Technical Support Line: Phone: +1.780.440.4440 | Toll Free: +1.866.640.4440 | USA: +1.877.246.2612 | www.rubicon-oilfield.com Rev 03-2017 Dec stage cementing tools OPERATING MANUAL TYPE 680 – Running Instructions Contents 1. GENERAL INFORMATION 1 2. INSPECTION 2 3. RUBBER SHUT-OFF BAFFLE PLATE INSTALLATION 3 4. INSTALLING AND RUNNING IN STAGE COLLAR 4 5. HYDRAULIC OPENING of STAGE COLLAR 5 6. CONTINGENCY MECHANICAL OPENING of STAGE COLLAR 6 7. USING WEIGHT on BIT (WOB) to CLOSE 7 8. SETTING HYDRAULIC OPENING PRESSURE 8 9. DRILL OUT PROCEDURE 12 Type 680 Hydraulic Stage Tool Plug Set for Type 680 Stage Tool Stage Tool Equipment Top-Co 680 Two Stage Cementing Collars are supplied with: 1. First stage flexible shut-off plug. 2. Rubber first stage shut-off baffle plate. 3. Second stage closing plug. Certain applications will require a landing collar instead of a rubber baffle plate for landing the first stage shutoff plug. First Stage Flexible Shut-Off Plug and Baffle Plate Plugs to be run in order shown from left to right. Second Stage Closing Plug GENERAL INFORMATION 1. Note: Stage tool drill-out materials are all PDC drillable: • aluminum • rubber • phenolic
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Technical Support Line: Phone: +1.780.440.4440 | Toll Free: +1.866.640.4440 | USA: +1.877.246.2612 | www.rubicon-oilfield.com Rev 03-2017 Dec
stage cementing tools
OPERATING MANUAL TYPE 680 – Running Instructions
Contents 1. GENERAL INFORMATION 1 2. INSPECTION 2 3. RUBBER SHUT-OFF BAFFLE PLATE INSTALLATION 3 4. INSTALLING AND RUNNING IN STAGE COLLAR 4 5. HYDRAULIC OPENING of STAGE COLLAR 5 6. CONTINGENCY MECHANICAL OPENING of STAGE COLLAR 6 7. USING WEIGHT on BIT (WOB) to CLOSE 7 8. SETTING HYDRAULIC OPENING PRESSURE 8 9. DRILL OUT PROCEDURE 12
Type 680 Hydraulic Stage Tool
Plug Set for Type 680 Stage Tool
Stage Tool Equipment
Top-Co 680 Two Stage Cementing Collars are supplied with: 1. First stage flexible shut-off plug. 2. Rubber first stage shut-off baffle plate. 3. Second stage closing plug.
Certain applications will require a landing collar instead of a rubber baffle plate for landing the first stage shutoff plug.
First Stage Flexible Shut-Off Plug and Baffle Plate
Plugs to be run in order shown from left to right.
Second Stage Closing Plug
GENERAL INFORMATION 1.
Note: Stage tool drill-out materials are all PDC drillable: • aluminum • rubber • phenolic
Technical Support Line: Phone: +1.780.440.4440 | Toll Free: +1.866.640.4440 | USA: +1.877.246.2612 | www.rubicon-oilfield.com Rev 03-2017 Dec
stage cementing tools
OPERATING MANUAL TYPE 680 – Running Instructions
Sequence of Operation:
Step 1: Stage collar in running-in and first stage cementing position. First stage shut-off plug will pass through stage cementing collar while displacing first stage cement, landing on baffle plate located in float collar.
Step 2: Hydraulic Opening - Opening sleeve shifted down after opening through application of pressure, allowing second stage cement to be displaced through ports.
Step 3: Second stage closing displacement plug landed in stage cementing collar. Application of pressure will close the stage collar ports. Two stage cement job is complete.
• Inspect stage collar and auxiliary equipment upon arrival at location. • Check stage collar for dents, damaged threads, etc. • If present, remove all plastic port plugs from the tool OD. • Check inside of stage collar for any foreign debris; dirt, cutti ngs, etc. • Check closing plug to verify that it will seat properly in stage tool. • Ascertain that the first stage flexible plug will seat properly on the baffle plate. • Verify that the cementing head contains no foreign plugs or objects. • If first stage flexible shut-off plug and second stage closing plug are to be pre-load in cementing head, verify
that the plug release mechanism is operable, that the retaining mechanism is sufficient to retain the first-stage flexible shut-off plug and the second-stage closing plug.
• Verify that the nose of the second stage closing plug will pass through the ID of the cement head or any joints or tools between the cement head and the casing.
• If for some reason it is felt that the cementing head cannot properly retain the first-stage flexible shut-off plug, it will have to be loaded by hand.
INSPECTION 2.
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stage cementing tools
OPERATING MANUAL TYPE 680 – Running Instructions
RUBBER SHUT-OFF BAFFLE PLATE INSTALLATION
Before running casing, install rubber shut-off baffle plate on top of float collar with tapered sid up.
a. For API Buttress and 8RD connections, the rubber baffle is press fit into the box end of the float equipment. The pin of the casing will hold the baffle plate in place once the float equipment is installed on the casing.
Note: Thread lok can be used to hold the baffle in place.
b. For premium connections, the first-stage shut-off baffle plate should be installed by mixing up thread lok compound and placing thread lok on the top exposed surface of the float collar. (It is recommended that a cloth be placed in the circulation port of the float collar during this operation to prevent thread lok from dropping down into the valve). Apply the thread lock onto the cement at the bottom of the box threads. Press the baffle plate firmly onto the thread lock while centering it in the bore. Allow the thread lok to cure until the baffle plate is held in place (usually about 60 minutes).
Rubber Baffle Plate
IMPORTANT:
The rubber shut-off baffle plate should not be used on float equipment with tapered surfaces, such as ball-activated differential or auto-fill float equipment. It is recommended that both a Float Shoe and a Float Collar be run for two-stage cementing. This gives maximum assurance that the cement is retained in the desired location upon completion of displacement of first stage cement.
3.
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stage cementing tools
OPERATING MANUAL TYPE 680 – Running Instructions
1. Run casing and install Top-Co 680 Stage Cementing Collar at desired depth. Thread lok must be applied to the
stage collar pin. Do not use casing tongs or any other type of tong, on any part of the stage collar body during installation.
Body NO Tongs Permitted
The reduced diameters at the box and pin end of the stage tool can be tonged for make-up purposes. 2. Run casing and install Top-Co 680 Stage Cementing Collar at desired depth. Thread lok must be applied to the
Stage Collar pin.
4.2 METHOD A
a. Screw the stage collar onto the casing string and torque as per thread requirements. IMPORTANT: Tongs can ONLY be placed on the reduced diameters on the box and pen end of the stage tool during make-up to the casing (Reference EB- 38).
b. Insert the pin from the next casing joint into the box of the stage collar and torque as per the thread requirement.
c. If thread lok is being used ALWAYS apply to the pin not the box.
4.2 METHOD B
a. Partially thread the stage collar pin onto the casing string. b. Position pin of next casing joint in box end of stage collar. c. Apply torque to casing above stage collar to tighten joints. d. Torque casing as per thread requirements.
IMPORTANT: Tongs can ONLY be placed on the reduced diameters on the box and pen end of the stage tool during make-up to the casing (Reference EB- 38). e. If thread lok is being used ALWAYS apply to the pin not the box.
3. Run casing to total depth. 4. Circulate to condition the hole and the drilling fluid. 5. Mix and pump First Stage Cement into casing. 6. Launch from cementing head first-stage flexible shut-off plug on top of first-stage cement. If first-stage flexible
shut-off plug is loaded in cementing head, do assure that the plug release mechanism is sufficient to retain the first-stage flexible shut-off plug. If it is felt that the cementing head’s plug release mechanism is insufficient, the plug should be loaded by hand to avoid premature releasing of the first stage flexible shut-off plug.
INSTALLING AND RUNNING IN STAGE COLLAR 4.
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stage cementing tools
OPERATING MANUAL TYPE 680 – Running Instructions
7. Start pumping calculated amount of fluid to move first stage flexible shut-off plug to the float collar. It is highly
recommended that the pumping rate be slowed to 0.5 cu.meter/minute (3 bpm), as the flexible plug is pumped through the stage collar (Do not exceed 0.8 cu.meter/minute or 5 bpm when pumping through stage collar). After the plug passes through the stage collar, resume the regular pump rate and pump the total calculated amount of displacement fluid necessary to land the first stage flexible shut-off plug at the rubber shut-off baffle.
8. Pressure 3.447 MPA (500 psi) over circulating pressure to seat the plug in baffle plate. 9. Release the pump pressure against the first-stage flexible shut-off plug and check the float shoe / float collar
for flow back. Record the amount of fluid bled back to the pumping unit. This information may be helpful later in determining if the opening dart is in place.
1. With the float shoe / float collar holding back pressure, pressure float collar.
If an external casing packer is being used, increase pressure to inflate and set the external casing packer. 2. Apply pressure to casing until Stage Tool hydraulically opens. Opening pressure to be set before running as per
Section 7.0 and Table 1 (Opening Pressure Hydraulic). 3. When stage collar opens, circulation can be established to condition the hole. After conditioning of the hole,
circulation should be maintained at a lesser rate until second-stage cement is ready to be pumped. This will prevent solids in the drilling fluid from settling in the stage tool and preventing proper shifting of closing sleeve.
4. Mix second stage and pump into casing. 5. After second stage cement slurry is pumped, release second stage closing plug from plug loading head. (Or
release manually if plug loading head is not used). Verify that the plug has left the head. Cement lines may or may not be washed out before dropping the plug.
6. Maximum rate of pumping cement through the stage tool should be 5 – 8 bbl. /min. Pump the calculated amount of fluid to seat second closing plug in the stage collar. As the closing plug approaches the stage collar, for the last 5 barrels slow the pump rate to a flowrate between 2 bpm and a flow rate (in bpm) equal to half of the casing diameter in inches, up to a maximum of 8 bpm. (Example: 7" tool = 2.0 - 3.5 bpm)Monitor pressure and check for bumping of the plug.
7. When closing plug seats in stage collar, pressure as indicated in Table 1 (Closing Pressure) above circulating pressure to close stage collar.
8. Hold pressure for 5-10 minutes to assure stage collar has shifted to closed position. 9. Bleed off pressure; check for flow back to make sure the stage collar is locked in the closed position. If excessive and
continued flow back is observed, gradually increase pressure by 500 psi above the maximum closing pressure on Table 1. Increase pressure again by another 500 psi and hold for 10 minutes. Pressure should be increased for a third time by another 500 psi and held for 10 minutes then bleed off.
JOB IS NOW COMPLETE.
Note: These are the primary instructions recommended for use when operating the Type 680 Stage Collar. In the event that unforeseen circumstances arise; due to wellbore conditions or other factors; it may be necessary to deviate from these instructions.
HYDRAULIC OPENING of STAGE COLLAR 5.
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stage cementing tools
OPERATING MANUAL TYPE 680 – Running Instructions
CONTINGENCY MECHANICAL OPENING of STAGE COLLAR
1. With the Float Shoe / Float Collar holding back pressure, open cementing head and drop the aluminum second stage opening dart. Important: Allow time for opening dart to free fall to the stage collar. If well bore inclination is greater than 25º, the tool cannot be operated mechanically (dart does not free fall). Normal free fall rate would approximately be 300m per 5 minutes or 200 feet per minute. Mud weight and hole deviation may alter free fall time.
2. When opening dart is seated in the Stage Collar, pressure up as indicated in Table 1. (Opening Pressure Me- chanical) to open the stage collar.
3. When stage collar opens, circulation can be established to condition the hole. After conditioning of the hole, circulation should be maintained at a lesser rate until second-stage cement is ready to be pumped. This will prevent solids in the drilling fluid from settling in the stage tool and preventing proper shifting of closing sleeve.
4. Mix second stage and pump into casing. 5. After second stage cement slurry is pumped, release second stage closing plug from plug loading head. (Or
release manually if plug loading head is not used). Verify that the plug has left the head. Cement lines may or may not be washed out before dropping the plug.
6. Maximum rate of pumping cement through the stage tool should be 5 – 8 bbl. /min. Pump the calculated amount of fluid to seat second-closing plug in the stage collar. As the closing plug approaches the stage collar, for the last 5 barrels slow the pump rate to 2 barrels (0.32 cu. Meter) per minute for casing size 10 ¾”/173mm and higher, and to 1 barrel (0.16 cu. Meter) per minute for casing size 9 5/8” and smaller. Monitor pressure and check for bumping of the plug.
7. When closing plug seats in stage collar, pressure as indicated in Table 1 (Closing Pressure) above circulating pressure to close stage collar.
8. Hold pressure for 5-10 minutes to assure stage collar has shifted to closed position. 9. Bleed off pressure; check for flow back to make sure the stage collar is locked in the closed position. If excessive and
continued flow back is observed, gradually increase pressure by 500 psi above the maximum closing pressure on Table 1. Increase pressure again by another 500 psi and hold for 10 minutes. Pressure should be increased for a third time by another 500 psi and held for 10 minutes then bleed off.
JOB IS NOW COMPLETE.
Note: These are the primary instructions recommended for use when operating the Type 680 Stage Collar. In the event that unforeseen circumstances arise; due to wellbore conditions or other factors; it may be necessary to deviate from these instructions.
6.
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stage cementing tools
OPERATING MANUAL TYPE 680 – Running Instructions
1. Tag the closing plug with BHA. 2. Mark the drill string when the closing plug has been tagged. 3. Apply the minimum weight to close the tool. Increase the weight until movement of the mark is seen or up to
the maximum closing weight. Refer to Table 1 for closing loads. Approximately 3-1/8” movement indicates the tool is closed.
4. If the tool has not shifted when the maximum weight is applied and held for 1 minute, increase the load by 15%. 5. Again, approximately 3-1/8” confirms the inner sleeves have shifted to the close position.
JOB IS NOW COMPLETE
Note: These are the primary instructions recommended for use when operating the Type 680 Stage Collar. In the event that unforeseen circumstances arise; due to wellbore conditions or other factors; it may be necessary to deviate from these instructions.
USING WEIGHT on BIT (WOB) to CLOSE 7.
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stage cementing tools
OPERATING MANUAL TYPE 680 – Running Instructions
1. The opening pressure of the stage tool is controlled by the number of shear screws (Figure 1) used on the body (see Table 1). The standard factory setti ng is for maximum opening pressure as listed in Table 1.
2. All shear screws removed need to be replaced with alu- minum Blank Screws to prevent debris from entering the stage tool body; see Figure 2.
IMPORTANT: The shear screws are not to be confused with the guide screws which can be identified by 2 holes drilled into the head. Do not remove or replace the guide screws.
3. The opening pressure shear screws are the bottom set of
screws (from the pin end); see Figure 3. DO NOT REMOVE OR ADJUST THE CLOSING SHEAR SCREWS (THREAD-LOK).
4. Determine the required hydraulic opening pressure and remove shear screws until required opening pressure is obtained. When removing screws, use an alternating pattern (i.e. 1st, 3rd, 5th around the tool) DO NOT REMOVE MORE THAN 6 OF THE 8 SHEAR SCREWS.
5. The shear screws have a right hand thread. Using a slotted screw driver, they are removed by turning them counter clockwise (Figure 4).
6. Care must be taken to ensure that, while the screws are being removed, no foreign objects land in shear screw holes.
7. Install the blank screws using a slotted screw driver, rotating them clockwise (Figure 5)
8. The blank screws should be tightened until the screw bottoms out.
9. If shear screws are being installed they should be peened to the stage tool body to lock them into place. The shear screws are peened with a hammer and punch. The punch should be placed at the joint between the Stage Collar body and the shear screw, and given a sharp hit with the hammer, the hit being hard enough to indent both body and shear screw. Only the shear screws need to be peened, not the blanks (Figure 6).
10. This is an optional procedure to peen the shear pins for the T680. It is only used if concerns about the screws backing off.
Note: Unless otherwise specifi ed, all Type 680 Stage Collars are shipped with a full set of shear screws in place.
Top-Co standard Stage Collars are equipped with aluminum sleeves that can be drilled using a PDC or Tri-Cone bit. Likewise, the opening dart and closing plug are made from a combination of rubber, phenolic plastic and aluminum and are also drillable with the same type of bits.
Top-Co Stage Collars with Phenolic Seats can be drilled using a PDC or Tri-Cone bit. Likewise, the opening dart and closing plug are made from a combination of rubber, phenolic plastic and are also drillable with the same type of bits.
During cementing of the 2nd stage, it is recommended to spot some cement slurry on top of the closing plug to help prevent the plugs from rotating during drill out. If drilling out the stage tool in a production casing, the use of a junk basket is recommended.
• Do not drill in automatic mode; maintain manual control at all time. • Do not start drilling after WOB has been established. Begin rotation before engaging the stage tool. • Drill at least 80-100 RPM. Caution: NEVER EXCEED 100 RPM. • Do not exceed 10,000 lb. WOB • Do not spud on target while drilling out. • Use a pump rate that will circulate cutti ng without decreasing bit weight on the target. • Raise and lower the bit occasionally while continuing to drill. This action will help clear junk from the bit. • Do not exceed the torque limit torque indicated on table (Table 1), keep within 70% of the maximum torque
limits during drill out. • After Drill Out is complete, pass rotational drill bit thru stage tool several times to assure Stage Collar is cleaned
out of debris.
DRILL OUT PROCEDURE
DRILLABILITY
PREPARATIONS
DRILL OUT 9.3.
9.2.
9.1.
9.
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