Smaller, Smarter & Stronger

Technology consumers want more powerful tools in smaller packages. They also want these packages to withstand physical abuse. This is especially true for drilling professionals concerning the equipment they rely upon.

Everyday devices show the smaller, smarter, and stronger trends. Cellular telephone manufacturers race each other to bring out smarter devices in smaller packages. Computer makers chase accelerating technology in an almost free-fall market for their smaller and smarter computing devices. Over decades of development batteries have slowly increased useful life and charge capacity. Their goal is to pack more punch in smaller volumes that adapt to person’s needs.  Smaller, smarter and stronger are the trends.

Advances in drilling technology parallel advances in other tech-intensive businesses. In fact, the instrument package that gives the driller insight and control over the downhole assembly could not exist before the solid state circuit was practical in equipment. Solid state technology is essential to many current consumer and commercial products. The earliest instrument packages to accompany the bottomhole assembly consisted of connected single-gate (And, Nor, Not logic) components. These first circuits were much larger than today’s microscopic imprints and carried the limited intelligence of early 1960’s cutting edge technology. In perspective, it was similar technology that allowed the United States to go into space.

Down in the borehole, delicate circuits shattered under the vertical acceleration (about 100 gravities) created by a drilling bit in action. Researchers immobilized the electronics in a solidifying gel. This solution protected the package contents. As drilling tests continued through the 1970’s, electronics development made packages more capable of sensing and recording data in the same or smaller space. Current instrumentation can measure these greatly expanded factors:

*                Formation properties and content

*                Borehole direction

*                Casing wear damage

*                …and for directional drilling, the instrument let the driller steer the downhole assembly.

Batteries presented their own difficulties for instrument designers. The heat and violent vertical acceleration of the bottomhole assembly shortened battery life. So, instrument designers used mud motors developed in the 1980’s and early 1990’s to power the electronics package. The mud motor is a form of turbine rotated by the forced flow of drilling mud down the drill pipe. The mud motor’s primary purpose is to power drilling bit rotation and power the directional steering motors of the downhole assembly.

When people see footage of the first Red Stone and Atlas rockets spectacularly exploding on launch, they usually don’t appreciate that it is these failures that were the hard but necessary steps to later successful launches. Mud motors like instrument packages had a tough beginning. The mud motors which now function for days operated only for 20 minutes when first deployed.

People tend to forget the not-so-glorious uphill struggles that precede success. It took 20 years to develop a stable and reliable dowhhole instrument package. The mud motor took a few years less. Drilling professionals and researchers work through the failures and marginal successes to find better designs and more reliable tools that will be smaller, smarter, and stronger.

Casing Wear Series - 11: A Little More About Rubber Pipe Protectors

If rubber pipe protectors can be used, they will greatly reduce wear in intermediate casing. However, if they are to be used, it is recommended that they not be run during the first bit run out of casing. Running rubber protectors in newly installed casing, they will encounter high frictional resistance to rotation. This is caused by the layer of mill scale and rust on the surface of the new casing. Until this layer is removed, the coefficient of friction will be very high, and, in some cases, Hade made it impossible to rotate the drill string.

This behavior is pictured in Figure 1.

Drill Pipe Protector Friction VS Time

Figure 1: Drill Pipe Protector Friction VS Time

If analysis of the directional survey and drilling program indicates that casing wear will be a problem, it is recommended that 2 protectors be used on each drill pipe: one on one end of the pipe, and the other at the middle of the pipe.

CWPRO was developed to conduct this analysis. The results of a CWPRO analysis will indicate exactly where and how severely casing wear can be expected.

A typical rubber pipe protector is shown in Figure 2. Since these rubber protectors will tend to restrict mud flow up the hole, some manufacturers have cut `flow channels’ in their protectors to reduce their flow resistance. Figure 3 shows two configurations of a `fluted’ protector. The one on the left, with the `straighter’ flutes will offer slightly less flow resistance to the drilling fluid, but will be a source of drillstring vibrations. Therefore, the `spiral fluted’ protector on the right is preferable.

Still better, both from the standpoints of flow resistance and vibration, is the configuration shown in Figure 4. We used to refer to this configuration as our `tractor tire’.

All these drill pipe protectors are clamped to the drill pipe, and rotate with it. Another option is a system where the body of the protector is stationary with respect to the casing. The body of the protector rotates in two end bearings, which are clamped to the drill pipe. This avoids the uncertain friction generated by rotation of the body of the protector with respect to the casing.

Slick Protector

Figure 2: Slick Protector

Fluted Protector

Figure 3: Fluted Protector

Hydril Diamond Type Protector

Figure 4: Hydril Diamond Type Protector

Western Well Tool Non Rotating Pipe Protector

Figure 5: Western Well Tool Non Rotating Pipe Protector

Western Well Tool developed such a `non rotating’ pipe protector which was quite successful. This unit, shown in Figure 5, consists of three pieces: Two end pieces which are clamped to the drill pipe, and a rubber center section which rotates between these end pieces. The end pieces provide low friction bearings upon which the center body rotates. These three pieces are shown in Figure 6.

 

 

 

 

Elements of Non Rotating Protector

Figure 6: Elements of Non Rotating Protector

 

Western Well Tool non rotating protectors have been used in several wells (that I know of) to remedy the excessive torque required to rotate the drill string.

Speed: Ferrari and Drilling Software

I spent quite a few weeks in Dubai teaching drilling software. One day, one trainer came into the class wearing a traditional white garment and a fashionable red cap, with a label “Ferrari World”. The color contrast enticed me to ask what it is. Suddenly, all students started talking about the theme park close to Abu Dhabi, which they visited during the weekend.” “You should go. It has the fastest roller coaster in the world, simulating F1 race car!” They all got excited.

Sure enough, I went there on the following weekend and had a whale of a time. It was about 1 hour drive from Dubai. Human being is always dreaming to achieve higher speed. We were fascinated by Jamaican Usain Bolt’s performance at 100 meters sprint event at the 2012 Olympic Games (Olympic record time of 9.63 seconds). In 2012 Olympic Games, there are 302 events and I counted that 124 of them are speed related.

We not only try to run fast, but also invent machines or tool to enable us to acquire higher speeds, including bike, car, boat, air place ,etc. But what I experienced in Ferrari World is so extraordinary that I will remember it forever. Here are the 2 pictures of the park and ride.

Ferrari World

Ferrari World

 

The Thrill of Roso - The world’s Fastest Roller Coaster

The Thrill of Roso - The world’s Fastest Roller Coaster

The world’s fastest roller coaster has seats like those of F1 cockpit. We all had to wear safety goggles as we blasted away 52 m into the sky. The track is 2.07 km with sharpest turn of 70 degree. The most shocking trending is at the beginning when the coaster reached 100 km/ hr. within 2 seconds and then 240 km/h in 4.9 seconds, with 4.8 gs. I never felt so sudden and strong push on my back before. Then I felt the wind, trying to tear my skin off my face. That was the first time I felt the goggles was extremely necessary.  Scream was our speech. Adrenalin rushed into blood. The world was falling behind us. We died and came back to life as we crossed the fishing line like heroes.

When we resumed our training next day, I echoed their expression in Ferrari World. I also added “Now that you have equipped yourselves with our cementing software, it is like if you are a driver in a Ferrari!"

Software Training in Ramadan

Our software training session continued into Ramadan period in Dubai.  On the 1st day (July 20), hotel sent a sheet with some information about Ramadan to all guests. I put some of the warnings here.

“1.           It is illegal to eat, drink or smoke in public during daylight hours (including in your car). Urban legend has it that you end up in jail for the remainder of the month of Ramadan if caught (the law says a fine up to 2000 dhs or a one-month jail sentence as far as we know), however it is more likely that you’ll get a lecture from the police and possibly a fine.

2.              It is respectful and polite to dress more conservatively during Ramadan – shoulders and legs should be covered.

3.              Almost all restaurant and cafes will be closed during the day but many will extend their opening hours at night.

4.              There will be a few eating outlets open during the day for dine-in customers in larger hotels and shopping centers.  Some fast food restaurants allow drive through or take outs.

5.              Bars in Dubai are usually still open but patrons will be asked what religion they are and refused entry if they are Muslim. Live and loud music is banned, so is dancing. Bars in Abu Dhabi might be closed.  Bars in Ras Al Khaiman stay open.  Bars in Sharjah don’t exist.

6.              Car stereos should be turned down.”

Local newspaper started publishing articles about keeping healthy during Ramadan.

I also survived the very 1st day of Ramadan. I was sightseeing on the street on Friday (their weekend). The afternoon heat made me thirsty like I was in the oven. Finally I saw a stand selling coconut water. I bought it but was advised not to drink on the street. Eventually, I found a metro station and went into a restroom to quench my thirst. . .

For a visitor like me, coming to a place like Dubai during Ramadan is not a good choice.  As opposed to other holidays, when people often indulge, stores often profit, Ramadan is by nature a time of self-restraint.  The idea is that through fasting, people experience hunger and thirst, and sympathize with those in the world who have little to eat every day.  Visitors might feel inconvenient, as almost restaurants and cafes are closed during the day.

But people who are fasting can enjoy quite a few physiological benefits including weight managements, lower of blood sugar, cholesterol, and the systolic blood pressure, etc. Peace and tranquility are achieved through fasting.  Personal hostility is at a minimum, and the crime rate decreases.

There is a reason for everything. I appreciate this opportunity of being there witnessing people doing fine in Ramadan. We live in a world of interruption. Arguably, eating multiple times a day is a kind of interruption to our body. During fasting, when the body’s energy is not being consumed to digest food, it can be directed forward building up the immune system.

Parallelly thinking, our daily life is full of interruption, with the greatest sources of interruption being our computers and mobile phones.  Yes, they are convenient, resourceful. But many have found that great clarity and a fresh perspective can be achieved by temporarily unplugging ourselves from the grid and grabbing pens and paper to sketch out our ideas.

Dr. Medina, author of the best-selling book “Brain Rules” (Pear Press, 2009) cites “When you’re always online, you’re always distracted”. “We are biologically incapable of processing attention-rich inputs simultaneously”.

Giving up something to gain certain benefits is not only restricted to food we eat. It probably helps to “fasting” on information we take daily.

Oops, should this article to be in your ‘fasting” list?

Casing Wear Series - 10: Zero Casing Wear?

Although some of the proprietary hardbanding alloys can significantly reduce casing wear, there is only one material which we know of will spectacularly reduce the wear groove depth limit. What is this marvelous material?

Rubber!

Rubber? Yes, rubber. 70 durometer rubber.

This was discovered as a result of a casing wear test using a specially built pipe protector as a tool joint.

What we discovered was that the `wear groove’ was a `mirror finish’ strip where the wear groove should have been. This results from the fact that the rubber `tool joint’ polishes the inner wall of the casing instead of grinding it. The polishing mechanism is pictured in Figure 1.

The Mechanism of Polishing

Figure 1 - The Mechanism of Polishing

This is the same mechanism that has been used for centuries to polish optical elements.

The difference between grinding and polishing is that the abrasive particles imbed themselves into the pliable surface of the rubber (or pitch, beeswax, wood, paper, or felt) protector, and `shave’ very small elements of the casing surface. The pliable surface of the rubber tends to orient the abrasive particles rather than to give them an unyielding background against which to push into the casing surface, exceeding its yield, and fracturing the casing surface.

The extremely low casing wear using a rubber `tool joint’ is shown in Figure 2. This figure shows a plot of the casing wear data from an 8-hour test in which the steel tool joint is replaced with a rubber pipe protector. The casing wear groove rapidly reaches a depth limit of 0.005 inch, and produces a mirror finish on the 0.653 inch wide wear groove.

Wear Test of Rubber Pipe Protector

Figure 2 - Wear Test of Rubber Pipe Protector

To put this into perspective, Figure 3 shows the results of three casing wear tests. These are all with N – 80 casing in a water-based mud containing 7 volume % Clemtex #5 sand. The upper plot of the figure is data using a steel tool joint. The second plot is data using a tool joint hardbanded with BOLTALLOY, and the bottom trace is data from the test using a rubber protector as a tool joint.

Steel Boltolloy and Rubber Tooljoint

Figure 3 - Steel, BOLTALLOY, and Rubber tool Joints

So why aren’t rubber pipe protectors routinely used to protect intermediate casing strings? They have a couple of limitations: (1) thermal and (2) chemical.

In Casing Wear Series - 11, we will talk about a few of the properties of rubber pipe protectors.

Pegasus Vertex Inc. Internship

This summer, PVI was pleased to welcome three new interns to our team. Our goals were to teach them new skills and to provide them with a unique learning experience. We sincerely hope that they enjoyed their time spent here.

John Cheng

Working at PVI this summer has been an eye-opening and invaluable experience for me. Despite all the stories you read and hear about working a first job, there is nothing quite like experiencing it firsthand. After sitting through company meetings, working with coworkers, and discussing design choices with my boss, I have learned that being able to communicate effectively is an indispensable skill to have in the office. Communication can be practiced in school and everyday life, but what school had failed to teach me was professionalism – that is, the level of professionalism needed for a company to thrive and flourish. Meeting deadlines, following rules, and being accountable for my actions were all aspects of professionalism that I picked up fairly quickly. However, it was the attention to detail that caught me off guard. Being a software company, every product had to work as intended without any bugs and that meant testing, testing, testing. I had to learn the ins and outs of each program and ensure that every feature worked flawlessly. All the spellings, formatting, and graphics had to be correct and in place. It truly opened my eyes to the amount of effort put in to deliver the best product to the customer. Needless to say, I am extremely grateful to have the opportunity to work at Pegasus Vertex. The values I have learned here are things that I will carry with me through the rest of my career.

William Chiu 

As a rising junior, interning at Pegasus Vertex has provided me with the perfect opportunity to test the waters of working at a software company. The office is lively, my co-workers are friendly, and I manage to learn something new every day. I am responsible for finding bugs and OS compatibility issues in the software so apart from learning how to test software, I have also picked up some deepwater exploration knowledge and jargon as well. Every day feels like a new challenge and I am just trying to get the most out of this generous opportunity. I have no doubt that the skills I have attained here will be invaluable to me in the years to come.

Debanhi Reyes

This summer, I was given the opportunity to intern at Pegasus Vertex. Not many 17-year-olds get a chance like this so needless to say, I was very thankful. Since this is my first job, I was really nervous at first, but the friendliness of my co-workers and the positive work environment eased all my worries. I have learned so much since I started working, especially the importance of communication. As a native Spanish speaker, I have to revise all the translations in the company’s software. To ensure that everything is correct, I have had to learn how to speak and listen effectively with my fellow co-workers. Additionally, getting first-hand experience working with professionals in the industry has increased my technical skills tremendously. Most importantly, my experience with Pegasus Vertex has provided me with the determination and motivation to succeed in all my future endeavors.

PVI Interns

PVI Interns

Drilling Software: Lost in Translation?

Literally, being lost in translation happens not only to travelers in foreign countries, but also in our daily lives, where essential meanings are dropped in communication; or in the software development process, in which the specifications might be compromised. That's why it's important to work with Professional Website Translation as such companies can guarantee the quality of their translation.

Drilling software, used by drilling professionals, is rarely developed by drilling engineers. The gap between eventual users and developers is inevitable. We can attempt to minimize it, but we cannot remove it completely, simply because two groups of people speak different languages.

While developers speak computer languages such as VB, C#, etc., drilling engineers speak an operation language. The communication is through meetings, specifications, testing, and so on. It is easier for developers to speak the field language and we have proved this.

One of the translation tools between these languages is visualization, especially 3D. It is hard enough for field engineers to explain what happens downhole. It is equally challenging for developers to express the computer simulated numbers in a meaningful yet easy-to-understand format. The following graph is one of our approaches to show the buckling of a pipe in a well.

Pipe buckling

Quite a few years ago, I visited Japan with a delegate of casing running and cementing experts from Unocal. The Japanese are known for their beautifully arranged dishes, such as bento. But what (pleasantly) surprised me was that the plastic models of dishes or noodle bowls were so real. They could easily fool our eyes. These models were mostly handmade and custom-tailored for restaurants.

Their idea is to really get you interested in the dishes. Dish pictures in the menu help non-Japanese speakers order. Dish models displayed in the restaurant ultimately translate the entire description to a vivid virtual order so that ordering food is as effortless as possible.

Back to our title. 3D visualization is a great help in translating computer language to field language. But if you really want to conquer the world, we have the drilling software (with 5 languages: English, Spanish, Portuguese, Chinese and Russian) to enable you to do so.

Multi-language drilling software

The Tallest Building & the Deepest Well

Dubai has several wonders. Among them is the Burj Khalifa: the tallest building in the world (828 m, 165 floors).

Burj Khalifa

Burj Khalifa

It looks like a needle piercing the sky, like a scene from Star Wars. Calling it a landmark would be an understatement. There are more than 1700 high-rises in Dubai. Every building has a different shape. But when compared with Burj Khalifa, other buildings are like chicks and Burj Khalifa is like a huge, elegant crane…

I was in Dubai to teach a cementing software course. I would not miss the opportunity to visit it. The ticket to go up was AED 100 Dhs ($33) if booked on line or AED 400 Dhs if purchased on-site. And you have to select a particular time slot, e.g., 9:30am. The most popular time slots from 4:00pm to 8:00pm are often sold out.

It took the elevator less than 1 minute to rise from the ground to the 124th floor. Visitors can step onto the terrace on the 124th floor and see the world sinking to the bottom.

The World Below

The World Below

I felt like I was on top of the world and wondered what kinds of challenges they had to face to build this dream. I am almost certain that one of them was financial. The tower was originally named Burj Al Dubai. During the late phase, it was renamed Burj Khalifa to honor the UAE President for his injection of much needed money, the critical blood of life, to complete the construction.

This blood of life must have originated from another type of blood: oil, especially in the Middle East.

Talking about the quest for oil and gas, the deepest well ever drilled is Russia’s Kola Superdeep Borehole with the deepest point below the surface (12,262 m or 40,230 ft).

Tallest building and deepest well comparison

Comparison

For the sake of comparison, I put the tallest and deepest points together on this graph.

Doing simple math, we can find that for every 1 meter of the tallest building, we drilled 14.8 meters of rock.

It is much easier to drill a well than build a skyscraper.

Between Me and the Sun is the Umbrella

Dubai. 1:00pm. 42°C. I finished the software training and planned on heading to the neighboring Mall of the Emirates to eat at an Iranian restaurant for lunch. It was brutal outside: millions of the sun’s rays hit the sandy surface. The scorching heat was a monster engulfing every living creature outside.

The idea hit me that I should get an umbrella. Upon my request, the hotel staff fetched a slim umbrella with a clear plastic film. Looking surprised, I asked, “Is this for rain or the sun?”

“It is specially designed to protect you from the sun,” he explained.

On my way to the mall, under the sun and the clear umbrella, I could not help but laugh at myself: the sole purpose of an umbrella in a city, where any rain would be newsworthy, is probably for the sun. How could I overlook something so obvious?

Maybe the clear plastic was a high-tech material such as ceramic that blocked more UV rays than cloth, while still allowing you the pleasure of viewing your surroundings, just like the window coating on my car. When I did my front side window coating, the shop technician told me that the clear one (not the dark coating) actually blocks more harmful rays.

Suddenly, it did not feel as hot under the umbrella. It might have been the film rejecting the heat or just my wishful thinking. To verify this, I extended my hand and arm outside of the umbrella and pulled them back in. You know what? It felt noticeably different: it was much less irritating when my hand and arm were under the umbrella. I repeated the experiment and was pretty sure about my feeling. I even closed my eyes when doing it.

Upon entering the mall, I collapsed the umbrella. Of course, there was no rainwater forming earthworms on the floor. But I could almost feel millions of heated air molecules falling and bumping around.

Luxurious yet Affordable

Dubai was such an eye-opening experience for me. People elsewhere may have to cut down trees to build a concrete forest, while Dubai is transforming the desert into vertical cities. I stayed in a new business area called Al Barsha. A couple of years ago, it had nothing but sand. Now, the shining glass buildings are like mushrooms, no, actually more like bamboo reaching up to the sky.

My hotel was close to the new mall (Mall of the Emirates). Can you believe that they have an indoor ski inside called Ski Dubai?!

Ski Dubai from outside

Figure 2: Ski Dubai from outside

 

Inside Ski Dubai

Figure 3: Inside Ski Dubai

My daughter and I had a good time in this first indoor ski resort in the Middle East. The full day access to the snow park was AED 130 Dhs (US $36) and the 2-hour ski pass was AED 180 Dhs (US $50). Although high for entertainment expenses, it is affordable for ski fanatics: they do not need to fly to snowy countries to ski.

The landmark of Dubai is Burj Al Arab, one of the most luxurious hotels in the world, as shown in the first picture. Its rates start from AED 5000 Dhs (US $1389) per night.

But there are many decent hotels with prices below US $200/night.

Luxurious yet affordable: that is Dubai. That is also Dr. DE, our drilling engineering toolbox software.