Drilling Innovative Solutions’ Gatekeeper Cement Retaining Collar (CRCPA) is among our most revolutionary and popular tools. As a mechanical isolation device offering the customer significant time savings during costly cementing operations, the Gatekeeper has been utilized by several major oil and gas operators and has been field proven everywhere from the Deepwater Gulf of Mexico to the frigid waters of the North Sea.
Several factors made the Gatekeeper such an improvement over conventional mechanical isolation devices—chief among which is the fact that, during production liner application, no drill out is required and brine displacement operations could commence following a cement job without a pipe trip. Naturally, this results in major cost savings for operators: the amount of rig time saved by this process is highly significant. As a result, there has been great demand for the tool from several operators across the globe.
The Problem
Despite the success of the standard Gatekeeper CRCPA, it became clear that under some circumstances, it could potentially be advantageous to have a lighter alternative that could provide valve actuation for Temporary Abandonment (T&A) applications. In these instances, drilling out will be necessary and therefore would require a drillable solution. As a result, a new variant of the Gatekeeper CRCPA was conceived: one that would be optimized for rapid drill-out. The primary difference between the standard variant and the new one being tested would be the material from which it was constructed. While the Gatekeeper CRCPA is typically made of high-strength steel, the new one utilized lightweight aluminum instead.
Incorporating several design elements from previous Gatekeeper models, the DIS team set to work designing and manufacturing this new Gatekeeper Cement Retaining Collar Plug Activated variant. The end result was a lightweight tool composed of 6 sections, each of which was designed for separate, distinct drilling profiles.
The Test
Once the new variant of the CRCPA was ready for testing, the DIS team convened with the engineers from Baker Hughes and Exxon at the Baker Hughes facility. After determining startup parameters and reviewing the drill-out procedure, the testing commenced. According to the report, the entire drill-out test lasted approximately 2 hours and 15 minutes, including four brief pauses to stop the Data Acquisition (DAQ) system and perform progress inspections. In total, the effective drill-out time for the valve was roughly 92 minutes. This duration included intervals for bit pickup, washout, and slowdowns due to testing amperage issues. These tests are not typical in field operations, however. The bit used for this test was provided by Baker Hughes.
There were a few snags throughout the process, but these worked in our favor; providing valuable data that would help us to make modifications to the design of the CRCPA. These modifications would even further optimize the effectiveness of the tool and reduce drilling time even further. Initially, the process began slowly due to a low weight on the bit, which was rectified by the simple increasing of weight and raising the RPM. Additionally, the end of the process during section 1 was slowed slightly as a result of the tool’s shape, but a simple design modification resolved this issue and ensured a speedy conclusion to the first section’s drill-out.
Throughout the third section, various adjustments were necessary to ensure a consistent Rate of Penetration (ROP). While the third section provided several challenges that resulted in further modifications to the tool’s design, there were also hindrances that were specific to the testing process and would not be likely in a field operation. Alternatively, the fourth section was a success: it was the fastest drilled section and required no adjustments or recommendations for improvement. Finally, the fifth section also demonstrated a rapid rate but experienced a snag when a section was dislodged and ended up in the shoe track area. A simple design modification to the tool will prevent similar occurrences in the future.
The Results
Though there were a few snags throughout the testing process, they were all easily rectified with simple design modifications. The recommendations made for optimal performance based on the test were the following:
- Adjusting the angle of thimble and add serrations to enhance chip generation and prevent the formation of a free-spinning ring
- Reducing excess material around the sealing area to minimize the potential for material stringing during drilling
- Reducing the inner diameter to allow the bit to fully complete the center section before detaching
- Deploying a 6-bladed Polycrystalline Diamond Compact (PDC) bit to mitigate aluminum accumulation and inter-blade stacking
By making these relatively simple adjustments and modifications, along with accounting for the factors that are unlikely to impact a field operation, the team came to the conclusion that the drilling time could be reduced from 92 minutes to a blistering 45 minutes or less.
A Promising Future
Naturally, the entire team was thrilled with the results of this test and the valuable insights that were gleaned from the process. The DIS engineers in particular are looking forward to putting this tool to use in the field and seeing the results of all the hard work and innovative thinking that took place. They are very grateful for the valuable resources and knowledge that were provided by their partners in this project: Baker Hughes and Exxon.
The ability to make adjustments and modifications in real-time is fully on display here, but it was not an isolated incident. Tailor-making a custom tool to perform a specific job in the most efficient way possible is precisely what DIS is all about. Our full line of specialized downhole tools have demonstrated that saving rig time and money for major operators is the DIS ethos, and the team that makes it happen is exceptionally proud of their accomplishments.
If you would like to know more about Drilling Innovative Solutions, LLC, please don’t hesitate to reach out! Keep an eye on our blog and our social media pages to learn more about exciting new innovations that are happening all the time!
