FOAM BALL TESTING THROUGH PBL® MULTIPLE ACTIVATION BYPASS SYSTEM
Challenge
A Major Operating Company in Norway wanted to qualify if 2 x 5” OD foam balls could be pumped down the 5” Drill Pipe and circulated out through the side ports of a 6-3/4” and 4-3/4” PBL circulating sub into the annulus. Various projects would benefit in their cementing program if this could be achieved, allowing the 5” Drill Pipe to be effectively cleaned of cement debris.
Solution
Equipment & BHA:
TFS Services AS supplied the following DSI Dual Ported PBL Multi-Activation Circulating Subs:
6-3/4” PBL with Serial # WES 675 SBP 577
Toolbox # B032
No. of cycles: 5
Activation ball size and type: 2” vinyl ball (1 no. per activation)
De-activation ball size and type: 1-3/8” steel balls (2 no. per de-activation)
Port size: 2 no. 1.235” diameter (Total TFA= 2.396 sq. inches)
De-activation shear pressure = 3200psi (221 bar)
4-3/4” PBL with Serial # WES 475 BP 266
Toolbox # A009
No. of cycles: 5
Activation ball size and type: 1-1/2” vinyl ball (1 no. per activation)
De-activation ball size and type: 1-3/8” steel balls (2 no. per de-activation)
Port size: 2 no. 1.225” diameter (Total TFA= 2.358 sq. inches)
De-activation shear pressure = 3000psi (207 bar)
All 5” OD Foam balls were provided by a third-party service company.
Fluid Used: Fresh Water
6-3/4” PBL Circulating Sub Bottom Hole Assembly
7” OD Bullnose with 1 no. 19/32” centre nozzle (TFA = 0.277 sq. inches). Length approx. 0.75m. 4-1/2” IF Box up.
5” OD Pup Joint. Length approx. 5m. 4-1/2” IF Pin x Box.
6-3/4” OD PBL Circ Sub. Length approx. 3m. 4-1/2” IF Pin x Box.
Float collar # 1: ID = 2.2”. Length = approx. 0.5m. 4-1/2” IF Pin x Box.
Float collar # 2: ID = 2.2”. Length = approx. 0.5m. 4-1/2” IF Pin x Box.
5” OD Drill Pipe (1 joint): Length = approx. 10m. 4-1/2” IF Pin x Box.
5” OD Side Entry Sub: Length = approx. 3m.
Bottom FOSV: Length = approx. 0.5m.
Top FOSV: Length = approx. 0.5m.
5” OD Pup Joint. Length = approx. 5m
4-3/4” PBL Circulating Sub Bottom Hole Assembly
7” OD Bullnose with 1 no. 19/32” centre nozzle (TFA = 0.277 sq. inches). Length = approx. 0.75m. 4-1/2” IF Box up.
5” OD Pup Joint. Length approx. 5m. 4-1/2” IF Pin x Box.
XO with 4-1/2” IF Box x 3-1/2” IF Pin. Length = approx. 0.5m
4-3/4” OD PBL Circ Sub. Length approx. 3m. 3-1/2” IF Pin x Box.
XO with 3-1/2” IF Box x 4-1/2” IF Pin. Length = approx. 0.5m
Float collar # 1: ID = 2.56”. Length = approx. 0.5m. 4-1/2” IF Pin x Box.
Float collar # 2: ID = 2.56”. Length = approx. 0.5m. 4-1/2” IF Pin x Box.
5” OD Drill Pipe (1 joint): Length = approx. 10m. 4-1/2” IF Pin x Box.
5” OD Side Entry Sub: Length = approx. 3m.
Bottom FOSV: Length = approx. 0.5m.
Top FOSV: Length = approx. 0.5m.
5” OD Pup Joint. Length = approx. 5m.
Conclusion & Recommendation
The testing conclusively demonstrated that both the 6-3/4” and 4-3/4” PBL multi-activation circulating subs will successfully allow for 5” foam balls to pass through the side ports without any issue. Each size of tool recorded a 100% success rate, including the passage of 2 x 5” foam balls and successful activation and de-activation of the PBL sub on each cycle.
We observed a variance in the increased SPP which was recorded as the foam balls passed through the PBL sub ports. This may have been due to the fact that the foam balls were supplied in two separate batches, with the densities of each ball appearing to vary. Foam balls are known to be supplied in hard, medium, and soft compounds
