Application of Hydraulic Port Collars in Two Stage Cementing Operations Reduces Rig Time/Drilling Cost in the Permian Basin

Abstract

Operators in the Permian Basin have been performing two stage cementing operations on their casing strings for decades utilizing conventional diverter tool technology, often in combination with casing annulus packers. Over time, issues with legacy diverter tools (DV) have been identified and solutions sought. These issues range from longer than desired time to drill-out the DV tool, reluctance to drill-out a DV tool with a directional assembly due to drill bit dulling and premature drilling motor/MWD failures, damage to the DV tool while drilling causing leaks and remediation, and an inability to pressure test the whole casing string after cementing. A development effort was made to eliminate these issues. The Hydraulic Port Collar (HPC) was designed and extensive qualification/testing of the HPC design was performed prior to field deployment. Running procedures were written and revised in consultation with a variety of operators. Several wells were identified for field trials. The wells were selected based on the operator’s desire to eliminate a DV tool drill-out. The wells had complex directional plans that required high bend drilling motors resulting in the operator’s reluctance to drill-out conventional DV tools with the curve BHA’s. The hydraulic port collar functioned as designed on all field trials. Pressure readings from the cement trucks confirmed the tools opened within the calculated pressures and closed and sheared out within the calculated pressures. Full communication of compressed volume, from the float collar to surface was achieved, allowing the operator to perform a full string casing test. The wiper plug was mechanically confirmed as released from the HPC and subsequently pushed to bottom and drilled up when the shoe track was drilled out. Utilizing curve BHA’s with 2.12° to 2.38° bend motors, all wells were drilled and landed in the drilling window with one curve BHA run. As a result, dedicated DV tool drill-out runs were eliminated, no unusual damage or dulling of the curve BHA was observed and no post drill-out damage/leaks at the HPC were experienced. A review of the field trials showed efficiency gains up to 40% when compared to previous operations where legacy DV tools had been deployed. These trials confirm that the novel Hydraulic Port Collar can increase operator efficiency in wells that require two stage cementing operations. This paper will document case histories and lessons learn to date.