are
becoming increasingly important in encouraging and facilitating
multi-company training programmes. That said, more could
and should be done. Increasing the skills and capability for
the sector as a whole is without doubt a positive for the
organisations operating within it.
Is your advertising campaign ticking
all the right boxes?
Find out through our
reader survey measuring the
July 2013 issue of
FOR MORE INFORMATION PLEASE CONTACT BEN MACLEOD OR CHRIS LETHBRIDGE:
E: ben.macleod@oileldtechnology.com E: chris.lethbridge@oileldtechnology.com
T: +44 (0)1252 718999
Need for informal learning
Whilst monetary investment in employees learning and
development is critical, formal programmes alone are not a proven
recipe for success, and in some corporate cultures formal training
become a tick box exercise. Informal learning, the passing on
of knowledge to emerging talent, and fostering a collaborative
culture is of equal importance. There is a need to develop as
well as formally train employees and this can only realistically be
achieved through structured mentoring programmes.
All graduates and new joiners are assigned a mentor
and meet on a regular basis to discuss challenges that have
been faced, both from the technical side and as part of the
development of so called soft skills.
Outlook: what else can be done?
The industry as a whole has come a long way in recent
years. It has become better at formalising, standardising and
collaborating in attempts to develop current and emerging
talent. That said, improvements could certainly be made.
In order to maximise capability across the whole sector there
is a need to move towards standardised international learning and
development practices. Presently, even formal training differs by
company and by country. Change cannot happen overnight, but
standardisation should be a core area of focus for the industry
over the next 10 years. All stakeholders have a role to play, from
the international oil and gas companies such as BP, through to
the regional and international industry trade bodies and societies.
The result can only mean an increase in safety, capability and
VWLYH[PVUHSLMJPLUJ` O T
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Deepsea Atlantic, a sixth-generation semi-submersible
drilling rig designed by GVA Consultants and owned and
operated by Odfjell Drilling, is ideally suited to operate
in environmentally sensitive areas. Along with its highly
efficient design, the rig features electrical solutions with
state-of-the-art technology ensuring safe operation and
high availability.
The entire electrical system, from the generation plant
to the drive systems, has been designed and supplied by
Siemens. As Deepsea Atlantic often operates in harsh
climates, availability is key, and Siemens technology has
proven itself superbly here, braving the elements and
ensuring reliable operations delivering the Siemens
promise literally anywhere and anytime.
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Image courtesy of BP p.l.c.
LauraDrysdale,
ChangeInternationalRecruitment,
UK, explains how the growth in
demand for hydrocarbons has
fuelled a boom in the deepwater
market, which is stretching the
limits of manpower availability.
18
t looks likely that 2013 will herald a number of changes
I in offshore drilling, and in particular the deepwater
market. High levels of investment across the board,
from virtually every major contractor and operator has
resulted in the industry experiencing aggressive newbuild
strategies to keep up with demand from operators; and
rigs becoming more advanced in terms of their drilling
depth and operational capabilities.
With an increase in dual activity in water depths
never before attempted, it is not just a matter of having
 Managing the
advanced rig designs, but finding the shipyards that
have the experience, and can deliver projects on time,
whilst meeting client requirements.
A prime example of how the market is driving
demand is the Saipem Sacrabeo 9. The rig was
specifically built to drill in extreme water depths
offshore Cuba, and tap into reserves never drilled
before. While this rig has yet to strike oil, the Cuban
government is determined to continue in its quest to
successfully drill in the region.
Last year, several contractors increased their asset
portfolios through either newbuilds during the past two
years, or acquisitions, or both.
The UKs Ensco plc. is one such company that has
embraced a buy-and-build strategy wholeheartedly. The
company expanded its fleet by three new 8500 series
rigs over the last year, and acquired Pride International,
which came with two moored semisubmersibles,
four DP semis and three DP drillships. Pride also had
numerous deepwater DP drillships under construction
19
at the time of the acquisition. The end result is that Ensco
now has two deepwater moored semisubmersibles and
17 DP semis and drillships, with two more drillships to be
completed.
Transocean has also steadily increased its deepwater
fleet. Over the past four years the company has gone
from operating 12 moored rigs and 24 DP units (with
eight rigs under construction at the time) to a moored rig
fleet of 11, but an increase in its DP units of 12, taking
the total to 36. This increase came about after acquiring
two rigs from Aker Drilling and the delivery of several new
rigs. The company still has a further two drillships under
construction.
Noble Corp. also expanded its deepwater rig
fleet, acquiring Frontier Drilling, which operated the
Frontier Driller (now Noble Driller) moored semisubmersible.
The acquisition included two shallow water drillships and an
FPSO, and Frontier had three drillships under construction.
Two of these drill ships were delivered the Noble Bully I
and Noble Globetrotter I and the contractor still has five
drillships under construction, three for delivery this year
and two set for delivery in 2014.
Other organisations that have added to their portfolios
include Norways Ocean Rig, which increased its deepwater
LL[I`MV\Y\UP[ZPUHKKPUNMV\Y:HPWLTKLZPNU
KYPSSZOPWZ[VP[ZLL[VU[OLWYL]PV\Z`LHY0UHKKP[PVU
7HJPJ+YPSSPUN:(OHZHKKLK[OYLL:HPWLTKLZPNU
KYPSSZOPWZ[VP[ZLL[ZPUJLHUKOHZ[^VHKKP[PVUHS
deepwater drillships scheduled for delivery this year.
Draining the personnel reserves
However, newbuild plans are heavily reliant on operators
being able to find the staff for these rigs, and with a finite
number of experienced personnel within the market,
companies need to plan ahead for the future.
It was reported last year that there could be up to
10 000 new jobs created by the end of this year in the
North Seas subsea sector. And for a sector that is certainly
booming, this was welcome news, especially as concerns
have been raised about the number of suitably qualified
candidates for the positions.
The subsea industry is outperforming other sectors and
an increase in demand for candidates in this field is being
seen. A survey by Subsea UK, which represents more than
250 companies, suggests that 50% of companies reported
finding the staff they need has become very difficult, and
14% of operators said recruiting qualified personnel was
almost impossible.
The industry supports around 50 000 jobs and is
expected to grow by 40% in the next two years and there
is an obvious skills gap that needs to be filled. The sector
needs to continue to attract new talent in order to help
meet the growing demand.
In order to fill the perceived gap in skilled shipyard-level
maintenance crew, some organisations are looking outside
the oil and gas industry and at other trade where skills
are transferable with the transport, military and heavy
industry sectors being a breeding ground for the kind of
skilled engineering and ship building graduates who are
capable of moving sectors and making a positive impact for
their employers.
OILFIELD TECHNOLOGY
20 June 2013
A shortage of engineering graduates has created major
issues across the sector. Reducing workforce pressures
and ensuring that skilled staff are developed and retained
within the industry is therefore vital to safeguard future
prosperity in a hugely competitive market.
There are currently pinch points in a range of
highly specialised technical roles and people, who
have experience of the sector, moving around different
companies, rather than new talent being recruited. This
can have a big implication in terms of cost inflation for
companies and is not healthy for the wider economy, with
premiums paid for some roles.
A large number of the young people coming into
the sector need training, and the infrastructure and
partnerships needed to bridge the skills gap are largely
in place. However, it is likely to take a number of years to
address the shortfall of skilled workers.
Finding experienced staff may not be the only hurdle
that operators need to overcome as recent research
undertaken by Change Recruitment revealed that many
workers perceived a lack of progression opportunities as
a result of the global economy. With these frustrations
bubbling over, 75% of respondents admitted to actively
hunting for alternative employment and 44% specifically
saying they were doing so in order to take a step up the
career ladder.
Add to this the fact that almost half (48%) of oil
and gas professionals questioned stated they had not
received inflationary pay rises over the past two years,
with a fifth (20%) saying they had received nothing at all,
and it is hardly surprising that more than a quarter (26%)
of respondents felt they were not appreciated by their
organisation.
Nearly three quarters (73%) subsequently felt that
they would be paid better if they worked for a different
organisation, and over half (54%) also thought the benefits
they received as part of their package would be better if
they moved company.
The deepwater drilling market continues to be a
very candidate skills-driven market. It has bucked the
trend throughout a difficult time in the economy and has
continued to grow despite setbacks in the market, which
have stunted, and at times changed how business is done.
Candidates with industry experience are in a luxurious
position of being in high demand and sought after and in
many cases have the happy headache of multiple clients
offering opportunities within the industry. This has driven
salaries and competitive benefits packages up, and clients
are finding that they have to work hard to keep their
compensation in line with the rest of the market.
From the North Sea to the rest of the world
One thing remains the same though: employers across the
globe continue to look for North Sea experience, which can
help to open up the rest of the world in terms of jobs and
career development as it is still seen by the industry as the
most advanced area in the world to work.
As it is a mature market, a number of company assets are
ageing. This has led to a separate industry being developed
to service these assets, which in turn requires a great deal of
specialist expertise to look after the infrastructure.
 However, the North Sea employment market still has some
of its own challenges, and at present is thought to be short of
personnel with between 10 and 20 years of experience. This
could be because experienced personnel are more reluctant
to make a move to a new role during an economic dip, and
V]LY[OLWHZ[ML^`LHYZYTZOH]LHSZVILLUZLLUJ\[[PUN
back on their trainee intakes.
The sector has remained fairly resilient in the face of the
economic situation, but a number of organisations have seen
restructuring and even downsizing, resulting in a drop off of
hierarchical positions.
in terms of what newer rigs are assigned to East Africa for
drilling operations beyond the already established basins in
Mozambique.
The booming Golden Triangle areas of West Africa, Brazil
and the Gulf of Mexico have been a primary focus for many of
the worlds leading operators and their continued investment
in exploration throughout the region is shaping the things to
come both in 2013 and beyond.
Looking into the not too distant future for a snapshot,
there are currently 178 drilling rigs in construction in
South East Asia alone. If each of these rigs requires
4VYL[OHU[^VM[OZVM[OLWLVWSLX\LZ[PVULKZHPK
they believed their career would have progressed further had
the UK not been hit by recession; and two thirds said they
would be prepared to work anywhere, including emerging
markets, for the right career opportunity and remuneration.
;OLYLHYLZ[PSSZPNUPJHU[VWWVY[\UP[PLZH]HPSHISLPUIV[O
established and emerging markets for those workers willing
to take the plunge and move and a marked increase is
being seen in the number of people showing interest in
opportunities available in Africa and the Middle East. The
tougher jobs market in the UK has had a knock-on effect on
the number of younger workers showing interest in moving
overseas and for many it is not just down to money, but the
opportunities and career progression that working in another
country offers.
Elsewhere, the East coast of Africa is proving to be very
exciting, with a great deal of experimental drilling taking
place. Many larger operators are tapping up contracts in
this largely untested region, and 2013 could be a big year
Media planners and advertisers need reassurance too.
An ABC Certicate shows our gures have been
independently veried, giving you condence
in our claim.
Ask to see our ABC Certicate.
See it, believe it, trust it.
For more information visit www.abc.org.uk
or email info@abc.org.uk
500 employees, then there will be a huge number of jobs
created.
(S[LYH[PVUZ[V[OL<2ZZJHSYLNPTLOH]LYLZ\S[LKPU
fairly substantial changes to the industry. The bigger players
have taken a back seat, allowing smaller operators to enter
[OLTHYRL[^P[OZVTLVM[OLSHYNLYJVTWHUPLZZLSSPUNLSKZ
to independent companies who can be more nimble and
cost-effective in how they operate. By their very nature, the
independent companies tend to have a smaller portfolio
VMLSKZ[VJVUJLU[YH[LVUTLHUPUN[OH[[OL`HYLSPRLS`[V
TH_PTPZL[OLWV[LU[PHSVM[OLLSKZ[VHNYLH[LYL_[LU[
Looking ahead
On the whole, the future continues to look promising for the
industry. It will be interesting to see what impact renewable
energy has in terms of talent attraction. While the green
energy industry cannot compete in terms of remuneration, the
renewables route might appear prosperous to some young
engineers, and therefore could be one to watch this year. O T
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 Matt Corbin, Aker Solutions, UK, provides an overview of
the development of a subsea gas compression system that
could pave the way to easier operations in the Arctic.

24
 eveloping technology to compress natural gas The solution is to instead put the platform on the

D on the seabed and send it straight to shore -

as an alternative to installing a large offshore
platform - has been a long term goal for the offshore
industry. Now that goal is one step closer to becoming
YLHSP[`HZUHS[LZ[PUNPZ^LSS\UKLY^H`MVY[OLM\SSZJHSL
Ormen Lange subsea compression pilot, designed and
built by Aker Solutions. The technology could be the
key to unlocking the Arctics oil and gas reserves.
According to the US Geological Survey, the
Arctic holds 90 billion bbls of oil in reserves plus
47 trillion m3 of gas. But ice-infested waters combined
with reservoirs hundreds of miles from shore make
VPSHUKNHZLSKKL]LSVWTLU[ZHO\NLWO`ZPJHSHUK
technological challenge. Due to the ice and freezing
cold, oil companies will, in many cases, have to rule
out platforms on the surface of the sea.
ZLHILK;OPZTLHUZ[OH[[OLLSKJHUILVWLYH[LK
under ice, and the facility is not dependent on
VWLYH[PUNPUH]LY`KPMJ\S[LU]PYVUTLU[4VYLV]LY
subsea compression in the Arctic reduces risk
because it means no people offshore, no
OLSPJVW[LYPNO[ZHUKUVZ\WWS`]LZZLSZ
;OLYZ[THQVYZ[LW[V^HYKZSVJH[PUN
a subsea compression system on the
seabed is the Ormen Lange subsea gas
JVTWYLZZPVUWPSV[WYVQLJ[
At Nyhamna, on the west coast of Norway,
a large pit is currently playing vital part in a
25 year long technology saga. Inside the pit and
Z\ITLYNLK\UKLY^H[LYZP[Z[OL^VYSKZYZ[
full-scale subsea processing and compression
system. It is in the middle of a two year rigorous test

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1.
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pr
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25
programme to ensure it can meet the demands of one of the stream, which therefore must be controlled. The solution is to
toughest challenges ever set by the offshore industry. remove the bulk of the liquid condensate before it reaches the
This large subsea system, some 120 ft (36 m) long and compressor, raise its pressure and inject it back into the gas
weighing over 1000 t, is the pilot subsea compression plant for export line downstream of the compressor.
[OLNPHU[6YTLU3HUNLNHZLSK^OPJOZ\WWSPLZVM[OL
UKs gas requirements.
Ormen Lange, operated by Norske Shell, came onstream in
September 2007 and reached plateau production in November
 KLSP]LYPUN\W[VIPSSPVUM[3 (70 million m3/d) of gas and
32 000 bpd of condensate to the Nyhamna processing plant in
mid-Norway.
([WYLZLU[[OLYLZLY]VPYOHZZ\MJPLU[UH[\YHSWYLZZ\YL[V
drive the hydrocarbons to shore, but that pressure will steadily
decline, and later this decade gas compression will be required
[VIVVZ[WYLZZ\YLHUKTHPU[HPU[OLV^)LMVYL[OLUHJYP[PJHS
decision must be made: should gas compression be achieved
conventionally by locating compressors on the topsides of
a new offshore platform, or could gas boosting be achieved
entirely subsea by using the subsea pilot plant?
;OLILUL[ZVMVW[PUNMVYZ\IZLHJVTWYLZZPVUMVY
6YTLU3HUNLVYHU`V[OLYNHZLSKHYLU\TLYV\Z*HWP[HSHUK
operating costs of a subsea station are more economical than
those for a new deepwater compression platform. Another
key advantage is that by locating the compression system on
the seabed near to the subsea gas wells, the back pressure
exerted on the gas reservoir will be much reduced, enabling
greater production to be achieved.
Full-scale pilot
Subsea compression is not a new concept, but despite the
concept being mulled over by the industry for decades, it
was not until 2006 that Aker Solutions was awarded the
YZ[JVU[YHJ[[V[HRLKL]LSVWTLU[MVY^HYKI`KLZPNUPUNHUK
I\PSKPUN[OLYZ[M\SSZJHSLWPSV[Z`Z[LT
The Ormen Lange pilot was built throughout 2010 at the
companys Egersund offshore construction yard.
The pilot consists of eight large subsea modules, grouped
to form process, control and high voltage power systems.
Together these make up a single full-sized compression train.
The modules for the pilot contain the essential equipment
for solving the technology challenge. The entire system was
put through months of testing at Egersund, before being
disassembled and shipped to Nyhamna for reassembly in the
42 m x 28 m x 14 m deep test pit, where it is currently being put
through its paces on live Ormen Lange gas and condensate.
([[OLOLHY[VM[OLWPSV[PZ[OL.HZ)VVZ[LYJVTWYLZZPVU
TVK\SLOV\ZPUNHJVTWYLZZVYHJVTWHJ[TOPNO]LY[PJHS
centrifugal machine, which will operate at 11 000 rpm. The
compressor and its high speed electric drive motor are housed
in a single, hermetically sealed enclosure which is pressurised
with a barrier system to keep the motor and compressor
spaces separate, and also to ensure clean operating conditions
for the motor and bearings.
More than compression
As important as the compressor and its reliable operation are to
the project, there are many other new components necessary
to create the overall system. One example is for achieving
liquid separation and boosting.
A characteristic of all gas compressors is that they have a
limited tolerance to the volume of liquids in the incoming gas
OILFIELD TECHNOLOGY
26 June 2013
Separation of the condensate is achieved in a 3 m diameter
vertical separator upstream of the compressor. The condensate
PZYV\[LK[VH3PX\PK)VVZ[LYW\TW^OPJOMLLKZ[OLSPX\PKZPU[V
the high pressure export gas line for transportation to shore.
The separator also contains a system for removing sand from
[OLPUJVTPUN^LSS\PKZ[VWYL]LU[ZHUKI\PSKPUN\WPUZPKL[OL
vessel and to protect the compressor.
;OLZHUKPZW\TWLKI`[OL3PX\PK)VVZ[LYPU[V[OLNHZ
L_WVY[SPUL[VILJHYYPLK[VZOVYLI`[OLNHZV^
Power play
The Ormen Lange pilot is all electric there are no
hydraulically operated components. The full compression
station would be electrically operated and controlled, with
HWWYV_PTH[LS`4>VMWV^LYILPUN[YHUZTP[[LKMYVTZOVYL
through a subsea power cable at 132 kilovolts, which would
be stepped down by transformer to 22 kilovolts at the subsea
station.
The list of sophisticated electrical components that had
[VILKL]LSVWLKZWLJPJHSS`MVY[OL6YTLU3HUNLWPSV[PZ
long. High on that list are the variable speed drives (VSDs) for
the compressor and pump, which would be controlled from
ZOVYLI`ZPNUHSZZLU[[OYV\NO[OLIYLVW[PJZPU[OLZLHILK
power cable. As gas production rates and pressures from
the Ormen Lange reservoir change over time, the VSDs will
regulate the speeds of the drive motors by varying the supplied
voltage and current frequency, thus enabling the compressor
duty to be changed and the pump speed to be regulated to
control the liquid level in the separator.
And so to Nyhamna where all of the ingenuity and
engineering effort that has gone into the Ormen Lange pilot is
currently being tested. In February 2011, the Egersund yard
shipped to the test site a purpose-built 900 t process module,
^OPJOPZKLZPNULK[VZPT\SH[LHYHUNLVMV^JVUKP[PVUZ
including slugs, to test the pilot. The Nyhamna test loop has
JHWHJP[`[VKLSP]LY\W[VTPSSPVUZ[HUKHYKM[3
TPSSPVU:T3/d) of gas per day, 11 300 bpd (1800 Sm/d) of
JVUKLUZH[L4>VMLSLJ[YPJHSWV^LYHUKWZP
operating pressure.
;OL6YTLU3HUNLWPSV[PZ[OLYZ[HUKILZ[VWWVY[\UP[`[OL
industry has had to prove that subsea gas compression is the
future.
;OLYLPZUVKV\I[[OH[(YJ[PJNHZLSKZ^PSSILUL[MYVT
Z\IZLHNHZJVTWYLZZPVU[LJOUVSVN`)`[OL[PTL[OLYLHS(YJ[PJ
LSKZPU[OLPJLPUMLZ[LK^H[LYZHYLYLHK`MVYKL]LSVWTLU[[OL
technology will be there for platform-free production. O T
SEARCH hundreds of
international industry
events on Energy Global
www.energyglobal.com/events
 Mapping out
the arguments
uropes shale gas future is still looking
Cyril Widdershoven, TNO,
the Netherlands, shows E bleak. Ongoing discussions are not focusing
on the economic and technical aspects of
a possible shale gas revolution in EU member
how the arguments for and countries, but on the political-environmental
against the production of aspects. Perceived threats, not supported by
independent assessments, taking into account the
shale gas in the EU are specific situation of a certain shale gas project in
a country, are ruling the current debate. Instead of
mapped out, and explains trying to find a bridge between techno-economics
the political-economic and environmental issues, the current debate is
only polarising opinion. Some analysts are already
decisions that need stating that the current debate is no longer based
to be made. on the possible pros and cons of shale gas, but on
the perceived threat that shale gas could pose to
a possible green energy future, as indicated by

27
green politicians and lobby groups. The latter discussion is
irrational and counter-productive in all aspects.
Navigating the arguments
To set up a more fundamental discussion, Dutch
independent applied science and technology company TNO
has set up a so-called Argument Map. The company has,
after in-depth assessments of the pros and cons of shale
gas, devised a tool to summarise the arguments for and
against shale gas production in different EU Member States.
The main focus of this map is to bring clarity to the positions
in the shale gas debate and promote a rational discussion.
Instead of the Argument Map only being presented in the
Netherlands, the decision was taken to publish the map in
Brussels, targeting a Europe-wide audience. Without taking
any political or economic stand, the map explains, based
on a literature review and input from experts from different
backgrounds and Member States, the possible issues
surrounding shale gas exploration and production in the EU.
European and national policy makers, industry stakeholders
and lobby groups, should take the current discussion to a
much more abstract level to build up a possible co-operation
framework. This is needed to address the vast amount
of misconceptions in the public domain. The map could
be a possible instrument to lay the ground for such an
effort. Without setting up an open and rational discussion,
uncertainty, fear of the unknown and mistrust of reputable,
peer-reviewed scientific evidence, will keep on constraining
Figure 1. Argument Map: shale gas production in EU member states.
OILFIELD TECHNOLOGY
28 June 2013
the current developments. Initiatives like the Argument Map
can help to shed light on the shale gas debate. Also, TNO
will be working with the European Research Agency to
develop a European Research Programme on shale gas to
bring more scientific evidence to the table, can help to shed
light on the shale gas debate.
In the coming years, Europe will stand at the front of
a major discussion on how to adjust to the ongoing shale
gas revolution in the USA, the overall implications for the
global gas sector and its technical challenges. At the same
time, European politicians will have to adjust to the ongoing
economic crisis hitting Europe, while addressing requests
from its industry to make use of the possible low cost
energy resources available on the continent. Until now the
discussion has only been centred around environmental
issues, largely due to the infamous American movie
Gas Land, which has been showing a rather subjective view
of shale gas operations and environmental consequences.
Taking stock
Some moves already have been made by the EU to assess
its options. In recent months, several major conferences
have been held by the EU and stakeholders to address these
issues. At a recent event at the European Parliament in
Brussels, parties involved have been trying to look behind
the hype of shale gas and dispel myths surrounding the
resource. Still, analysts have been disappointed until now,
as most discussions again were full of exaggerations and
speculative positions. Anti-shale gas lobbyists have been
playing the environmental disaster position if shale gas
production would be allowed in Europe. At the same time,
pro-shale gas groups have been exaggerating the impact
of shale gas revenues on the European economy. Some
have even been stating that European shale gas could be
enough to bring about European energy independence,
and revolutionise the continents economy. As indicated
already by the Argument Map (Figure 1), the truth will lie
somewhere in the middle.
Shale gas production has the potential to bring additional
energy resources to the market. Some European countries
could be reaping the rewards, including potentially:
Germany, Poland, the UK and maybe even the Netherlands.
The total volumes available are as yet unknown, but even
the most optimistic scenarios do not show Europe to be
in the same league as the US, China, Russia, Algeria,
Saudi Arabia or Jordan. Optimism has taken over from
rational assessments by investors and operators. At the
same time, negativism is only part of the discussion currently
supported by anti-shale gas environmentalists, NIMBY
lobby groups or green politicians. The Gas Land issue is
not of any relevance to the European situation. The US shale
gas revolution, in contrast to Europe, is based on ownership
of the land, different environmental laws and investment
regulations. The unexpected vast volumes available in the
Bakken or other shale gas regions in the USA dwarf the
potential of the European players. Geological specs of the
YOUR SHALE
HAS CHARACTER
shale gas reserves in the USA are also different from the
Netherlands or UK. Threats to ground water reserves in
Europe are different from the USA or elsewhere in the world.
Still, environmental issues should not be taken lightly, but
approached in the normal way of technical and economic
analysis through methods already in place for decades due
to conventional oil and gas operations in the EU. Hence the
set-up of the Argument Map, designed to bring a rational
way of thinking to the current emotional debate.
When talking about the EU, the real discussion should
focus on the available reserves. The need for an assessment
by independent parties of the available reserves, the related
costs and possible rewards, is needed to substantiate the
future developments. Until now, most of the economics
of shale gas have been not shown to the public. At the
Brussels conference (EUP), one of the main messages
presented was that the economics of shale gas are still
unclear for European operations. At the same time, the
size of shale gas resources both in the US and the EU have
been vastly over-exaggerated, or current assessments are
based on suppositions, which are somehow not the reality.
Several analysts even have stated lately that there could
be a false bubble in the gas sector, which is liable to blow
up in the faces of the involved parties very soon. Still, the
overall discussion at present is that the green lobby was
hoping to reap the expected reward of a high (and no longer
economically viable) crude oil price, which would have seen
a move towards green technologies. The high gas prices at
Every shale tells its own story.
Through innovative high
resolution predictive models
TNO unravels this story to
improve our understanding and
optimize the number of
required wells and frac jobs;
essential for safe, responsible
and profitable shale gas
exploration and production.
For more info go to
TNO.NL/SHALEGAS
TNO.NL
the end of the 1990s and the first decade of the 21st century
certainly gave way to this approach. However, the global
economic crisis, the immense worldwide investments made
in gas production and the unexpected boon of the shale
gas revolution have resulted in plummeting gas prices.
Economically, gas is the fuel for the future. Its availability,
combined with low prices and geopolitical issues, have put
the break on the run for renewables. The costs of wind,
solar and biomass, are too high, especially when comparing
them with gas prices.
The Green Lobby also is now confronted by another
remarkable aspect. Europes race for renewables, supported
by the Energie Wende in Germany, and the multibillion Euro
projects proposed by the European Union and its member
countries, has not resulted at present in a reduction of
emissions. The 2020 goals of the EU are not going to be
reached, maybe the opposite will be the case. Renewable
energy has not had the effect that was expected.
American exceptionalism
The USA however has become the leading example of
good economic strategy implementation designed to
support industry, create vast amounts of jobs, and (albeit
unintentionally) reduce CO2 emissions. In stark contrast to
the EU, China, India and others, Washington can brag about
its emission reductions. No other country has been able
to show these results. Geopolitical economists even have
stated that the world should follow the USA. When looking
at the emissions situation, Washington is leading the pack.
Emissions can be reduced while at the same time supporting
basic economic fundamentals, increasing investments in
hydrocarbons, and creating jobs and energy independence.
The need for US investments in renewables has become a
minor issue. No economic factors or lobby groups are able to
push for new solar or renewable investment schemes in the
^H`[OH[[OL`^LYLHISLK\YPUN[OLYZ[6IHTH(KTPUPZ[YH[PVU
Going for the Golden Age of Gas, as presented last year by
the IEA in Paris, has become a reality in North America.
This success has, to the astonishment of several experts,
not resulted in a gas revolution in the EU. After decades of
supporting gas-fuelled power generation, clearly functional in
Northwest Europe due to indigenous gas production (Norway,
UK, Germany and the Netherlands), Brussels now is betting
on renewables. EU investment schemes for technology
development in CCS, renewable energy (solar, wind), have been
known for decades. However, success rates are still nothing
to brag about. CCS projects in the EU are largely on hold, the
NIMBY issue is also a major factor here; Green lobbyists
want to promote CCS, but please, somewhere else. The
lack of investment and support by the EU and the respective
governments for conventional oil and gas technology
development and production, has resulted in a lack of follow
up to meet new challenges in the future. The tendency to only
promote renewables, as shown by 2020 or the Dutch 2050
HWWYVHJOOHZUV^IHJRYLK3V^NHZWYPJLZHUKL]LYTVYL
competent technology has become the main stumbling block
for green projects in the EU. Investors and power generation
JVTWHUPLZHYLUV[PU[LYLZ[LKPUWVZZPIS`SV^WYV[THYNPUZ
OILFIELD TECHNOLOGY
30 June 2013
at the end of the 21st century, shareholders and clients need to
be supplied at present. The shale gas revolution has not only
caused Americas emissions to decrease, surprisingly it also
has decreased renewables and gas consumption in the EU.
The lack of demand for coal in the USA (and elsewhere) has
brought down the global coal market prices. European power
generation companies have been taking advantage of the latter,
^OPJOYLZ\S[LKPUHYLLTLYNLUJLVMJVHSYLKWV^LYWSHU[Z
European CO2 emission levels of course are showing tendency
to go up further than ever before. The market has taken over,
no EU emission strategy or CO2 pricing schemes will be able to
prevent the latter on the short run.
Looking to the future
This situation can be stopped, the solution is again to
promote more natural gas or shale gas usage. As the IEA,
and others, have been stating for years. The easiest, most
cost-effective way to reduce emissions is to go for gas.
Yes, gas is a hydrocarbon source of energy but it produces
much lower emissions than other hydrocarbon resources.
For Europe there is only one solution: to go for gas. Gas is
the only applicable intermediate energy resource to bridge
the conventional (high CO2) energy economy of the present
and the unconventional/renewable energy situation wanted
in future. If the EU does not take the necessary steps, the
future of the European economy (and its citizens) looks
bleak. It is possible that European emissions levels will
be reached without shale gas, but it will be at the cost of
prosperity and high unemployment rates. The current energy
dependency of Europes basic industries is too high to
gamble with renewables. In the short term (10 - 15 years),
European companies, such as BASF, Unilever or Krups,
will struggle to keep producing within the EU at current
energy rates. Global competition is high, major American
companies are already reinvesting in their home country to
reap the reward of low shale gas prices. Europes economic
future will not depend totally on shale gas in Poland or the
Netherlands, but it will be a mistake not to take advantage
of resources. Shale gas in Europe needs to be addressed
in a rational way, not based on emotions or pure political
assessments. If shale gas is technically and environmentally
producible at economically interesting price levels, the right
choice is to start production. At present, the answer is still
out there, no specifics have yet been delivered.
The need for investment in setting up research and
independent assessments of the available shale gas
resources and their potential effects is clear; to prevent such
investment would be foolish. John F. Kennedys dream to
put a man on the moon also was confronted by opponents.
Some even thought that the Apollo rocket would destroy
the moon. It seems that current debates have the same
irrational quality. Fracking, the devil in disguise according
to environmentalists and opponents, has been used for
decades, also in Europe. Perhaps it is time to let Brussels
play the part of Aladdin and let the Genie out of the bottle?
Technical economic research is needed; the only Genie then
to be found is perhaps a new gas revolution, Europes shale
gas adventure. O T
 Doug Crice, WirelessSeismic,
USA, examines the growing
range of cableless seismic
systems available to
operators, and compares
these with traditional
cable-based systems.
s a general rule, geophysicists are

A pretty creative - when they see a

problem or envision a better way
to do things, they envision a solution. If
the problem is generic to the geophysical
industry, they might even develop the
idea with the support of their employer
or otherwise. Generally the idea is way
ahead of the technology required to make
it practical, or the industry is slow to adopt
a method, and it is some time before it
shows up in practice. The Vibroseis is
HUL_HTWSLVM[OPZ!YZ[L_WLYPTLU[ZI`
Conoco, years in development, and widely
adopted perhaps 20 years later. 3D seismic
took even longer because a lot of things
had to happen to make it practical: the
recording systems had to be developed to
collect data from thousands of geophone
groups, seismic contractors had to acquire
the systems and methods to collect the
data, software was needed to process the
information on more powerful computers
(and later individual workstations), and
interpreters had to learn how to understand
these new images.

Figure 1. Juggie deploying a cable-based seismic system. The

difficulties involved in deployment are obvious, as are the safety risks. 31

Figure 2. Geospace GSR autonomous
recording system shown with battery and
geophone. The GSR and second-generation
GSX is the market leader in autonomous nodes.
Figure 3. Wireless Seismic RTSystem2 real time acquisition system
at work in rough terrain in Columbia.
OILFIELD TECHNOLOGY
32 June 2013
These innovations and countless others have resulted in continuous
improvements in the way seismic data is collected and in the quality of the
information about where the elusive hydrocarbons reside.
Considering cables
Cables used in land seismic might be classed as an annoyance rather than an
obstruction. In conventional 2D surveys, the maximum number of channels was
limited to approximately 240, because the cables required two conductors for every
geophone. The cables were broken up into segments short enough that they could
be carried by one person. Surveys with more active channels were limited to an
occasional oil company funded experiment, which was really multiple 2D surveys
conducted in parallel.
The advent of 3D surveys exacerbated the problems multifold. Before 3D
surveys could be practical, what are called distributed systems were created to
facilitate data collection with exponentially greater numbers of channels. Common
distributed systems deployed small boxes spread out in the survey area. Each
digitised the analogue signal from four, six or eight geophone groups. The data was
[OLU[YHUZTP[[LKPUKPNP[HSMVYTKV^UHJVH_PHSVYIYLVW[PJJHISL[V[OLJLU[YHS
recording system, which at that point was more like a computer than an acquisition
system.
0U[OLTVKLYU+Z\Y]L`L]LU^P[OIYLVW[PJZP[PZJVTTVU[V\ZLTPSLZ
of cables on an average sized survey. Consider the problems with cables:
They require significant manual effort to deploy and retrieve
ZLL-PN\YL
Animals, all kinds, chew on them, so the first part of each
day is spent on cable maintenance.
Crossing highways and rivers is troublesome.
Permission to lay cables may not be available in patches of
the survey.
Cables are difficult to use in urban environments with streets
and buildings.
Permission is difficult or impossible in environmentally
sensitive areas.
On the other hand, cable-based systems offer substantial
ILUL[Z;OLKH[HJVTLZPU[V[OLJLU[YHSYLJVYKPUNZ`Z[LT
immediately, so the client representative can evaluate the
quality of the seismic information. Cultural and wind noise can
be monitored to see if the survey can continue. In desert areas
without roads and few animals, it is possible to lay out huge
ZWYLHKZVMNLVWOVULZ^P[OJOHUULSZVYTVYLHUK[V
use multiple vibrator groups to achieve high productivity. But, for
most surveys, eliminating cables is a desirable goal. Doing so
has been a challenge.
For a long time, geophysicists have wanted to eliminate
cables. As discussed earlier, the ideas came about well before
the technology was available to provide a practical solution to
the problem.
The dawn of cable-free systems
Early attempts at cable-free seismic systems met with
marginal success. Autonomous memory-based systems using
magnetic tape storage were limited by cost, complexity, and
environmental problems. Early radio-based systems were limited
by the available bandwidth. Eventually, technology advanced,
and costs came down, to allow development of practical
HJX\PZP[PVUZ`Z[LTZ^P[OV\[JHISLZ;OLYZ[YLHSS`WYHJ[PJHS
Z`Z[LT^HZ[OL9:9PU[YVK\JLKPU I`0UW\[6\[W\[
UV^065.LVWO`ZPJHS;OL9:9Z`Z[LT^HZHJOHUULS
IV_[OH[YLJVYKLKKH[HVUHOHYKKPZRPU[OLLSK3PTP[LK8*
information was transmitted to a central recorder by VHF radio.
The data was harvested by physically visiting the unit with
Some conditions leave no
room for choice

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a second device. Some RSR units remain in use today, but
they are approaching obsolescence because of the visitation
requirement and the lack of replacement parts.
About the time the RSR was introduced,
Vibration Technology, aka Vibtech, was founded to build a
system to collect data wirelessly in real time. This system
utilised WiFi technology using multiple towers, each able
to communicate with clusters of local acquisition units. By
JVUULJ[PUNHU\TILYVM[V^LYZ^P[OHIYLVW[PJJHISLP[^HZ
possible to create a wireless seismic system with enough
stations to compete with a cable-based system.
In 2005, the cableless revolution really took off, with
ION Geophysicals announcement of FireFly. This event
JVPUJPKLK^P[OH\YY`VMKL]LSVWTLU[VM^PYLSLZZZLPZTPJ
acquisition systems. As is common with pioneering designs,
there were initial problems.
In 2007, Geospace introduced the GSR, followed later by
-HPYLSK5VKHSP:LPZ>PYLSLZZ:LPZTPJHUK(\[V:LPZ:LYJLS
purchased Vibtech and integrated it with their cable systems.
Catagories of cableless systems
The cableless systems can be grouped into different types:
Autonomous blind nodes are deployed in the field where
they collect the data and put it in an internal memory in the
unit. They must be picked up and brought to the central
computer to retrieve data. The data from the individual units
is sorted and combined with the data from the other units to
construct the seismic record. Representative units are made
by Geospace, FairfieldNodal, and AutoSeis. Instrument
quality control is performed by either passing by the unit
or connecting a separate device that checks the operation
and battery charge level. The units can operate continuously
in the field for a month or so, although the data cannot be
examined until they are picked up.
Autonomous nearsighted nodes operate in a similar
fashion, but the data can be harvested wirelessly by
visiting the unit in the field and transferring the data to a
second device, usually wirelessly from a distance of many
metres. Representative models are the Sercel Unite and the
Inova Hawk. If the data is collected daily, the danger of lost
data due to equipment failure or theft is minor.
7HY[PHS8*UVKLZ\ZL=/-YHKPVVYHTLZOUL[^VYR[V
JVSSLJ[8*Z[H[\ZHUKTVUP[VYUVPZL0UV]H-PYLMS`HUK
iSeis Sigma fit in this group.
Real time nodes send the complete seismic data to the
doghouse continuously. They are essentially equivalent to
a cable-based system. Examples are the Wireless Seismic
RT System 2 and the Sercel Unite system (when used with
fibre connected multiple towers in real time mode).
Early attempts at
cable-free seismic
systems met with
marginal success.
data (a common-receiver gather) does not lend itself to simple
L_HTPUH[PVU\U[PS[OLSLZMYVTTHU`\UP[ZHYLTLYNLKPU[V
a suitable record (a common source gather). Consequently,
the initial tests to determine the sweep or shot parameters
HYLJ\TILYZVTL8\HU[PM`PUN[OLLMMLJ[VM^PUKUVPZLPZUV[
supported by these units, and estimates must be made.
Nonetheless, the autonomous blind systems are the leading
seller. Surprisingly, despite the expectation of fewer workers,
LSKWYVJLK\YLZOH]LL]VS]LK[V^OLYL[OLJYL^ZPaLPZQ\Z[
about the same as on a cable crew, but the survey proceeds two
or three times as fast.
Sercel has done a good job on integrating their cableless
Unite system with their cable systems. The units can be
mixed on a survey to accommodate deployment problems
such as a survey with a town located as part of the area of
interest. The central recording system accepts data from the
mobile harvesters and integrates it nicely with the cable data.
Sometimes a single tower is put up to collect data from a
local group of stations, but the logistics of distributing towers
around the complete site are daunting enough that the preferred
approach has been to use mobile harvesting.
Real time wireless systems such as the Wireless Seismic
RT System 2 potentially eliminate all the perceived problems
with blind systems at the expense of a little extra infrastructure,
in the form of radio backhaul systems. The system has worked
extremely well on some surveys because the initial geophysical
tests are completed quickly, allowing the survey to proceed.
Deployment is easy because the system can leap over roads,
tracks, rivers and non-permit areas. If an individual fails, the
YHKPVZJHUSLHWV]LY[VRLLW[OLZ`Z[LTVWLYH[PUNLMJPLU[S`
Wireless future?
The industry is now seeing a transition in technology without a
predetermined outcome. What will be the product mix between
JHISLIHZLKHUKJHISLSLZZZ`Z[LTZ`LHYZMYVTUV^&
Cable-free systems started to gain acceptance with purchases
PUTVKLZ[U\TILYZPU ;OLPYTHYRL[ZOHYLNYL^HZ\ZLYZ
Industry reaction V]LYJHTLLHYS`ZRLW[PJPZTOLSWLKHSVUNI`[OL% KH[H
So, how has the industry greeted the advent of this new type YLJV]LY`Z[H[PZ[PJZ)`JHISLSLZZZ`Z[LTZYLWYLZLU[LK
of seismic system? It is safe to say that initial scepticism is
evolving to acceptance, if not widespread enthusiasm. The
blind autonomous nodes offer the easiest deployment they
JHUQ\Z[ILWYVNYHTTLKWSHU[LKI`[OLHNZHUK[LZ[LK[V
check their performance. To extract the data, users have to wait
until it is time to roll the units, carry them back to the central
computer, extract the data in a special rack into a computer,
charge the batteries, and take them out to their next location.
Deployment is easy, though it requires a little more skill on the
part of the operator than does a cable system because of the
8*[LZ[Z+H[HYL[YPL]HS[HRLZZVTLLMMVY[HUK[OLMVYTVM[OL
OILFIELD TECHNOLOGY
34 June 2013
HWWYV_PTH[LS`VM[OL^VYSK^PKLZHSLZVMSHUKZLPZTPJ
systems. Now, there are reports of contractors retiring perfectly
good cable-based systems because those surveys are not as
competitive in the geophysical contracting market. According
[VYLJLU[UHUJPHSYLWVY[Z+H^ZVU.LVWO`ZPJHSOHZYLWSHJLK
some RSR and ARAM crews with autonomous nodes and
V\[[[LKHUL^JYL^^P[OH>PYLSLZZ:LPZTPJ9;:`Z[LT
Global Geophysical has replaced all their cable-based
acquisition crews with nodal systems. On the other hand, the
JOHUULSJYL^ZVWLYH[PUNPU5VY[O(MYPJHHYLZ[PSS\ZPUN
cable-based systems where the surveys are huge. O T
 or years, many in the drilling industry
Tyler Cobb,
Baker Hughes, F have claimed that drill bits are a
commodity. It appears that many drill
bit suppliers these days are offering bits
USA, reiterates that have the same number of blades and
cutter sizes, some form of leached cutters,
the importance design similarity and even their respective
marketing propositions begin to blur
of selecting the together. It is only natural to assume they
correct drill must all be fairly equal.
The truth is that not all bits perform the
bit from the same and selecting the right one can have
a dramatic impact on drilling performance
perspective of and overall well and drilling campaign
operators and costs. Much like a set of golf clubs, meal
choice, or new pair of boots, it may make
contractors. sense to choose based on lowest price to

35

Figure 1. Utility patents awarded per year by technology class. *Batteries includes thermoelectric
and photoelectric i.e. solar panels. Source: USPTO.gov.
spare the immediate budget pains, but the consequences of this
choice could leave long term regrets.
Similarly, despite the industrys best intentions to reduce
vendor costs, selecting the cheapest bit up front in many
applications may end up costing the operator more than they
bargained for. Understanding where the differences are in drill
bits and becoming savvy in what makes those differences
perform, is where operators stand to gain much.
The keys to identifying real value in the drill bit world can be
found in the categories of technology, reliability, quality and
service assurance.
Technology
Smoke and mirrors vs. game changer
For those in the know, drill bit technology can be considered
advanced. This is especially true when comparing drill bit-related
patent activity to other high-technology classes such as
aeronautics/astronautics and ships as shown in Figure 1.
Similar to any technological industry, there will be those who
make use of game-changing technology to add real value and
those who employ smoke and mirror gimmicks, which add little
documented performance to the product.
Finding a game-changer amongst all the feature noise in
the marketplace does not mean it necessarily has to look
dramatically different in order to deliver big returns on the
additional micro-investment toward bit price.
Vital clues to potential game-changing technology worth
[OLL_[YHKVSSHYJHUPUJS\KL!]LYPHISLSHIKH[HJVYYLSH[LKLSK
performance, industry papers and patents. A drill bit company
who can provide supporting materials for all four of these topics
very likely is offering a feature that is more than smoke and
mirrors.
Not only does the technology need to stand up as an individual
performer in a controlled lab environment, but this measured lab
WLYMVYTHUJLZOV\SKHSZVJVYYLSH[L[VK`UHTPJLSK[YPHSZ
Furthermore, multiple industry papers, especially ones
co-authored by operators, are some of the best signs in the
OILFIELD TECHNOLOGY
36 June 2013
oil and gas industry that a technology is
worthy of consideration. Finally, a patented
product affords greater assurance that it is
differentiable from competitors products.
Where is the value?
The best way to review the impact of
innovation is to group the top innovators
together versus all others, and then review
a sample application data set. Figure 2
shows how the 318 utility patents that
were awarded in 2011 are split between
the top two organisations and the
other 39 contributing organisations and
UVUHMSPH[LKPUKP]PK\HSS`V^ULKWH[LU[Z
Consider a snapshot performance
comparison from the Williston Basin, USA,
with Figure 3 representing the performance
of the top two innovating companies
and Figure 4 representing all others. The
results demonstrate a difference of 22%
in rates of penetration (ROP), and 13% in
distance drilled.
The bottom line is the enduring top performers in the industry
are those who deliver the highest amount of new, quality
technology in the form of novel intellectual property to the drill
bit industry.
Reliability
How do we measure?
Every operator knows one of the most important metrics in
the drilling industry is reliability. And yet many believe the only
important metric for drill bits is ROP.
Times are changing, and it is time drill bits are held to the same
standards as other downhole drilling tools. How can reliability be
measured for drill bits? For tricone bits, many turn to the practice
of measuring the statistical reliability of the bearings and seals in
terms of thousands of revolutions (Krevs).
With regard to polycrystalline diamond compact (PDC)
bits, which lack any moving parts to constructively measure
traditional reliability, it boils down to the concept of performance
consistency. A drill bit manufacturer who consistently delivers high
levels of PDC performance demonstrates that the spread between
upper quartile and lower quartile results is relatively small.
This consistency offers gains in terms of authorisation for
expenditure planning and wellbore delivery timetables.
Where is the value?
Imagine a bit drilling an 8000 ft section that reached total depth
at an ROP of 200 ft/hr. Now compare that to the same bit drilling
an identical successive well, but only at an ROP of 120 ft/hr. This
comes to a difference of more than 26 hrs for interval completion.
Beyond the immediate expense of 26 additional hrs of rig time,
the resultant extended timetable can cause innumerable pains
and headaches for successive service planning.
With service companies all striving to increase their asset
\[PSPZH[PVU[OPZZPNUPJHU[KLSH`JV\SK]LY`^LSSTLHU[OL[VVSZVY
crews that were originally planned for have now been on standby
at additional cost, or worse, are no longer available, leaving the
OILFIELD TECHNOLOGY
June 2013 37

Figure 2. Percentage splits for utility patents awarded in drill bits (earth boring) in
2011. *Individual, nonafliated patents.**Others representing 39 organisations.
Source: USPTO.gov.
Figure 3. Top two innovators performance in Williston Basin 8.75 in. PDC depth in
6000 to 12000 ft. Source: Baker Hughes WebBITS data.
operator/contractor scrambling to line up second-best options.
This delay could mean higher costs, longer lead times and
additional logistical consequences.
The wiser, long term bit solution may in fact lie in using the
manufacturer that can deliver drill bits that perform in a highly
consistent manner, and this can only be determined through
diligent measurement and analysis.
Quality
Quality for drill bits can be segmented into two sources: original
quality and sustainable quality. Original quality stems from
three primary factors including quality of design, materials and
manufacturing processes. The sustainable quality trait refers to
the repair process.
At a fundamental level, drill bits may be designed using similar
methods, made from comparable materials, manufactured in a
OILFIELD TECHNOLOGY
38 June 2013
related process and repaired likewise, but once the
details are exposed, the differences are exponential.
Original quality
It is no secret that drill bit designers around the world
use sophisticated computer-aided design software to
create their design models. The quality comes into play
in the form of the proprietary modelling software each
company custom builds for running simulations prior to
manufacturing.
Additionally, most bit vendors will hesitate to
describe their particular recipes for drill bit success,
but rest assured some employ extensive research
and development resources dedicated to delivering
consistent innovations in advanced materials to gain an
edge over the competition.
Beyond the design work and material sciences, each
drill bit is only as good as their manufacturers equipment
and skilled workforce responsible for machining and
assembling. Most manufacturers are happy to host a
tour of their facilities, and this is highly recommended
as it gives insights into the rigor of their manufacturing,
tolerances upheld throughout the process, and testing
methods and capabilities.
Some great questions to ask on the plant tour are:
What is the extent of manufacturing traceability - if
there is an identified failure, how can it be traced back
to the particular component of concern?
How does their quality department function?
What sort of testing is undergone before releasing
radical new designs to the field?
Sustainable quality
So, the bit manufacturer has impressive simulation
software, some of the highest quality materials and an
impeccable manufacturing facility, but what happens
[V[OLIP[IL[^LLU^OLUP[YHU[OLYZ[[PTLHUKP[Z
following run(s)?
With the ever-increasing presence of the rental
market for drill bits, the repair process has never been
more important. Even the slightest variances in the
cutter placement in the repaired bit can dramatically
change the drilling characteristics or performance
consistency of the drill bit.
While repair centres may not always be open to
public tours, it certainly would be within reason to request the
occasional analysis of consecutive runs for a particular drill bit to
ensure it is delivering the consistency of performance one should
expect from a high quality repair process.
Where is the value?
Much like the difference in car manufacturers, drill bit
manufacturers all operate under different levels of quality
from the materials they use, the manufacturing processes
they employ, the tolerances they uphold, and the consistency
of their repair centres.
The value here ties back to the reliability of the bit and
the consistency of performance, which was previously
discussed.
Also, much like the automobile industry, it is at least
in part the consumers responsibility to conduct their
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Figure 4. Other innovators performance in Williston Basin 8.75 in. PDC depth in 6000 to
12000 ft. Source: Baker Hughes WebBITS data.
own background research and comparisons to determine
whether the variances in quality are fairly represented by the
differences in pricing.
Service assurance
What service?
The operator purchases a bit, the vendor makes sure it has
[OLYPNO[UVaaSLZ[VWYV]PKL[OLVW[PT\TV^YH[LZHUK
drilling performance, and then perhaps picks the bit up
afterwards. What more to service is there?
For some operators, this may seem a perfectly reasonable
argument. To others, they realise the impact that a heavily
experienced and resourced bit supplier can have on long term
drilling performance.
These bit manufacturing majors are not only employing
some of the most experienced drill bit application engineers,
but also have rigorous training and competency programmes
to provide unparalleled service assurance when it comes to
bit recommendations and drilling improvement support.
Beyond the human capital, many of the biggest drill bit
companies maintain remarkable records of wells drilled
around the world. They are able to leverage this drilling
data to identify opportunities for improvement and offer
HWWYVWYPH[LHUKZWLJPJKYPSSPUNYLJVTTLUKH[PVUZ;OPZPZ
especially true when they are provided with foot and
time-based drilling data and formation evaluation information
where they are able to identify the exact rock type the bit is
having trouble in and make improvements in the design to
maximise performance and reliability.
Where is the value?
The real value of service assurance, which sets any particular
bit supplier apart from another is the means by which that
OILFIELD TECHNOLOGY
40 June 2013
service company is able to provide
continuous improvement beyond what
may be possible with other drilling tools.
Several of the service companies have
an iterative application/design process
operators are invited to or can request to
participate in.
Since drill bits have a relatively short
design and manufacturing cycle time
(compared to some downhole tools), it
is certainly possible to conduct several
design iterations over the course of a
KYPSSPUNJHTWHPNUHUKHJOPL]LZPNUPJHU[
improvements in consecutive wells with
higher quality and lower total cost per
foot.
Competition certainly is the lifeblood
that drives improvements, but creating
long term, performance-based
relationships with a bit supplier can be
extremely rewarding to an operators
drilling campaign.
Conclusion
For drill bits, there is a large quantity of
service companies all reaching out to pedal their products.
Some even make drill bits that look very similar to other
more mainstream brands and occasionally even deliver
comparable ROP. This can create a false impression that
drill bits are all the same and have become a commodity
product.
Despite the occasional exceptions depending on the
application challenges, the overriding evidence shows that for
drill bits, the differences are deeper than the naked eye can
see and include differentiating factors in technology, reliability,
quality and service assurance.
The sheer number of patents being pursued and awarded
for drill bit technologies is evidence of the innovations being
introduced to the industry.
Like many other tools in the drilling environment, a
critical metric of value delivery for drill bits is reliability,
or performance consistency. High reliability can reduce
[V[HSJVZ[ZHUKKLJYLHZLSVNPZ[PJHSPULMJPLUJPLZMVYKYPSSPUN
campaigns.
Quality in design, materials, manufacturing, and repair
should always be a consideration when making purchases or
rental agreements that can affect the success rate of an entire
operation on such a grand scale.
Finally, operators should expect a level of service
assurance from their drill bit vendor partners. Leveraging
long term relationships with service companies can provide
performance-enhancing design iterations and valuable
application support for reducing total well-delivery costs.
For operators and contractors alike, it is imperative to
always be wary of the effects of drilling service selection
purely on cost or convenience as the total cost of that
simple decision may far exceed what was invoiced. Do not
be deceived by appearances, because not all drill bits are
made equally. O T
Todd Bielawa and Jack Castle, Century Products, Inc., USA, outline some
recent developments in drill bit technology that are helping operators
continue to get the job done in ever-harsher conditions.
rowth in the oil and gas industry has led to the
G development of new technologies and techniques as
it pertains to the way in which wells are being drilled
and tools are being designed in order to get the job done.
As more attention has been placed on the PDC drilling
arena, many bit manufacturers have placed less emphasis
on the large magnum bit technology. Whether it is for oil
and gas, salt domes, storage or HDD applications, large
hole openers and tri-cone bits remain integral components
in the drilling arena worldwide.
In todays competitive environment there is a need for
ever changing, creative R&D offered with state of the art
designs, especially in the magnum bit size range. The use
of larger carbide inserts and shapes has been expanded by
design feature advances within the manufacturing process,
such as: the latest technology hard facing materials and
applications, vacuum sealed bearing technology and the
continued development of tighter tolerances and synthetic
lubricants.
As the wells drilled get more complicated, there is a
growing need for durable, low torque tools.
Tungsten carbide inserts
The magnum bit arena has been dominated by milled tooth
designs. However, technology and process improvements
have led to an expanded availability of various
41
 application techniques to keep the highest concentration
of tungsten material at the cutting surface without heat
degradation, is used. The dominant problem in many MT
applications is the ability to maintain gauge. Centurys bit
design incorporates three rows of active tungsten carbide
gauge cutting inserts. These back up the hard facing
Figure 1. Tungsten carbide inserts. thereby extending the bit life and improving the overall
penetration rate.

Sealed bearing vs. open bearing

In the magnum bit arena, non-sealed bearing (open
bearing) bits are often utilised for pennies of savings
on the initial bit price. However, sealed bearings offer
significant performance advantages over open bearing
products. The key feature of sealed bearings is the
significant prevention of drilling fluids and abrasive
formation cuttings from entering the bearing cavity. This is
achieved by using elastomer O-ring seals, metal-to-metal
seals, or highly engineered synthetic seals to prevent
contaminated slurry from entering the bearings. In
addition, the most technically advanced sealing systems
Figure 2. 30 in. milled tooth are also vacuum-sealed, lubricated and compensated.
design.
This is achieved by pulling a vacuum on the bearing cavity
before greasing. By applying this vacuum, it ensures no air
tungsten carbide insert (TCI) pockets exist once the grease has been pumped in.
options to better serve the Non-sealed bearings are exactly what the name infers.
industry. When discussing Here the open bearing is susceptible to all the drilling
;*0[LJOUVSVN`P[PZKPMJ\S[ fluids and soil matter in the hole without any lubrication
not to notice the larger available. Imagine any bearing being open and exposed
more robust inserts that to the extreme downhole conditions without protection.
adorn todays magnum Open bearing bits do not last long and are not capable of
hole openers and bits. handling todays drilling performance expectations.
Kennametal produces one Considering their advantages over earlier open seal
of the largest carbide inserts bearings in terms of quality, dependability and
for Century Products. At performance, it is easy to see why sealed bearing designs
1 1/8 in. diameter, this insert are preferred when these characteristics are important.
clearly dwarfs yesterdays Century utilises seals made from HSN, which is the best
technology. available material for compression set and chemical resistance
With the larger range to the extreme downhole conditions. The largest cross section
Figure 3. 24.75 in. Century hole
of inserts, there is a seal in the industry is utilised. This is a case where bigger is
opener.
new need for applying better. The tolerances offered, which are tighter than industry
better grade selections. standards, give reduced axial play, which enhances seal
The combination of improved grades and geometry has life, and improves bearing performance. The close tolerance
established new performance standards that eliminate machine-matched components, crowned roller main bearings
many failure methods of the past. HUKZPS]LYWSH[LKVH[PUN[OY\Z[ILHYPUNZJVTIPULMVYHILHYPUN
By utilising the new design and grades available in system that reduces friction and dissipates heat under the
the larger carbide inserts, it was possible to decrease high rotary loads encountered in the magnum bit lines.
the amount of carbides per cone while still offering the
ability to load the insert with the required weight to fail the Additional concerns for improving performance
formations. The new design options allow them to achieve and specific design features
higher penetration rates without the traditional insert mode Selecting the right bit for the application or the right
failures. Whether the requirement is for the crushing action company to trust for help with that selection is imperative
provided by conical inserts or the aggressive scraping to the overall success of a drilling operation.
action provided by chisel shapes, the right combination As the industry continues to explore deeper, more
can be offered to get the job done. sophisticated methods of well designs, there is a need
for the advancement of drill bit resources to accomplish
Latest technology in hard facing for milled tooth ever-greater feats. From larger more demanding surface
cones applications to highly deviated well designs, there needs
In the magnum bit range, milled tooth bits are still the to be the proper product for every application. The biggest
dominant IADC range called for. A proprietary material factors affecting performance are: durability, stability,
that has both spherical and cast carbides and the latest in performance and proper bit selection.

OILFIELD TECHNOLOGY
42 June 2013
9:25AM
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=N9GD86G7DC"G>8=:CK>GDCB:CI

5:25PM
:MEADG>C<I=:I:GG6>CL>I=6
8GDHH"8DJCIGN7>@:G>9:

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XVgZZg#Ldg`^c\l^i]V\adWVaaZVYZg^ci]ZZcZg\n^cYjhignVYkVcXZhndjg
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9G:6B7><Villl#6gVbXd#?dWh$DI
Case study
36 in. magnum bit required in South America
Due to safety and hole stability concerns, a 36 in. magnum
bit was selected to drill the 65 m surface hole in a single
pass. The customer had been using traditional 1-1-1 IADC
code bits but decided to utilise the magnum 36 in. bit. Due
to the improved gauge and hydraulic configuration the
magnum bit drilled the 65 m surface hole in less than 35 hrs,
where in previous wells it took up to 175 hrs due to deviation
control issues. The ROP on the magnum bit was 1.87 m/hr
versus 0.66 m/hr on the offset. One of the reasons for the
improved performance is the 6-point stabilisation feature.
While deviation was the concern with this application,
the magnum line comes standard with the most durable
gauge protection and the latest in hard facing materials
offered. This allows the magnum series to perform well in
the abrasive environments encountered in the Middle East
and the sealed bearing technology offered will allow for the
longer sections encountered in the North Sea as well. The bit
graded out a 1/1/No/A/E/I/NO/TD and will be more
cost-effective on the second and third runs in this field.
Technical considerations
Hydraulics: a good general rule for flow is 30 GPM x
hole size = minimum; 50 gpm x hole size = maximum.
Example: 30 x 30 in. = 900 minimum GPM. 50 x 30 in. =
1500 maximum GPM.
Specific energy vs. torque: calculation for specific
energy is as follows:
The *()&2.is the most advanced and
Where:
SE = Specific energy.
W = Weight on bit.
N = Rotary speed.
d = Diameter of bit.
PR = Penetration rate.
This calculation can be used to further examine the
relationship of bit selection and proper design application to
help ensure that the torque output necessary to fail the rock
will not exceed the drill string limitations.
Example: a hole opener using 8 12 in. cutters will
require more energy to fail the rock than a Century 5 cutter
design. Add in the larger bearing and slower rotational cone
speed and maximum performance can be achieved with lower
torque for longer downhole drilling time.
Summary
Drilling wells for the oil and gas industry is not going to
change in the future. What will change is the development
of new technologies and techniques in the way the wells are
being drilled. In order to be successful, companies need to
stay ahead of the game. O T
.%
%1K

easy-to-operate rig in the world. The safe, efficient 20
: 4 % 

operation keeps your PDQFUHZout of Danger J
201.
Zones! 2QO\WHQORDGVfor the rig, power packs,
Drillers Cabin and Pipe Handler makes for IDVW
PRELOLW\, fast rig up and fast rig down while leaving a
small foot print.
The *()&2.has a hook load of 500,000 lbs.
(226 Tonnes). The Top Head Drive, 5DFN 3LQLRQ
rig also features a Slip Spindle, prolonging the life of
the pipe threads. The *()&2.is equipped with
a Self-Erecting Drillers Control Cabin, Hydraulic
Wrenches for Make Up & Break Out, Drillers Cabin
operated Pipe Handling System, 27 1/2 in. (698.5 mm)
Master Bushing and Accommodates Range III Drill
Pipe as well as Drill Collars & Casing to 20 in.
(508 mm).

 }

+~|
 

*()&2,1&an Astec Industries Company

2215 SOUTH VAN BUREN ENID, OKLAHOMA, USA 73703 PHONE 580.234.4141 domsales@gefco.com intsales@gefco.com www.gefco.com

ringing together advanced knowledge and
B understanding of PDC bit design with the latest
manufacturing technology, the Katana series of steel
PDC bits embodies the latest in cutting structure design,
J\[[LY[LJOUVSVN`HUKO`KYH\SPJV^VW[PTPZH[PVU
Katana bits are unlike other PDC bits, with smaller sizes
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VUS`PU[OLLSKI\[HSZV]PZ\HSS`PU[OL[HPSNH[L[LZ[;OL
ZOHURSLZZKLZPNUTHKLWVZZPISLI`HIP[IYLHRLYZ`Z[LT
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J\[[LYWVJRL[KLZPNUMVYIL[[LYJVVSPUNHUKJSLHUPUNHYV\UK
LHJOJ\[[LY
Katana bits are available with abrasion-resistant
=\SJHU7+*J\[[LYZ>P[OHZTHSSLYZPaLKPHTVUKNYHPU
Cary Maurstad, VarelInternational,
USA, takes a look at some of
the latest advances in drill bit
technology that are helping oil
producers drill faster and further.
and enhanced thermal stability, these cutters resist abrasive
wear while maintaining toughness to deliver longer cutter
SPMLHUKMHZ[WLUL[YH[PVUYH[LZ
Katana bit cutting structures are designed utilising the
:76;+5TVKLSSPUN[LJOUVSVN`^OPJOHSSV^Z[OLKLZPNU[V
ILVW[PTPZLKMVY[OLZWLJPJYVJR[VILKYPSSLK)/([VIL
\ZLKHUK[OLVWLYH[PUNWHYHTL[LYZ[VILY\U
One BHA performance
In addition to the Katana bit series, a new line of steel body
IP[Z[OH[PZKLSP]LYPUN6UL)/(WLYMVYTHUJLPU<:ZOHSL
^LSSZ^HZPU[YVK\JLKSHZ[`LHY
-VYVWLYH[VYZPU[OL+LU]LY1\SLZI\YN)HZPU
+1)HZPUVM5VY[OLHZ[LYU*VSVYHKV^OLYL[OL
HWWSPJH[PVUJHSSZMVYSVUNSH[LYHSZ[VILKYPSSLK[V[OL
target shale formation through variable lithology, bits
[OH[LZ[HISPZOLK[OLILUJOTHYRWLYMVYTHUJLPU[OL
45
LSKOHKHSYLHK`ILLUWYVK\JLK!H=HYLSKLZPNUOHKZL[[OL
WHJLH[TOYM[OY^OPSLKYPSSPUNTM[H
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HWWYV_PTH[LS`TM[WLYOY
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PTWYV]LTLU[ZZLLRPUNHIP[JHWHISLVMKYPSSPUNIV[O]LY[PJHSHUK
curve sections of these shale wells on a single bottom hole assembly
MVY6UL)/(WLYMVYTHUJL
;OL=HYLSZ[LLSIVK`IP[ZSLUK[OLTZLS]LZKPYLJ[S`[V[OL6UL
)/(HWWSPJH[PVU+\L[V[OLK\J[PSLUH[\YLVMZ[LLS[OLZLIP[ZJHUIL
THU\MHJ[\YLK^P[OT\JO[HSSLY[OPUULYISHKLZ;OPZVULJOHYHJ[LYPZ[PJ
WYV]PKLZ[OLHK]HU[HNLVMHT\JOSHYNLYQ\URZSV[HYLHHUKVWLUMHJL
]VS\TL^OPJONYLH[S`YLK\JLZ[OLJOHUJLVMIP[IHSSPUN
;OLLYVZPVUYLZPZ[HUJLVM[OLHK]HUJLKOHYKMHJPUNTH[LYPHS
on these bits allows designers to take full advantage of hydraulic
JVUN\YH[PVUZ^OPJOHYLVW[PTPZLK[OYV\NOL_[LUZP]LJVTW\[H[PVUHS
\PKK`UHTPJZ*-+L]HS\H[PVUZ[VLUZ\YLWVZZPISLZ[HNUH[PVUaVULZ
HYLLSPTPUH[LKMVYPTWYV]LKJSLHUPUNLMJPLUJ`J\[[LYJVVSPUNHUK
967
In terms of steerability, steel body bits can be designed with a
]LY`ZOVY[THRL\WSLUN[O^OPJOJYLH[LZHZOVY[LYIP[[VILUK
SLUN[OMVYNYLH[LY+3:JHWHIPSP[`;OLZOVY[LY[OLKPZ[HUJLIL[^LLU
[OLILUKPU[OLTV[VYHUK[OL[VWVM[OLIP[[OLLHZPLYP[PZ[VI\PSK
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[VKYPSSIV[O]LY[PJHSHUKJ\Y]LZLJ[PVUZPUH6UL)/(ZVS\[PVU[OL
KLZPNUHK]HU[HNLZVMZ[LLSPUJYLH[PUNIP[Z[OH[^V\SKWYV]PKLIL[[LY
[VYX\LTHUHNLTLU[HUKNYLH[LYJVU[YVSH[MHZ[WLUL[YH[PVUYH[LZ
^LYLJHWP[HSPZLKVU
2UV^UMVYP[ZL_[YHVYKPUHYPS`ZVM[MVYTH[PVUZ[OL+1)HZPUVMMLYZ
L_[YLTLS`MHZ[KYPSSPUN^P[OPUZ[HU[HULV\ZYH[LZVMWLUL[YH[PVUVM
TVYL[OHU TL[YLZWLYOV\YM[OY;OLTHPUWSH`ZHYL[OL
5PVIYHYH:OHSLHUK*VKLSSMVYTH[PVUZ^P[OJVTWYLZZP]LZ[YLUN[OZ
YHUNPUNMYVTRZP[OYV\NOV\[[OLMVYTH[PVU[V[OL[HYNL[
5PVIYHYH
+\YPUNPUP[PHSY\UZVM[OLZ[LLSIVK`=V`HNLYIP[PU[OPZHWWSPJH[PVU
[OLVWLYH[VYPUZ[P[\[LK[HYNL[JOHUNLZ^OPSLKYPSSPUN[OLJ\Y]LZLJ[PVUZ
VM[OL^LSSZ5L]LY[OLSLZZ^OPSLJOHUNPUN[YHQLJ[VY`VU[OL`
=HYLSZ=4:/IP[^HZHISL[VHJOPL]L[OLULJLZZHY`KVNSLN
ZL]LYP[`+3:[VI\PSKHUNSLHZYLX\PYLK!HM[LYJVTWSL[PUN[OLLU[PYL
Figure 1. Varels steel body VM513SH is dull graded 0 - 2, with only
two delaminated cutters on the outer shoulder when pulled after
drilling a One BHA run in the DJ Basin, from drillout to landing the
curve in only 25.4 hrs, a total distance of 5580 ft, at an average
penetration rate of 219.7 ft/hr.
]LY[PJHSZLJ[PVU[OLVWLYH[VY^HZZ[PSSHISL[VYV[H[LTVYL[OHUVM
[OL[PTL^OPSLKYPSSPUN[OLJ\Y]L
+\YPUN[OLZLJVUKZ\JJLZZM\S6UL)/(Y\U[OL=HYLS=4:/
JVTWSL[LK[OLLU[PYLPU[LY]HSMYVTKYPSSV\[[VSHUKPUN[OLJ\Y]LPU
OYZLZ[HISPZOPUN[OLLSKILUJOTHYRWLYMVYTHUJLMVYV]LYHSS
PU[LY]HS[PTL;OLIP[KYPSSLKH[V[HSKPZ[HUJLVMTM[PU[OL
ZPUNSLY\U^P[OHUH]LYHNLWLUL[YH[PVUYH[LVMTL[YLZWLYOV\Y
 M[OY
0UHKKP[PVU[V[OLZWLLKHUK[OLYLK\JLKKYPSSPUN[PTL[OLZ[LLS
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characteristics being two delaminated cutters on the outer shoulder
HYLHVM[OLIP[

SPOT design upgrade

Figure 2. Katana series steel
PDC bits incorporate hydraulics
optimisation. Also available in
a shankless conguration in
many sizes, for minimisation
of bit length for responsive
drilling.
Figure 3. The solid tungsten
carbide EdgeGuard pucks are
brazed into the bit in strategic
position to afford maximum
wear resistance in high
angle directional drilling, and
can double bit life in some
applications.
;VNHPUM\SSHK]HU[HNLVM[OLTH[LYPHSJOHYHJ[LYPZ[PJZVMZ[LLSMVY
UL^HUKTVYLJVTWSL_KYPSSIP[HWWSPJH[PVUZ[OLZLZ[LLSIVK`IP[Z
PUJS\KPUN[OL2H[HUHZLYPLZHYLJYHM[LK\ZPUN[OL:76;+5TVKLSSPUN
[LJOUVSVN`
;OLSH[LZ[\WNYHKLLUHISLZHSSMHJL[ZVMIP[KLZPNU[V
ILJVUZPKLYLKPUSPNO[VMHJ[\HSLSKWLYMVYTHUJLKH[HPU
JVUQ\UJ[PVU^P[ONLVZJPLUJLZKH[H;OPZJVTIPUH[PVUN\PKLZ[OL
KLZPNU[LHTPUZLSLJ[PUN[OLTVZ[HWWYVWYPH[LJ\[[LYHUKTVZ[
effective cutting structure to control bit behaviour as desired for
[OLHWWSPJH[PVU
)`MVJ\ZPUNVU[OLZWLJPJ^LSSVIQLJ[P]LZHWWSPJH[PVUHUK
KYPSSPUNZ`Z[LT\ZLK[OLKLZPNUWYVJLZZWYV]PKLZPTWYV]LK
TVKLSSPUNVM[OLJ\[[PUNZ[Y\J[\YLHUKHMMVYKZNYLH[LYL_PIPSP[`
PUJ\[[LYWVZP[PVUPUN[VJYLH[LIP[Z[HPSVYTHKLMVYZWLJPJKYPSSPUN
JOHSSLUNLZ
;OYV\NO\WKH[LKHSNVYP[OTZL_[LUZP]LLSKVWLYH[PUNHUK
WLYMVYTHUJLKH[HZ[YHPNO[MYVT[OLYPNHUKYVJRHUHS`[PJZPUW\[[OL
KLZPNUWYVNYHTKLULZ[OLJVUULJ[PVUIL[^LLUZWLJPJIP[KLZPNU
JOHUNLZHUK[OLPYM\SSPTWHJ[VUKYPSSPUNKLSP]LYHISLZ+LZPNULYZJHU
then determine how changing bit features and dimensions affect

OILFIELD TECHNOLOGY
46 June 2013
Z[LLYHIPSP[`HUKIP[^HSR+3:JHWHIPSP[`HUK]PIYH[PVUJVU[YVSMVYHU`
NP]LU^LSS[YHQLJ[VY`HUK)/(
)`PUJVYWVYH[PUNLSKY\UHUK.LV:JPLUJLYVJRKH[H[OL
WYVNYHTJYLH[LZHKLZPNUWYVJLZZ[OH[LUHISLZKLZPNULYZ[VUV[VUS`
TVKLSIP[ILOH]PV\YI\[HSZV[VZLLOV^HIP[HJ[\HSS`WLYMVYTLKPU
[OLYLHS^VYSK0UZVTLY\UZPU[OL,HZ[LYU/LTPZWOLYLTVZ[VU
YV[HY`Z[LLYHISLZ`Z[LTZJVYYLSH[PVUIL[^LLUTVKLSZHUKLSKY\UZ
JVUYTZ[OL\WNYHKLK:76;+5KLZPNULKIP[ZHYLV\[WLYMVYTPUN
WYL]PV\ZKLZPNUZ
[OLSLHKPUNLKNLVM[OLIP[OLHKHYLHZTVZ[Z\ZJLW[PISL[V^LHYPU
OPNOHUNSLKPYLJ[PVUHSKYPSSPUN:\IZ[HU[PHSS`TVYL^LHYYLZPZ[HU[[OHU
[YHKP[PVUHSOHYKMHJPUN[OLW\JRZHYLZ\WWSLTLU[LK^P[OHKKP[PVUHS;*
PUZLY[Z^OPJOHYLHSZVHKKLKHYV\UK[OLYLZLY]VPYHUKJVTWLUZH[VY
[VWYV]PKLJVTWSL[LWYV[LJ[PVUJV]LYHNL
0UP[PHS[LZ[PUNPUOLH]`VPSZHUKZZOV^Z[OH[[OPZWYV[LJ[PVUJHU
double roller cone bit life in the high angle wells, where directional
demands call for high doglegs through the highly abrasive
MVYTH[PVUZ O T

Making things harder:

impregnated diamonds
and hardfacing
Last year saw innovations in
PTWYLNUH[LKKPHTVUKTHU\MHJ[\YL
as well as in roller cone bit
Leading Through Innovation
hardfacing, both of which hold
WYVTPZLMVYPUJYLHZPUNIP[SPML
Worlds Most Trusted Hardbanding
+L]LSVWLKV]LY[OLSHZ[ Supported by almost 200 applicators worldwide on every continent
months and introduced last year,
100% CRACK-FREE & REBUILDABLE
=HYLSZTHU\MHJ[\YPUNWYVJLZZ
MVYPTWYLNUH[LKKPHTVUKIP[Z
JVTIPULZ[OL\ZLVMHZWLJPHS
M\YUHJLPUJVUQ\UJ[PVU^P[O]LY`
high quality diamonds to create a
more robust, less brittle diamond
that is less likely to suffer breakage
MYVTPTWHJ[Z>OLUKPHTVUKZ
remain whole during drilling, the
IP[ZJHUZ[H`KV^UOVSLSVUNLY
;OLPTWYV]LKK\YHIPSP[`VM
DurabandNC
Decreases Downtime & Increases Productivity!
[OLZLPTWYLNUH[LKKPHTVUKIP[Z
Duraband NC Hardbanding
 Exceptional Reliability
PZWYV]PUNV\[PULSK[LZ[PUN0U
Uses: New Application  Excellent Casing & Tool Joint Protection
HYLJLU[HWWSPJH[PVUPU(SNLYPHZ and Re-Application to
Tool Joints  No need to remove existing hardbanding
tough Ordovician sandstone,
 Re-application costs up to 75% lower than
HUPTWYLNUH[LKIP[VUP[ZPUP[PHS
competitive cracking hardband products
Y\UL_JLLKLK[OLWLYMVYTHUJL
 Cuts NPT & Maintenance Cycles
benchmark of the established
 Fearnley Procter NS-1 Certified Product for
JVTWL[P[VY-PLSK[LZ[ZJVU[PU\L new application & re-application over other
^P[OHKKP[PVUHSY\UZWSHUULK[OPZ competitive hardbands
`LHYMVY*HUHKH

Roller cone bits with an

UltrabandNM
Patent Pending
Improves Wear Resistance
edge
In Non-Mag Applications!
,KNL.\HYKWYV]PKLZHU\WNYHKL[V
 Up to 500% Improved Wear Resistance
OHYKMHJLWYV[LJ[PVUVUYVSSLYJVUL
Over Ordinary Non-Mag Welding Alloys
bits, increasing overall durability
 Up to 500% Better Abrasion Resistance
HUKTVYLZWLJPJHSS`ILHYPUNSPML Than Drill Collar Base Materials
in directional work demanding high  Apply directly to non-mag tools & over
+3:)P[Z^P[O[OLWH[LU[WLUKPUN previous layers of stainless
WYV[LJ[PVUOH]L`PLSKLK  Meets API Spec. 7 Relative
PERFECT FOR ALL
greater bit life due to reduced wear permeability less than 1.01
HARDBANDING CONDITIONS
in high angle wells through abrasive  No spalling in multiple layers
Highly DHYLDWHG:HOOVSour Gas Well
MVYTH[PVUZ
GHRWKHUPDO:HOOV+3+T Wells
;OPZWYV[LJ[PVUYLWSHJLZ
hardfacing with a series of tungsten Available from drill pipe manufacturers
and rental companies
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PU[VWVZP[PVUVU[OLIP[IVK`
:WLJPJHSS`[OLZVSPK;*W\JRZ
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bit leg, around the shirttail and on

www.hardbandingsolutions.com
 OILFIELD TECHNOLOGY
48 June 2013
 Moving on
with MWD
Steve Krase, Ryan Directional Services, USA,
gives us a look at a unique approach to MWD for
unconventional wells.
n MWD system that was
A KLZPNULKZWLJPJHSS`MVY[OLSHUK
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OHZKLTVUZ[YH[LK[OLULLKMVYHKKP[PVUHS
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[V^HYKKYPSSPUNH\[VTH[PVUHUK[OLYLK\J[PVU
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Z[LHT;OLZLJOHUNLZPU[OLTHYRL[OH]L
OPNOSPNO[LK[OLULLKMVYUL^HUKPTWYV]LK
4>+Z`Z[LTZ
Drilling automation and unmanned
operation
4\JOVM[OLLMMVY[[V^HYKZLUHISPUN
KYPSSPUNH\[VTH[PVUHUK\UTHUULKKYPSSPUN
VWLYH[PVUZOHZILLUMVJ\ZLKVUTLJOHUPJHS
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WLYZVUULS;OLZLWLVWSLYLWYLZLU[UV[VUS`
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JVTWHU`I\[[OL`HSZVYLWYLZLU[ZPNUPJHU[
/:,YPZR;OLYLMVYLZPNUPJHU[LMMVY[ZHYL
ILPUNTHKL[VYLK\JLHUKVYLSPTPUH[L[OLZL
49
people from the wellsite entirely. Although technical challenges
remain, the reality of achieving total unmanned operation is not
so much hampered by technology but more so by a reluctance
to change by the industry itself. In order to accomplish full
unmanned operation it must be demonstrated that personnel can
be removed from the wellsite without reducing service quality or
inadvertently introducing additional HSE risk for remaining wellsite
personnel.
Downhole technology
In order to achieve a reduction in directional drilling and MWD
personnel at the wellsite it is important that the design of
[OL4>+Z`Z[LTPZ[MVYW\YWVZL;OLLX\PWTLU[T\Z[IL
designed with simplicity in mind and with a low operating cost to
address the lower cost land market. Additionally, there are two
more factors that must also be addressed. Firstly, the system
must require little or no human interface to setup prior to running
in the hole, therefore the downhole system must arrive at the
wellsite ready for use. Secondly, the system must provide the
real time measurements required by the drilling, geology and
ZLY]PJLJVTWHU`WLYZVUULS[OH[LUHISLYLTV[LVWLYH[PVU;OLZL
real time measurements must also be available remotely to
anyone that needs them to make decisions.
When drilling horizontal wells on land, the measurements
provided by the downhole MWD system must be focused
VUWYV]PKPUN[OLPUMVYTH[PVUZWLJPJHSS`YLX\PYLKMVYLMJPLU[
^LSSIVYLWSHJLTLU[0UVYKLY[VHJOPL]LLMJPLU[^LSSIVYL
Figure 1. Directional sensors. This photo shows the signicant
change in MWD sensors over time. The instrument in the lower left
is a directional sensor from circa 1980 minus electronics and the
instrument to the right is a present day directional module, which
includes electronics.
Figure 2. The Ryan Directional surface system takes advantage of
cloud computing to ensure database integrity and access to data for
unlimited users.
OILFIELD TECHNOLOGY
50 June 2013
placement, the applications of directional drilling, geosteering
HUKKYPSSPUNLMJPLUJ`T\Z[ILHKKYLZZLK(S[OV\NO[OL
measurements required for wellbore placement are readily
available and have been since the late 1980s, most of the
systems in the industry today were designed for use in the
offshore environment. When compared to the onshore drilling
environment the cost structure for drilling offshore is much
higher. Subsequently the majority of the MWD systems available
today are too expensive to operate cost-effectively in the
SHUKKYPSSPUNLU]PYVUTLU[;OLYLMVYLOH]PUN[OLTLHZ\YLTLU[
JHWHIPSP[`PZUV[LUV\NO;OLPKLHS4>+Z`Z[LTMVYKYPSSPUN[OLZL
types of wells will be reliable, short in length for ease of transport
HUKTH_PT\T)/(KLZPNUL_PIPSP[`
Directional drilling
It is generally accepted that MWD survey systems for accurate
wellbore surveying have been available since 1978 when
;LSLJV6PSLSK:LY]PJLZJVTTLYJPHSPZLK[OLYZ[4>+Z`Z[LTPU
the UK sector of the North Sea. Since that time, advances have
been made to improve the accuracy and survivability of these
ZLUZVYZ;OLYZ[ZLUZVYZ^LYLLSLJ[YVTLJOHUPJHSHUKPUJS\KLK
moving parts. Modern day sensors are much more accurate and
reliable and utilise the latest in digital technology.
Drilling an unconventional reservoir typically requires
ZPNUPJHU[S`OPNOLYI\PSKYH[LZ[OHU^LYLWYL]PV\ZS`YLX\PYLKMVY
drilling wells that targeted conventional reservoirs. In addition
to improved survey accuracy, increased frequency of surveys
has proven to be a necessity to insure wellbore placement.
Additionally, the ability to measure and transmit inclination surveys
continuously and preferably in closer proximity to the bit than
the position of the standard directional module, has also proven
[VILHK]HU[HNLV\Z;LZ[PUNOHZJVUYTLK[OH[[OLYLJHUIL
ZPNUPJHU[JOHUNLZPUIVYLOVSLPUJSPUH[PVUIL[^LLUZ\Y]L`WVPU[Z
and if these changes are unaccounted for in determining wellbore
WVZP[PVU[OLUHSNLVSVNPJHSPU[LYWYL[H[PVU^PSSILPULYYVY
Geosteering
Since the late 1980s when MWD technology development
became focused on the replacement of openhole wireline logs
MVYMVYTH[PVUL]HS\H[PVUZPNUPJHU[HK]HUJLZOH]LILLUTHKL
in developing sensors to aid in making real time decisions based
VUNLVSVNPJYLZWVUZL:WLJPJHSS`[OLYLOH]LILLUZPNUPJHU[
advances made in geosteering, which uses geologic information
that, when compared to a geological model, enables decisions
about correction to the well path to be made in real time. Most
recently this includes sensor systems with azimuthally sensitive
response, which enables the user to detect not only a change in
bed boundary but also the direction from which a bed boundary
PZHWWYVHJOPUN;OPZHaPT\[OHSS`ZLUZP[P]LKH[HJHUILJVU]LY[LK
PU[VHUPTHNL[OH[ZPTWSPLZPU[LYWYL[H[PVU
Drilling efficiency
;OLTLHZ\YLTLU[ZYLX\PYLK[VTLHZ\YLKYPSSPUNLMJPLUJ`HYL
NLULYHSS`^LSS\UKLYZ[VVK;OLJOHSSLUNLPUHKKYLZZPUN[OPZ
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quantities of this data from downhole to surface in real time to
enable a reliable interpretation of what is actually occurring at
the bit and or in the BHA. Although the measurements and how
to make them are generally well understood, the interpretation
of this data in a timely manner has been problematic; therefore
most drillers have preferred to rely on surface measurements
VM>6)HUK974[VPUMLY^OH[PZOHWWLUPUNKV^UOVSL
Powerful. Proven. Dyna-Drill.
Rotor Elastomer Stator

Chromed, or HR 4140/4142 QT
Carbon Coated NBR-HR P530 Non Mag SS
HSN
HT- HR

Power Section Sizes

1 11/16 Inches to 11 1/2 Inches

Proven performance for any application

Whether drilling with a PDC or roller cone bit and regardless of the formation,
Dyna-Drill power sections deliver the power you need to optimize ROP.

Dyna-Drill manufactures high-performance mud motor power sections from

conventional to ultra torque. Stator rubber formulations developed by Dyna-Drill
have produced innovations in elastomer durability resulting in products that serve
specific applications which can be compounded to withstand the most punishing
drilling fluids and downhole temperatures.

For over 50 years, Dyna-Drill has offered operators the most technologically
advanced and efficient downhole motor equipment in the oil and gas industry.

www.dyna-drill.com/powersection.asp
2013 Dyna-Drill
 L_WLY[Z)V[OVM[OLZLNYV\WZHYLPU[LYLZ[LK
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Figure 3. Ryan personnel support Permian Basin MWD Gamma operations from a KH[HJYLH[LJSPLU[MHJPUNYLWVY[ZL[J(JJLZZ[VIV[O
Remote Operating Center in Houston, Texas. YLHS[PTLHUKOPZ[VYPJHSKH[HNH[OLYLKH[[OL^LSSZP[L
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provide a useful interpretation of the data LHZ`^P[OHT\S[P[\KLVMVMM[OLZOLSMZVS\[PVUZ
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MVYKLJHKLZYLS`PUNZVSLS`VUZ\YMHJL 96*IHZLKWLYZVUULS;OLZ`Z[LTT\Z[PUJS\KL!
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ILWYV]PKLKJVZ[LMMLJ[P]LS`[OPZPTWVY[HU[
KH[H^PSSILJVTLHZ[HUKHYKTV]PUN Figure 4. Ryans AccuPulse MWD
MVY^HYKLZWLJPHSS`HZ[OL[YLUK[V^HYKZM\SS system is designed specically for
H\[VTH[PVUJVU[PU\LZ unmanned land based operation
0UHKKP[PVU[V[OLTLJOHUPJHS and requires no wellsite assembly.
TLHZ\YLTLU[ZVM>6)HUK;6)KV^UOVSL
there also exists a need for downhole
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LSPTPUH[LZ[OLN\LZZ^VYRUVYTHSS`HZZVJPH[LK^P[O[OPZWYVJLZZ
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[OLULLKMVYHUHJJ\YH[LTLHZ\YLTLU[VMHUU\S\ZWYLZZ\YL
[VKL[LYTPUL,*+OHZPUJYLHZLKZPNUPJHU[S`0UHU47+
HWWSPJH[PVU[OLHUU\S\ZWYLZZ\YLTLHZ\YLTLU[OHZWYV]LU[VIL
ILULJPHS^OLU\ZLK[VJHSPIYH[L[OL47+TVKLSZ0UJS\KPUNH
TLHZ\YLTLU[VMPU[LYUHSIVYLWYLZZ\YL^OPJO^OLUJVTWHYLK
[V[OLHUU\S\ZWYLZZ\YL^PSS`PLSKHKPYLJ[TLHZ\YLTLU[VM
KPMMLYLU[PHSWYLZZ\YL;OPZTLHZ\YLTLU[JHUZVTL[PTLIL\ZLK
[VKPHNUVZLPZZ\LZ^P[O[OLKYPSSPUNTV[VYHUK^P[O[OLKYPSSIP[
Minimising personnel requirements
0UVYKLY[VLSPTPUH[L4>+HUKKPYLJ[PVUHSKYPSSPUNWLYZVUULS
T\JOH[[LU[PVUT\Z[ILWHPK[V[OLKLZPNUVM[OLZ\YMHJLZ`Z[LT
[OH[PZYLX\PYLK[VYLJLP]LKLJVKLKPZWSH`HUKMVY^HYKKH[H
;OLZ`Z[LTT\Z[TLL[[OLULLKZVM[OLWLYZVUULSH[[OL^LSS
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9LTV[LVWLYH[PUNWLYZVUULSPUJS\KLKYPSSPUNHUKNLVSVNPJHS
OILFIELD TECHNOLOGY
52 June 2013
.\HYHU[LLKKH[HPU[LNYP[`![OLWYPTHY`
KH[HZ[VYHNLSVJH[PVUMVYHSSQVIZYLZPKLZVUH
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ZLY]LY\ZPUNHWYVWYPL[HY`TLJOHUPZT[OH[
allows for prioritisation of transferred data under
]HY`PUNSL]LSZVMIHUK^PK[O;OPZPZJYP[PJHSMVY
HJJ\YH[L[PTLS`KLJPZPVUTHRPUN
:THSSYPNZP[LMVV[WYPU[!RL`[V\UTHUULKVWLYH[PVUPZSPTP[PUN
[OLYPNZP[LMVV[WYPU[VM[OLZ\YMHJLZ`Z[LT9H[OLY[OHU
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[LJOUVSVN`[VHZPUNSLJVTW\[LY[OH[WLYMVYTZHSSRL`
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Conclusion
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YLZV\YJLZ[OLYLX\PYLTLU[ZVM[OL4>+Z`Z[LTZ\ZLK[V
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JOHUNLZPUJS\KLHKKP[PVUHSTLHZ\YLTLU[Z[VLUZ\YLLMJPLU[
^LSSIVYLWSHJLTLU[HUKPUUV]H[P]LTLJOHUPJHSKLZPNUVM[OL
KV^UOVSLZ`Z[LT;OPZPUUV]H[P]LKLZPNUWYVK\JLZPTWYV]LK
WLYMVYTHUJLPUOPNOZOVJRHUK]PIYH[PVUKYPSSPUNLU]PYVUTLU[Z
HSVUN^P[OSV^JVZ[VMVWLYH[PVU^OPJOPZJYP[PJHSPU[OLSHUK
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X\HSP[`ZLY]PJLPUSHUKKYPSSPUNVWLYH[PVUPZ[OLHIPSP[`[VVWLYH[L
^P[OYLK\JLKTHUWV^LYH[[OL^LSSZP[L0UVYKLY[VHJJVTWSPZO
[OPZYLSPHISLKH[H[YHUZMLYMYVT[OLYPNZP[LPZYLX\PYLKPUHKKP[PVU
[VHZTHSSYPNZP[LMVV[WYPU[[VSPTP[[OLWV[LU[PHSWVPU[ZVMMHPS\YL
PU[OLZ`Z[LT;OPZLUHISLZ[LJOUPJHSL_WLY[Z[VTVUP[VYHUK
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YLZ\S[ZPUYLK\JLK/:,YPZRHUKV]LYHSSPTWYV]LKZLY]PJL
X\HSP[` O T
Legendary Performance

Every well has a story, let our consistent

high performance bits be a part of yours.

1 877 PDC DRIL drilformance.com

 ime and again it is proven that safe and effective annular barriers are crucial to well management. Cementing is the

T industrys conventional solution, but it can be a complicated, expensive and time-consuming undertaking. Swellable
WHJRLYZOH]LLTLYNLK[VILJVTLHUHJJLW[LKHS[LYUH[P]LWYPTHYPS`K\L[V[PTLZH]PUNZ"OV^L]LY[OL`OH]LZPNUPJHU[
shortcomings, as degradable polymers represent a risk in the typically harsh and unforgiving environment of a well.
Horizontal drilling emerged in the 1990s and since then, drilling technology has continued to enable deeper and more complex
well designs. These advances in drilling technology go above and beyond the current capabilities of cement to provide a reliable
annular barrier that will last throughout the lifetime of the well.
Currently, more than half of the worlds rigs are drilling horizontally. The growing desire for increasingly capable, extended reach
^LSSZJVTIPULK^P[OHUPUJYLHZPUNU\TILYVMTH[\YLLSKZ^P[OKLWSL[LKaVULZOPNOSPNO[Z[OLWYLZLU[JVTWSL[PVUJOHSSLUNLZHUK
[OLULLKMVYHULMMLJ[P]LHUKJVZ[LMJPLU[SPMLVM^LSSZVS\[PVU

54
 Paul Hazel,
Welltec A/S,
UK, explains
how improved
annular barriers
lead to better
completions.

55

In a time where production
is declining and the global
demand for energy is on the rise,
the market needs innovation.
The primary driver behind the
development of new technologies
is a focus on how to do things
safer and more effectively.
A new concept
A novel solution, the Flex-Well, has been designed to
deliver cement assurance, zonal isolation and/or cementless
completions in all types of environments, as well as allow long
[LYTL_PIPSP[`MVYM\[\YL^VYRV]LYZPKL[YHJRHUKL]LU[\HS
well abandonment.
The concept provides the operator with all the
components required to design and construct a
[MVYW\YWVZLJVTWSL[PVU"ILPUNHZTPUPTHSPZ[PJVYHZ
intricate as the operator needs in order to accomplish optimal
reservoir drainage.
A central element of the solution is the Welltec Annular
Barrier (WAB), which is a rugged, large expansion ratio,
all-metal expandable barrier that can be used for a wide
variety of applications, and delivers reliable annular isolation
and maximised delta P capability across the entire borehole
over the full life of the well, withstanding up to 10 000 psi and
-*
Traditional completion methods have a number of
ZOVY[JVTPUNZ:^LSSHISLWHJRLYZOH]LZOV^U[VJH\ZLSLHRZ
entrepreneurial idea, the Well Tractor, allowed deployment
and operation of intervention tools into horizontal and highly
deviated wells, without the use of coiled tubing or similar
heavy-duty equipment. Today it is a widely accepted, industry
intervention standard means of conveyance.
In a time where production is declining and the global
KLTHUKMVYLULYN`PZVU[OLYPZL[OLTHYRL[ULLKZ
innovation. The primary driver behind the development of
new technologies is a focus on how to do things safer and
more effectively, allowing operators to manage their wells and
YLZLY]VPYZPUHT\JOTVYLLJVUVTPJHSS`LMJPLU[^H`
The Flex-Well system allows for multi-lateral well design
and an unlimited number of zones across the reservoir. It can
enable early production and increase ultimate recoverables
without compromising the long term well integrity. The
VWLYH[VYJHUKLZPNUJVTWSL[LHUKYL^VYR^LSSZHUK[OL
JVUJLW[YLK\JLZ[OLJVZ[ZYPZRZHUK[PTLL_WLUKP[\YL
associated with total well construction. The operator can
overcome current and future drilling, deployment and
production challenges, enabling complete, intelligent,
extended reach, multilateral wells with extreme reservoir
contact capabilities. With the introduction of the WAB, the
Flex-Well vision is becoming a reality.
Beginning with better barriers
The WAB for cement assurance can be set in wet cement or
at a later time in sections that are not cemented. It is installed
as part of the liner or casing string, positioned at depths
^OLYLJLTLU[PUNPZKLLTLKKPMJ\S[;OLSPULYVYJHZPUNPZ
hung off and the cement operation completed as normal.
When setting in green cement, while the cement plug is
being bumped, additional pressure is applied to the well to
expand the annular barrier. The hydraulic expansion of the
barrier in the wet cement ensures conformance to the open
OVSLHUKLSPTPUH[LZ[OLYPZRVMJLTLU[JOHUULSZ^OPJOJV\SK
JVTWYVTPZLPZVSH[PVU;OLYPZRVMTPJYVHUU\S\ZIL[^LLU
[OLJHZPUNHUKJLTLU[PZYLTV]LK*VU[YVSSLKL_WHUZPVU
extrudes the cement away leaving only a WAB-to-formation
PUHWWYV_PTH[LS`VM^LSSZPUHWWYV_PTH[LS`]L`LHYZ
from installation, and further problems arise due to formation
changes over time, as these impact cement causing it to
KL[LYPVYH[L:7,77(JOPL]PUNSHZ[PUNX\HSP[`
cementation and perforations is especially challenging and
costly in HP/HT environments.
Due to its design, the WAB addresses many of the
shortcomings of conventional completion methods, including
Z^LSSHISLWHJRLYZIV[OVU[OLZOVY[[LYTHUKPU[OLSVUN
run, even in extreme environments. Installation time is
considerably shorter and it allows for early production, as
there are no swellable elastomers to wait on. Long term well
integrity is secured due to its design, materials and testing,
and it has many HSE advantages. The Flex-Well concept
offers increased recoverables and reduces installation costs
substantially, which opens the opportunity to exploit a new
array of reservoirs that previously were not feasible a
potentially game changing development.
Unconventional challenges, unconventional
solutions
)HJRPU ^OLU[OLPKLHVM[YHJ[VYIHZLKJVU]L`HUJL
^HZYZ[PU[YVK\JLK[OLZJLW[PJPZT^HZO\NL/V^L]LYHU
OILFIELD TECHNOLOGY
56 June 2013
or a WAB-to-casing contact. The relative high plasticity of the
formation in comparison to the steel will ensure that
steel-to-formation contact remains after release of the
expansion pressure. Any cement trapped between the WAB
and the formation will not experience relaxation of pressure
when drilling mud is displaced. Removal of micro annulus will
KL[LYTPNYH[PVUVM\PKVYNHZILOPUK[OLJLTLU[LKJHZPUN
and liners.
Preservation of the intended zones of interest remains
the priority as well designs grow in complexity. No matter if
the well is a producer or an injector, it is critical to protect
[OLZLaVULZI`PZVSH[PUN[OLTMYVTPU[Y\ZP]LJYVZZV^VY
the introduction of contaminants. One contaminant results
from the cementing operations or the cement slurry itself.
*LTLU[SLZZJVTWSL[PVUPZH^H`[VYLZVS]L[OPZPZZ\LHUK[OL
WAB for zonal isolation has been developed in conjunction
with a number of global operators to address this.
Whether used for cementless completion or cement
assurance, the annular barrier assembly is mounted on the
exterior of the liner or casing, enabling a maximum diameter,
full-bore liner with rotational capability to be deployed. After
setting the liner hanger and under surface control, the outer,
high-grade steel alloy sleeve of the barrier is hydraulically
MODULAR INNOVATION.
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Our hydraulic drilling unit provides an economical alternative to
traditional platform and jack-up rigs. Its compact design accommodates
the space limitations of offshore rig platforms, while the vertical
racking feature allows intervention operations to be performed
between multiple wells without laying down work string or rigging
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easier marine transport.

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expanded to contact and conform to the open hole, while
simultaneously working to harden the alloy. During the setting
sequence, arrays of unique, pressure activated seals are
energised against the formation, providing the hydraulic seal
that allows the WAB to deliver a stable metal barrier with a
maximised delta P capability across the entire borehole for
the lifespan of the well.
From vision to reality
The idea of the annular barrier has been around for years,
I\PSKPUNVUHKLZPYL[VWYV]PKLVWLYH[VYZ^P[O[OLL_PIPSP[`
[VKLZPNUHUKY\U[OLVW[PTHSJVTWSL[PVUMVY[OLPYZWLJPJ
reservoirs. Thus the WAB has been developed in close
co-operation with a number of operators, addressing
[OLKPMJ\S[PLZMHJLKI`[OLTPUH]HYPL[`VMJOHSSLUNPUN
environments. The outcome is a hydraulically expandable
metal annular barrier, developed for the applications where
swellable external casing packers are traditionally used.
The WAB allows for surface operation, advanced
downhole monitoring and reservoir control, and re-stimulation
of multiple zones stretching horizontally over more than
30 000 ft. of wellbore and potentially comprising more than
60 zones. It is a unique, single skin well completion liner,
assembled on the outside diameter (OD) while maintaining
full-bore inner diameter (ID). It provides long term robust
and reliable zonal isolation in cemented or un-cemented
wellbores and may be used in conjunction with casing as
well as liners. It also provides higher differential pressure
capacity and higher expansion ratio to running OD without
compromising the ID. Consequently, it does not impair or
YLZ[YPJ[V^JVUKP[PVUZHUKM\Y[OLYTVYLLUHISLZZ\IZLX\LU[
well maintenance to take place unhindered.
Fast and safe deployment are key industry demands,
which are supplied through simple components and solid liner
functionality. Due to the lack of control lines, installation can be
Z^PM[HUKLMJPLU[HUKP[PZLHZ`[VWSHJLPUSH[LYHSZ;OPZHSZV
ensures safe well abandonment when required. The full-bore
construction ensures the highest production rate capacity,
and its rugged design and reliable nature allows for increased
reservoir contact, and enables cementless completions.
Over the last two years intensive design and development
work has been under way. One of the main challenges has
been moving into the realm of plasticity theory requiring the
involvement of external expertise combined with numerous
laboratory tests. The challenge lies in the complexity of the
interaction between the various components of the seal
^OLUZL[\UKLYWYLZZ\YLPLP[PZKPMJ\S[[V[LZ[[OL]HYPV\Z
components in isolated tests.
During the development of the annular barrier, the
development and engineering team faced an array of
challenges, including:
Relatively low expansion pressures.
A requirement to hold a high delta P in collapse
(production) pressure differential a property in conflict
with the expansion pressure specified above.
Choice of material and dimensioning of the expandable
sleeve, capable of very high expansion ratios.
Design of outer seals with an ability to withstand high
delta P across a wide temperature range after setting.
Preliminary engineering drawings were created based on
VM^VYR)HZLKVU[OPZUP[LLSLTLU[HUHS`ZPZ-,(TVKLSSPUN
was performed in the initial development stages to simulate
the expansion on the maximum required borehole size with
the available expansion pressure.
FEA considered the following parameters:
Maximum allowed expansion pressure.
Maximum allowed outside diameter.
Setting temperature.
Minimum operating temperature.
Pressure differential in production mode.
Material selection.
Maximum and minimum borehole size.
While standard FEA analysis characterises the borehole
as a rigid body, it is also possible to model the rock response
to the expansion stresses ensuring it does not exceed the
formation limits.
As the design was revised, the FEA analysis was re-run to
ensure all the project challenges were met. Once the FEA was
JVTWSL[LKIHYYPLYTHU\MHJ[\YPUNMVYX\HSPJH[PVUJVU[PU\LK
^P[OYLK\JLKX\HSPJH[PVUYPZRZ
;OLX\HSPJH[PVUVM[OL>()^HZJVUK\J[LK\ZPUN
the ISO 14310 V-3 testing protocol, which establishes the
pressure-drop limit of 1% for the pressure-testing cycles. It is
manufactured in accordance with ISO9001.
Case study: high pressure, cementless, zonal
acid stimulation
In the North Sea an operator needed to deploy a liner across
an 8000 ft horizontal section within a selected reservoir
comprised of eight zones. The challenges were that the zones
had to be completely compartmentalised and able to withhold
up to 8000 psi delta P during an extensive acid stimulation
job, as well as isolate a nearby water-bearing zone.
To improve economics and maximise reservoir exposure
to the acid, cement was avoided as part of this solution.
The baseline operation was built up from an extensive
drilling and production database, and using the annular
barrier completion solution, the well was projected to deliver
 IWK
After an extensive engineering study, 16 of these wellbore
annular barriers were installed on the operators line assembly
and deployed in the well, sealing off the selected eight zones.
Once the entire liner including WAB assembly reached the
desired target depth, pressure inside the liner was increased
to expand the WABs; an operation that took less than 30 min.
With the zones completely isolated, the acid stimulation job
^HZUHSPZLKHUK[OLKLZPYLKTH_PT\TKLS[H7\W[VWZP
was achieved between each of the zones. The pressure was
successfully contained within each zone while the stimulation
job went from one zone to the next as designed. The zonal
JVTWHY[TLU[HSPZH[PVUHUK>()PU[LNYP[`^LYLJVUYTLKI`
temperature and pressure sensors located within each of the
zones using independent readings.
Eliminating the need for cement in this project lowered
the Capex and enabled the operator to achieve the desired,
extended reach drilling target while overcoming the limiting
equivalent circulating density (ECD) concerns. The planned
productivity achievement was greatly surpassed and after six
months of production, an average of 4500 bpd was achieved
intellectual property gathered over the course of many years ^P[OVUS`^H[LYJ\[ O T

OILFIELD TECHNOLOGY
58 June 2013
 Stephen J. Chauffe, TEAM Oil Tools, USA, examines a new hydraulic
toe valve designed for a cemented environment.
large majority of North American long lateral wells
A are cemented and thus require initial toe injection
before these multi-stage wells can be completed.
;VPUJYLHZLLMJPLUJ`TPUPTPZLJVZ[HUKYLK\JLYPZRVM
[OL[VLPUQLJ[PVUYLZLHYJOHUKLSK[YPHSZOH]LWYV]LU[OH[
[VLPUQLJ[PVUZSLL]LZJHULSPTPUH[L[OLULLKMVY[OLJVZ[S`
and time-consuming use of coiled tubing (CT) or tubing
JVU]L`LKWLYMVYH[PUN;*7[VPUP[PH[L[VLPUQLJ[PVU
;OL[VLPUP[PH[PVUZSLL]LZHYLY\UHZHUPU[LNYHSWHY[VM
[OLZOVL[YHJRHUKM\Y[OLYHSSV^[OLVWLYH[VY[VWYLZZ\YL
[LZ[JHZPUN[VMYHJWYLZZ\YLZWYPVY[VVWLUPUN[OL]HS]L
6UJL[OLJHZPUNOHZILLUZ\YMHJL[LZ[LK[VMYHJWYLZZ\YLZ
HKKP[PVUHSWYLZZ\YLPZHWWSPLK[VVWLU[OL]HS]LHUKPUQLJ[
into the formation.
6UJLHJ[P]H[LK[OL]HS]LPZHS^H`ZVWLUHUK
PUMVYTH[PVUHIV\[[OLYLZLY]VPYJHUILNH[OLYLK[OH[^PSS
PU\LUJL[OLMYHJKLZPNUILMVYLHZZLTISPUN[OLYLX\PYLK
W\TWPUNLX\PWTLU[Z\JOHZHKPHNUVZ[PJMYHJ[\YLPUQLJ[PVU
test (DFIT) analysis.
-YHJZSLL]L[LJOUVSVNPLZHYL\ZLKMVYIV[OVWLUOVSL
HUKJHZLKOVSLHWWSPJH[PVUZ;OLLMJPLUJPLZMV\UKPU
open hole applications are desirable in completions that
\[PSPZLJLTLU[MVYHUU\SHYPZVSH[PVU/V^L]LY\UYLSPHISL[VL
ZSLL]LZPUHJLTLU[LKLU]PYVUTLU[^PSS\S[PTH[LS`PUOPIP[[OL
\ZLVMIHSSHJ[P]H[LKMYHJZSLL]LZPU[OLYLTHPUPUNSH[LYHS
60
;OPZHY[PJSLWYLZLU[Z[OLLSK[YPHS[LZ[PUNHUKYLZ\S[Z
VMHUL^[VLPUP[PH[PVUZSLL]LKLZPNULKZWLJPJHSS`MVYH
JLTLU[LKLU]PYVUTLU[;OLYLHYLUVTV]PUNWHY[ZVU
LP[OLY[OLPUZPKLVYV\[ZPKLVM[OL]HS]L>P[O[OYLLSH`LYZ
PUJS\KPUN[OLPUULYWPZ[VUVUS`[OLTPKKSLSH`LYTV]LZ
KPMMLYLU[PH[PUNP[MYVTWYL]PV\Z[VVSZ;OPZWHY[PJ\SHYMLH[\YL
allows the tool to function regardless of any residual or tail
JLTLU[SLM[PU[OLJHZPUN(KKP[PVUHSS`[OL[VVSHSSV^ZMVY
higher operating pressures and temperatures than other
tools.
;OPZHY[PJSL^PSSKPZJ\ZZLSK[YPHSZPU[OL,HNSL-VYK
Utica and Barnett shale plays. The tool has been tested
more than 300 times and by more than a dozen operators
HUKOHZZOV^U[VZH]LHU`^OLYLMYVT<:[V
<:WLY^LSS
Traditional methods: plug and perf and
tubing conveyed perforating
0U[OLJVU[PULU[HS<UP[LK:[H[LZOVYPaVU[HS\UJVU]LU[PVUHS
^LSSZ[`WPJHSS`YHUNLMYVT[VM[;OLTHQVYP[`
of these wells are cemented and require an initial toe
PUQLJ[PVUWYPVY[VJVTWSL[PUN[OL^LSS(UKPUHSTVZ[HSS
JHZLZ[OL^LSSZHYLJVTWSL[LK^P[OLP[OLY[OLWS\NHUK
WLYMTL[OVKVY[OLIHSSHJ[P]H[LKMYHJZSLL]LTL[OVK;V
IL[[LY\UKLYZ[HUK[VLPUP[PH[PVUVULYZ[T\Z[\UKLYZ[HUK
61
the current completion techniques utilised today plug and perf and
ball sleeve.
The plug and perf method uses a combination of frac plugs
and perforation clusters to complete the well. Once the lower most
zone is hydraulically fractured, a frac plug (bridge plug) is pumped
to depth and set. The zone above the frac plug is then perforated
with wireline and subsequently hydraulically fractured. Completing
wellbores using this technique requires an initial toe injection to
W\TWKV^U[OLYZ[MYHJWS\NHUKN\UZL[
Historically, the initial toe injection is established with the use
of TCP. With TCP, perforating guns are deployed on threaded pipe
or coil tubing, often times below a snubbing unit. This technique
is time consuming, costly and adds a safety issue with perforating
guns on surface.
The ball sleeve method utilises ball-activated stimulation valves
cemented in place along the lateral. In this case, which is similar
to the open-hole scenario, individual balls are dropped to open
each valve and subsequently hydraulically fracture each zone.
Similar to the plug and perf method, an initial toe injection must
ILLZ[HISPZOLKPUVYKLY[VW\TWKV^U[OLYZ[MYHJIHSS-HPSPUN[V
establish an initial toe injection typically results in all the
ball-activated frac sleeves being drilled out in order for TCP to be
run.
Figure 1. Top illustration: ORIO toe valve in closed position. Bottom illustration:
ORIO toe valve in open position.
Figure 2. ORIO toe valve
stimulating the production zone.
The next generation of toe sleeve technology is a sleeve that is
KLZPNULKZWLJPJHSS`MVYHJLTLU[LKLU]PYVUTLU[HUKVULPU^OPJO
[OLPUOLYLU[YPZRVM[VVSMHPS\YLPZTP[PNH[LK^P[OZWLJPJKLZPNU
characteristics.
The sleeve, once activated, fully opens regardless of whether or
not excess cement has been left in the lateral. The sleeve remains
fully open as hydrostatic pressure is constantly applying an opening
force, which is further secured with internal body-lock ring. The
sleeve offers an alternative to costly TCP operations and allows for
H+-0;WYPVY[V[OLTVIPSPZH[PVUVM[OLMYHJLL[
The next generation: cemented sliding sleeve toe
valve
The T1026 ORIO toe valve is a hydraulically actuated,
hydrostatic-operated sliding sleeve, which is run at the bottom of
a cemented casing completion. And, once activated, it is always
open. Injection is established and subsequent treatment operations,
Z\JOHZWS\NHUKWLYMHYLMHJPSP[H[LK;OL[VVSPZZWLJPJHSS`
designed for a cement environment and functions properly
regardless of the amount of excess cement left in the casing.
Unlike previous generations of toe sleeve, this tool is designed
with three layers and not two. The only part of the tool that moves is
the middle layer, thus mitigating the risk of premature opening while
both running in the hole or during the cementing operation.
The patented middle layer piston is protected with
K\HSY\W[\YLKPZRZWOHZLKHWHY[(WWSPLKWYLZZ\YLPZVUS`
required to rupture one of the disks. When one or both of the
disks burst, pressure enters into the middle layer and acts to
push the middle piston down into the atmospheric chamber,
[O\ZL_WVZPUN[OLV^WVY[Z[V[OLMVYTH[PVU
On previous generations of toe sleeves, the innermost
piston moves within the inner diameter (ID) of the tool. This
design is susceptible to both premature opening during the
cementing operation and also failure if tail or residual cement
is left in the low side of the casing. The new design mitigates
that problem by having three layers. With the three layers, the
middle layer moves into the protected atmospheric chamber.
Excess cement does not affect the tool at all.
The utilisation of rupture disks allows the tool to actuate
at very precise opening pressures. The pressure can be
pre-set to within 2% of required actuation pressure. The
surface actuation pressure is simply the disk rating minus
the hydrostatic pressure in the casing at the tool. This
JVUN\YH[PVUHSSV^ZJHZPUN[LZ[Z\W[V
20 000 psi prior to actuation.
Field trials: Eagle Ford, Utica
and Woodbine plays
The ORIO toe valve has been employed
in almost every North American shale
play, and internationally in China, Russia
and Australia. The tool has been tested
more than 300 times and by more than
a dozen operators and has shown to
save anywhere from US$ 80 000 to
US$ 120 000 per well.
-PLSK[YPHSZ^LYLJVUK\J[LKI`[OYLL
ZLWHYH[LVWLYH[VYZPU[OL,HNSL-VYK
Utica and Woodbine plays. A total of
62 wells were reviewed. The wells were
horizontal, with lateral lengths ranging
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 H[[LTW[Z^LYLTHKL[VVWLU[OL[VL]HS]LHM[LYJLTLU[^HZKYPSSLK
V\[9LTV]PUN[OL[OYLL^LSSZ^P[OMHPSLKJLTLU[QVIZYLZ\S[LKPUH
Z\JJLZZYH[LVMV\[VMVY 
;OL<[PJH^LSSZ^LYLZ\JJLZZM\S^P[OH]HYPHUJLI\[
^P[OVUL^LSSZPNUPJHU[S`HIV]L[OLKLZPNULKVWLUPUNWYLZZ\YL;OL
>VVKIPUL^LSSZ^OPJOYLWYLZLU[[OLZTHSSLZ[ZHTWSLOHKVUL[VVS
[OH[KPKUV[VWLUI\[[OLV[OLYZVWLULK^P[OHUH]LYHNL]HYPHUJLVM
;OL,HNSL-VYKYLWYLZLU[Z[OLSHYNLZ[ZHTWSLH[6M[OL
Figure 3. T1026 ORIO toe valve. MV\Y[VVSZMHPSLK[VVWLU6M[OLMV\Y[OYLLOHKMHPSLKJLTLU[QVIZ
from 4500 to 9000 ft in length. The tools were run on either 4.5 in. or
5.5 in. casing.
0UZVTLJHZLZTP_LKZ[YPUNZVMPUHUKPUJHZPUN
^LYLY\U/VSLZPaLZYHUNLKMYVT[VPU^P[O[OL
TVZ[JVTTVUILPUN[VPUPUKPHTL[LY)V[[VTOVSL
[LTWLYH[\YLZYHUNLKMYVT-;OLJLTLU[KPZWSHJLTLU[
\PK^HZLP[OLYMYLZO^H[LYVYSPNO[IYPUL
,HJO[VVS^HZHZZLTISLK^P[O^LSSZWLJPJY\W[\YLKPZRZ
[VHSSV^[OLVWLYH[VY[VYZ[[LZ[[OLJHZPUN[VHU[PJPWH[LKMYHJ
WYLZZ\YLZHUKM\Y[OLYVWLU[OL[VL]HS]L0UQLJ[PVUYH[LZ^LYL[OLU
established allowing wellbore cleanup and subsequent plug and
perf operations.
6M[OL^LSSZYL]PL^LK]L^LSSZ^LYLYLTV]LKMYVT[OL
ZHTWSLILJH\ZLVMVWLYH[PVUHSPZZ\LZ[OH[WYVOPIP[LK[OL[VL]HS]L
from being tested. The data captured illustrated designed opening
;OL[VVSZ[OH[KPKVWLUOHKHUH]LYHNL]HYPHUJLVM 
Next generation toe injection sleeves
0U[LY]LU[PVUSLZZ[VLPUP[PH[PVU[VL]HS]LZHYL\[PSPZLK[VPUJYLHZL
LMJPLUJ`TPUPTPZLJVZ[HUKYLK\JLYPZRVM[OLPUP[PHS[VLPUQLJ[PVU
9LZLHYJOHUKLSK[YPHSZOH]LWYV]LU[OH[[VLPUQLJ[PVUZSLL]LZJHU
eliminate the need for the costly and time-consuming use of CT or
;*7[VPUP[PH[L[VLPUQLJ[PVU^OPSLHSZVHSSV^PUNJHZPUN[LZ[ZWYPVY[V
VWLUPUN[OLZSLL]LZ
;OLUL^[VLZSLL]LKLZPNUPUJVYWVYH[LZWH[LU[LKMLH[\YLZ
[VTP[PNH[L[OLYPZRVMMHPS\YLILJH\ZLVML_JLZZJLTLU[VYMHPSLK
JLTLU[QVIZ;OLWH[LU[LKTPKKSLSH`LYWPZ[VUPZHISL[VM\SS`Z[YVRL
L]LU^P[OL_JLZZJLTLU[SLM[PU[OLJHZPUN;OL\[PSPZH[PVUVMK\HS
VWWVZPUNY\W[\YLKPZRZHSSV^Z[OL[VVS[VVWLUH[]HYPV\ZWYLJPZL
opening pressures.
;OLKH[HJVSSLJ[LKMYVT[OYLLVWLYH[VYZPU[OL<[PJH>VVKIPUL
HUK,HNSL-VYKZOHSLWSH`ZPSS\Z[YH[L[OH[[OLH]LYHNLVWLUPUN
WYLZZ\YLHJ[\HSVWLUPUNWYLZZ\YLHUKVWLUPUNWYLZZ\YL]HYPHUJL ]HYPHUJLPZ^P[OPU;OPZZTHSS]HYPHUJLHSSV^Z[OLVWLYH[VYZ[V
V\[VM[VVSZVWLULK^P[O[OLH]LYHNLVWLUPUN]HYPHUJLMVYHSS WYLJPZLS`[LZ[[OLJHZPUNWYPVY[VVWLUPUN[OLZSLL]L
[OL[VVSZH[ ;OLV]LYHSSZ\JJLZZYH[LVM[OL[VVSWYV]PKLZH]PHISLVW[PVU[V
6M[OL]L^LSSZ[OH[KPKUV[VWLU[OYLLOHKMHPSLKJLTLU[ JVZ[S`;*7ZH]PUNHULZ[PTH[LK<:[V<:WLY
QVIZ^P[O[VM[VMJLTLU[SLM[HIV]L[OL[VVS0[PZ\URUV^UPM well. O T

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OILFIELD TECHNOLOGY
64 June 2013 our
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 Sean Hollis and David Brown,
CSI-Technologies, USA, show
how common well repair
problems can be
overcome with
an engineered
sealant.

ime is not kind to wells can be in a variety

T wellbore equipment.
Equipment like casing,
tubing, packers, control lines and
wellheads can degrade over time due to
operation in harsh environments. Corrosion and unplanned
equipment failure can result in leaks, which require repair to
protect the environment, maintain well productivity and ensure
regulatory compliance.
Every year, hundreds of wells located on the
Gulf of Mexico shelf develop leaks. These leaks can be
located virtually anywhere in the well and under a variety
of conditions. A large number of these are very costly to
_HUKYLTLKPH[PVU]PHJVU]LU[PVUHSTLHUZPZUV[\Z\HSS`
LJVUVTPJHSS`Q\Z[PLK-\Y[OLYTVYLTHU`VM[OLZLSLHRZ
are on wells that have been plugged and abandoned or on
KLWSL[LK^LSSZ;OLJVZ[VMTVIPSPZPUNHYPN[V_HSLHRVU
this type of well is extremely uneconomical and is avoided
as much as possible by operators. However, the issue poses
operational problems, environmental hazards and regulatory
compliance concerns.
A range of conventional options is available for repair,
ranging from cement to mechanical solutions. Leaks in
of areas such as packers,
wellheads, cement plugs,
primary cement, control lines
and other areas. Many of these
areas provide significant sealing
challenges that are either too costly to
repair with cement or mechanical devices or simply cannot
be repaired by these methods. This issue creates the need
for an easily applied, economical sealing solution that
provides significant benefits to the operator. A unique and
effective sealing solution has been proven to be effective
in repairing a wide range of leaks in wells. This solution is a
unique resin sealant that does not require a rig and can be
placed in the well quickly and easily.
Novel sealant
A simple solution to satisfy these sealing needs is the use
of unique two-part resin sealant. This sealant has many
characteristics that make it an ideal choice for sealing
unique and difficult leaks. It provides excellent mechanical
properties, unique placement options, and allows variable
densities and cure times.

65
 The resin sealant possesses mechanical
properties that make it extremely effective
at sealing leak paths in a wellbore. Many
wells contain high wellbore stresses that
can cause other sealing materials to
fail. The resin sealant has over twice the
compressive strength of a typical cement
system1 and over six times the tensile
strength. 1-SL_PIPSP[`PZHUV[OLYRL`WYVWLY[`
of the resin. The Youngs, or elastic
modulus of the resin is extremely high. This
allows the resin to deform under changing
conditions without failing. It will also return
to its original size and shape once the
stresses are removed. The resin also has
great shear bond qualities. This allows it
to adhere and maintain a strong bond with
casing, cement, and many other materials.
The combination of these excellent
mechanical properties allows the resin to
maintain its seal even under extreme stress
Figure 1. Example of resin falling and
conditions.
roping through water.
The resin sealant is impervious to water
or brines. 1 This quality allows for more and
LHZPLYWSHJLTLU[VW[PVUZ-VYL_HTWSL
quite often a production packer between
the production tubing and the casing will
have a small leak. The leak is small enough
to prevent sufficient circulation around the
leak path but large enough to necessitate
sealing. This essentially prevents the
placement of typical sealing materials such
as cement, but it is not a problem for the
resin sealant. Because of the impervious
nature of the resin, it can be pumped into
annulus from the surface and allowed to
fall on top of the packer. The resin sealant
does not need to be pumped down to the
packer as it will fall in a rope through the
annular brine and puddle on top of the
resin. This method of placement has been
proven to be very simple and effective.
The resin sealant is also impervious to
gases. Many times, a sealant is needed to Figure 2. Example of resin to seal a
stop and seal bubbling gas. When the resin leaking packer.
sealant is placed on top of a gas leak, the
gas will bubble up through the resin until
the resin develops enough gel strength to prevent any further
gas intrusion. The resin is unaffected by the gas and does
not allow the formation of channels like in cement. Once the
gel strength of the resin sealant overcomes the gas bubbles,
the resin continues to cure and form a solid, channel-free
seal.
The density of the resin sealant can be adjusted by
adding various lightweight or heavyweight additives. This
allows the resin to have a density that can range from
7.0 ppg all the way up to 19.0 ppg. The use of weighting
agents is useful in the leaking packer mentioned earlier. The
resin sealant density must be weighted above the weight
of the annular brine in order to ensure it falls to the top
of the packer. While these additives add solids, the base
OILFIELD TECHNOLOGY
66 June 2013
resin sealant is a solids free fluid. This
allows it to be squeezed into extremely
small openings and flow paths. And unlike
cement, the resin sealant does not suffer
from fluid loss or dehydration. This means
the resin will cure regardless of the size,
geometry and permeability of its flow path.
The cure time of the resin sealant can
also be adjusted as needed. A wide range of
downhole conditions can affect the handling
and placement of any type of sealant.
The resin sealant can be formulated to be
WSHJLKHUKJ\YLKPU[LTWLYH[\YLZMYVT-
[V-;OLHTV\U[VM[PTLILMVYL[OL
resin cures can be increased for squeeze
applications or decreased for gas control.
All of these characteristics allow the resin
sealant to provide a unique and effective
sealing method. The resin sealant has been
used in many applications such as to seal
casing leaks, packer leaks, wellhead leaks,
plug and abandon applications and many
other applications. The successful placement
of the resin sealant has been carried out with
dump bailers, bullheading, pouring and by
HSSV^PUNP[[VMHSSPU[VWSHJL-\[\YLWYVQLJ[Z
may further the wide range of the resin sealant
applications and placement techniques.
Field application
A recent application for the resin sealant
provided a very unique situation to seal.
The well contained a control line that ran
down the annulus of the production casing
Resin Plug
and production tubing to a subsurface
safety valve. The top of the control line
connected to a port inside the wellhead.
Gravel This port connected to a nipple on the
Pack outside of the wellhead to allow pressure
to be applied to operate the subsurface
valve. This is a common setup in wells with
subsurface valves. In this well, however,
the production tubing and the control
line had both parted 200 ft below the
wellhead. Though the well was no longer
under production, the operator of the well
required the remaining control line to be
fully plugged in order to provide a barrier against formation
pressure.
The well was located in shallow water in the Vermillion
area of the Gulf of Mexico. The temperature at the wellhead
^HZ-;V[\YU[OLWHY[LKJVU[YVSSPULPU[VHIHYYPLY
200 ft of the in. ID line would need to be plugged from
the surface and the seal would have to be durable enough
to withstand at least 3000 psi. Due to the narrow ID of the
control line, a solution using resin sealant was developed.
The low viscosity and solids-free formulation meant that the
sealant could be pumped down this narrow opening without
bridging or plugging. In addition, the physical properties of
the resin sealant would provide an impervious barrier once
setting inside the line. The resin sealant was designed to fill
-i>i>>>Li
6>}ViVviv>

201 3
"VLi{U>v>ii]>>1-

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 sealant was mixed with an air-powered drill in a 5 gal.
bucket. Once it was thoroughly mixed, it was then loaded
The resin was designed into the hydraulic hand pump and pumped into the control
line port on the wellhead. The resin was slowly pushed into
and tested prior to the the full length of the hanging control line. The slow pumping
allowed the resin to build resistance in the control line as
job to ensure sufficient it developed gel strength and began to cure. Once the full
volume of the sealant was displaced into the control line,
placement time. No the valve on the control line port was shut to keep pressure
solids were added to the on the curing resin. A total of 36 hrs were allowed to pass
before opening the valve to ensure the resin had fully
resin sealant to ensure cured. The control line was confirmed to be fully plugged,
satisfying the operators requirements, and further repair
it would flow easily operations commenced on the well.

through the small ID of Conclusion

the control line.
200 ft of the in. ID control line. The required volume of
resin sealant to fill the control line was only 1 gal. Due to
the small volume of resin sealant as well as limited space
and equipment on location, the placement of the resin
sealant would be done with a hydraulic hand pump from a
workboat.
The resin was designed and tested prior to the job to
ensure sufficient placement time. No solids were added
to the resin sealant to ensure it would flow easily through
the small ID of the control line. Prior to pumping, the resin
The resin sealant provides an effective sealing method for a
variety of well repairs. The excellent mechanical properties,
wide temperature and density, adjustable set properties, the
ability to fall through water and penetrate small voids gives the
resin sealant a distinct advantage over other sealing methods.
The resin sealant reduces costs by eliminating the need for
a rig and other equipment. Field applications have proven
the sealing ability of the resin sealant and future well repair
projects will provide brand new challenges for sealing. O T
References
1. Sabins, Fred, and Larry Watters. Cement Alternative
Has Unique Properties. E&P Magazine 4 June 2007: n.
pag. Exploration & Production. 4 June 2007. Web. 01 May 2013.

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 Amir Mahmoudkhani, Kemira, USA,
explores the advantages of green
innovations in defoamers
for cementing applications.
oams are stabilised dispersion systems containing gas as the
F dispersed phase and a liquid or solid or a mixture of both as the
continuous phase. Most chemical additives needed to make
cement slurries are surface active molecules with an amphiphilic
structure; on one hand soluble and on the other insoluble (or of
limited solubility) in aqueous phase. This surfactancy is responsible
for the stabilisation of air-liquid interfaces and the potential generation
of excessive foam and air entrainment as shown in Figure 1. Such
HKKP[P]LZPUJS\KLJLTLU[YL[HYKLYZKPZWLYZHU[Z\PKSVZZJVU[YVS
additives, gas migration control agents and ductility improvement
additives. Chemicals used to enhance cement grinding are also
known to cause foaming to some extent.
Cement foaming, chemically entraining air in cement slurries to
HJJV\U[MVYHKKP[P]LZPU]VS]LKPZKPMJ\S[[VJH[LNVYPZLPU[OLZLUZL
of a conventional process. It can be viewed as an emulsion of air in
the cement water system or foam formation in the liquid phase and
retained by the gel or solid network, or both. Origins of air in cement
slurries include air already contained in the system and air entrapped
during mixing. Reviewing literature on air entrainment revealed that
it is clearly a complex process, which is affected by many factors
such as the mixing regime, physical and chemical properties of
oil well cements, water ratio and quality, dosage and properties of
the foaming agent, other chemical additives and supplementary
cementitious materials (SCMs), and a range of other parameters.
In well cementing applications, the reliable administration of
defoaming chemistries is a key step in preventing excessive foaming
HUKH]VPKPUNVWLYH[PVUHSKPMJ\S[PLZK\L[VLU[YHPULKHPY;YHKP[PVUHS
products that have been used in common operating conditions,
often pose a risk to the environment. A new generation of greener
chemistries is needed either in liquid or dry forms to meet industry
and environment regulations. Solid defoamers represent a particularly
attractive alternative, as they are characterised by long term stability
and ease of handling under severe climatic conditions.
Challenges with environmental regulations
Compliance with national and international environmental regulations
NV]LYUPUN\ZLHUKKPZJOHYNLVMVPSLSKJOLTPJHSZPZHJYP[PJHSMHJ[VY
in the development of new, environmentally-acceptable chemicals.
The most important institutions guiding these regulatory frameworks
are (1) the US Environmental Protection Agency for US Gulf Coast/
Gulf of Mexico and (2) the Oslo/Paris Commission (OSPARCOM) for
North Sea and other European Countries. The OSPAR commission
KLULKH]LY`YLZ[YPJ[LKSPZ[VMZ\IZ[HUJLZ[OH[HYLJVUZPKLYLK
to Pose Little Or No Risk (PLONOR) to the environment; some
countries follow the guidelines more rigorously than others. Most
of the service companies supply their customers globally; the need
for greener technologies becomes a requisite to operate, as many
state oil companies and international companies are looking into the
North Sea regulations when establishing their environmental controls
and legislations.
For the last few decades, the development of greener chemistries
MVY^LSSJVTWSL[PVU\PKZOHZILJVTLTVYLJOHSSLUNPUNK\L[V
69
 necessary high performance standards and evolving
restrictive regulations. Although one of the additives
with the lowest dosage rate, defoamers and antifoams
represent a particular challenge when looking into
formulations with more environmentally-viable
materials. There is a tendency to shift from
Figure 1. Mechanism of foam stabilisation. non-biodegradable silicone based products.
Non-silicone chemistries such as fatty alcohols,
esters and phosphates that show less toxicity
and better biodegradability, may represent viable
solutions. However, the challenge of achieving a high
performance and cost-effective product remains,
LZWLJPHSS`HZ[LJOUVSVNPJHSULLKZVU[OLLSKILJVTL
more strict and demanding. Kemira Chemicals is
^VYRPUN[V^HYKVPSLSKJOLTPJHSZ[OH[TLL[Z[YPJ[
global product safety requirements and promote
greener, alternative chemistries without compromising
WLYMVYTHUJL\UKLYLSKJVUKP[PVUZ
Using a systematic approach, different defoamer
chemistries were evaluated for highly foaming systems.
A series of non-toxic, biodegradable (more than
Figure 2. Systematic approach for development of green defoamers. 6,*+HUKOPNOS`LMJPLU[WYVK\J[Z^LYL
developed achieving yellow banding for Norway and
gold for UK applications. In addition, a Smart solid substrate with
green PLONOR banding was developed to be used as a carrier for
the above chemistry. The Smart dry technology is proving to be
OPNOS`LMJPLU[HUKJV\SKVWLUUL^WLYZWLJ[P]LMVY[OLKL]LSVWTLU[
of greener and even more cost-effective defoamers for cementing
applications.
As shown in Figure 2, the process for development of green
defoamers involves a systematic study and evaluation of active
defoaming chemistries, formulating agents and diluents or carriers.
Performance testing is also a key in development of green products
ZPUJLP[KLULZ[OLLMMLJ[P]LULZZVMUHSWYVK\J[ZWHY[PJ\SHYS`^OLUP[
TPTPJZLSKHUKVWLYH[PUNJVUKP[PVUZ
Figure 3. Graphical representation of foaming/defoaming patterns
from FEAT data. Testing methods for defoamers
There is currently no API standard for evaluation of defoamers for oil
and gas cementing. Cementing service companies often use their
own developed lab procedures, which often includes:
Slurry preparation using API procedure.
Measuring slurry density using a mud balance or other methods.
Visual investigation of air-entrainment in cement for voids and
channels.
Effects on other properties such as rheology, thickening time and
compressive strength.
Comparison of performance against a defoamer currently used
in the field as a benchmark.
A controlled approach has been developed for the evaluation
of cement defoamers using a unique Foam and Entrained
Figure 4. Blender foam test data in the latex system. All defoamers Air Test analyser (FEAT) and a more comprehensive blender foam
are dosed at 0.2% BWOC. test method that provide more insights into cement foaming
and defoaming processes. More detailed description of the
methodologies used can be found in the References section of this
Table 1. Defoaming chemistries and their discharge conditions article (Mahmoudkhani, 2011).
Sample ID Discharge permits The blender test was designed to address the effect of shear rate,
slurry volume and time on foaming during mixing of cement slurries.
Silicone A No
A clear protocol to evaluate densities of foamed slurries allow
Silicone B No for much controlled testing and better reproducibility of the data.
Non-silicone C Yes (Yellow for Norway, Gold for UK) ;OL-,(;[LJOUPX\L\[PSPZLZH\PKYLJPYJ\SH[PVUSVVWKLZPNULK[V
Non-silicone D Yes (Yellow for Norway, Gold for UK) K`UHTPJHSS`TLHZ\YL\PKMVHTPUNKLMVHTPUNJOHYHJ[LYPZ[PJZ

OILFIELD TECHNOLOGY
70 June 2013
The instrument is temperature controlled, open atmosphere, and adsorbent structure which strongly impacts defoamer release and
features an inline foam generation chamber to entrain air in the subsequent performance. Although high surface area substrates
experimental media. Density is continuously recorded using a density (such as precipitated silica) are often chosen due to their high
V^TL[LYVUJLYLJPYJ\SH[PVUILNPUZ;OLLMMLJ[VMHKKP[P]LZZ\JOHZ adsorption or loading capacities, they may lack performance owing
foamers, defoamers and antifoamers may be determined at any time to poor and slow release of the active defoaming chemistry from the
by injection into the foam chamber. Figure 3 represents a schematic Z\IZ[YH[LHUK[O\ZSLHK[VWYVK\J[TPZ\ZLZHJYPJPHSKLMVHTLY
of the defoamer densitytime curve obtained by the FEAT Technique. A careful selection of a substrate and active defoaming agent
;OLJ\Y]LJVUZPZ[ZVMZL]LYHSKPZ[PUJ[HYLHZ;OLYZ[WVY[PVUVM[OL should address several aspects ranging from environmental
curve with a downward slope (dinit to dmin) indicates the quickness
with which the test media entrains air and foams. Defoamer is then
injected at a chosen density or time noted on the graph. The initial
density minimum (dmin) of the graph represents the time which the
defoamer has begun to affect the media. The upward slope from
this minimum (dmin to dmax) represents the quickness with which the
defoamer acts upon the media to remove entrained air. The curve
then generally peaks at the defoamers maximum effectiveness (dmax).
An ideal defoamer would maintain the same density as the peak,
whereas a real defoamer gradually loses effectiveness causing the
J\Y]L[VKYVWHZ[OLKLMVHTLYILJVTLZLT\SZPLKPU[V[OL[LZ[
media.

Performance evaluation
As discussed earlier, a careful evaluation of the effectiveness of
a product, either as an anti-foaming or defoaming agent, should
Figure 5. FEAT analysis of silicone and non-silicone chemistries in the
YLLJ[[OLTP_PUNJVUKP[PVUZHUKKVZHNLWYHJ[PJLPU[OLLSK;OPZ
latex system.
systematic evaluation requires separate testing under the different
conditions. Both FEAT and blender tests were utilised here; while
blender test evaluates defoamer capability on a cement slurry, FEAT
analysis looks at the liquid mixing step prior to slurry creation.
1400
Non-silicone green chemistries are then benchmarked to traditional 1330
1285
silicone products.
Figures 4 and 5 show the blender and FEAT results for cement 1050
970
slurries with a gas mitigation control additive (a latex type product).
For such a highly foaming latex, the selection of non-silicone 720
products will be more effective than silicone chemistries and in
particular a better option when defoaming properties are needed in
the liquid mixing step prior to slurry creation.
=HYPV\Z\PKSVZZHKKP[P]LZHYLYV\[PULS`\ZLKPUWYLWHYH[PVUVM
cement slurries. They are often used at higher dosage in lightweight
and ultra-lightweight cement slurries to provide adequate properties
HUKJVU[YVSSLK\PKSVZZK\YPUNWSHJLTLU[PU[OLIVYLOVSL
Performance of silicone and non-silicone defoamers is evaluated Figure 6. Blender foam test data for API Class G Cement and PVA
MVYJLTLU[ZS\YYPLZJVU[HPUPUNH\PKSVZZHKKP[P]L!WVS`]PU`SHSJVOVS (0.9%) system. All defoamers are dosed at 0.2% BWOC.
(PVA). As shown in Figure 6, silicone based defoamers were found
to be not effective in PVA foaming systems,
instead both non-silicone based defoamers
exhibit superior performance as indicated by
measured slurry density in comparison to the
design density.

SMART dry defoamers

Liquid defoamers are predominantly used
in normal operating conditions, but dry
defoamers are preferred in extreme climates,
mainly due to ease of handling and storage,
long term stability and uniformity. In dry
defoamers, the active defoaming chemistry
is loaded on the voids of a high surface
area (solid) substrate. Consequently, the
development of dry defoamers brings another Figure 7. Formulation of dry defoamers, effect of substrate structure on defoamer adsorption
level of complexity associated with the and release.

OILFIELD TECHNOLOGY
June 2013 71
 ;OLNYLLUUVUZPSPJVULKLMVHTLY^HZMVYT\SH[LKHUKZ[\KPLK
PUP[ZSPX\PKMVYT3PXHUKPU[^VKY`MVYTZ!VULHKZVYILKVUH
[YHKP[PVUHSOPNOS`WVYV\ZZ\IZ[YH[L+Y`HUKHZLJVUKVULHKZVYILK
on a low porous smart substrate expecting faster release of the
HJ[P]LKLMVHTLYMYVT[OLZ\IZ[YH[L:+-PN\YLZOV^Z[OL
ISLUKLYMVHT[LZ[YLZ\S[ZMVYKPZWLYZHU[HUKZHS[Z`Z[LTH[KPMMLYLU[
dosages. It is noticeable how the liquid and smart defoamer sample
YLTHPUZOPNOS`LMJPLU[JVTWHYLK[V[OLJVU]LU[PVUHSKY`WYVK\J[
;OPZKH[HWYV]LZ[OLZPNUPJHU[LMMLJ[VM[OLZ\IZ[YH[LZ[Y\J[\YLVU
[OLYLSLHZLHUKOLUJL[OLZ\WLYPVYWLYMVYTHUJLVM[OL:THY[KY`
defoamer.

Figure 8. Blender foam test on cement A slurry using 2% Dispersant Conclusions

and 20% Salt System. Liq (liquid defoamer), SD (Smart Dry Defoamer)
and Dry (Traditional Dry Defoamer). Non-silicone liquid defoamer as
active component.
regulations and cost to operational conditions and practices such as
dosage points, nature of additives used and the need of defoaming
versus antifoaming functionalities. A solid substrate with green
736569IHUKPUNOHZILLUKL]LSVWLK0[ZSV^JOLTPJHSHMUP[`MVY
[OLKLMVHTPUNJOLTPZ[Y`N\HYHU[LLZHJVTWSL[LKLZVYW[PVUVM[OL
HJ[P]LJOLTPZ[Y`HUKP[ZSV^LYWVYVZP[`JVU]L`HMHZ[HUKJVTWSL[L
release upon mixing in foaming media. Figure 7 illustrates the
KPMMLYLUJLIL[^LLUJVU]LU[PVUHSKY`KLMVHTLYZHUK2LTPYHZZTHY[
KY`KLMVHTLYZ;OLLMMLJ[VMZ\IZ[YH[LZ[Y\J[\YL^OLUMVYT\SH[PUN
,_OPIP[PVU1\UL
KY`KLMVHTLYZPTWHJ[Z[OLLMMLJ[P]L\ZLVM[OLHJ[P]LJOLTPZ[Y`(U
VW[PT\TMVYT\SH[PVU^PSS[OLUYLLJ[[OLIHSHUJLIL[^LLUHKZVYW[PVU
(active defoamer uptake) and desorption (active defoamer release)
kinetics to maximise performance.
As local environmental legislations are under constant revision, it
PZPTWVY[HU[[VKL]LSVWUL^WYVK\J[ZJVUZPKLYPUNUV[VUS`J\YYLU[
I\[HSZVM\[\YLULLKZ;OL[LJOUPJHSJVUZ[YHPUZYLWYLZLU[H[Y\L
challenge when chemical companies need to formulate effective
[LJOUVSVNPLZSPTP[LKI`LU]PYVUTLU[HSS`]PHISLJVTWVULU[Z;OL
UL^KY`[LJOUVSVN`^HZWYV]LU[VILOPNOS`ILULJPHSNYHU[PUNHSS
[OLHK]HU[HNLZVMKY`WYVK\J[ZWS\ZL_PIPSP[`PU[LYTZVMKVZHNL
WYHJ[PJLZ;OLRL`[V[OLM\[\YLPZUKPUN^H`Z[VKVTVYL^P[O
less. O T
References
1. Mahmoudkhani, A., Bava. L., Wilson, B., An Innovative Approach for
3HIVYH[VY`,]HS\H[PVUVM+LMVHTLYZMVY6PSMPLSK*LTLU[PUN(WWSPJH[PVUZ
:7,)YHZPS6MMZOVYL*VUMLYLUJL
Maca, Brazil.
 )H]H34HOTV\KROHUP(>PSZVU93L]`3"5L^.LULYH[PVUVM
.YLLU+LMVHTLYZMVY*OHSSLUNPUN+YPSSPUNHUK*LTLU[PUN(WWSPJH[PVUZ
:7,:7,7YVK\J[PVUHUK6WLYH[PVUZ:`TWVZP\T4HY
6RSHOVTH*P[`6RSHOVTH<:(

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