DOWN HOLE EQUIPMENT FAILURE

DOWN HOLE
EQUIPMENT
FAILURE

An interruption in planned operations caused by drilling /evaluation tool failures other than drill string
failures. Down hole tool selection and operation is critical in the reduction of tool failure

DOWN HOLE EQUIPMENT CYCLE

Drilling engineer specifies equipment
Drilling foreman orders equipment
Toolpusher inspects/checks equipment
Driller picks up/runs equipment
Rig team post analyzes equipment

HIGH FAILURE RATE DOWNHOLE TOOLS

FAILURE

DOWN HOLE TOOL

ROLLER CONE BITS
.
DOWN HOLE MOTOR
.
SHOCK SUB
.
DRILLING JAR
.
MWD / LWD
.
LOGGING

Lost cones (most common fishing job)

.
Motor stops drilling
.
Seal washout
.
Untrained personnel
.
Dump valve, software, LCM plugging
.
Last-minute changes, inexperienced operators, no maintenance

SURVEY EQUIPMENT

Film, batteries, wireline failure, insufficient bar weight

SPECIALTY EQUIPMENT

Untrained personnel, unproven technology

PACKER / DST TOOLS

Leaks, packer does not release, incompatible with other tools, high angle
holes

CAUSE OF TOOL FAILURE

CAUSE
METAL FATIGUE
.
IMPROPER TOOL SELECTION
.
IMPROPER TOOL OPERATION
.
EXCEEDED DESIGN LIMITS
.
EXCEEDED DESIGN LIFE
.
TRANSPORTATION /
HANDLING DAMAGE
.
HOSTILE ENVIRONMENT
DESIGN / MANUFACTURING

NOTE
Cyclic stress reversals
.
Loads exceed design limits, incompatible with other tools
Untrained personnel, inattention
Accidental /intentional overload
Economic based, untrained personnel
.
Untrained personnel

H2S, CO2, high temperature, corrosive mud, high angle, hard abrasive
formations

Quality control failed

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DOWN HOLE EQUIPMENT FAILURE

Selecting the right tool for the job can significantly reduce tool failure. Following a standardized tool selection procedure ensures
the right tool is selected

FACTORS THAT INFLUENCE THE TOOL SELECTION PROCESS

FACTOR

INQUIRIES
WELLBORE CONDITIONS

DOWN HOLE
ENVIRONMENT

TOOL PHYSICAL
PROPERTIES

COMPATIBILITY
OPERATIONS

Temperature limitations of tools

H2S, CO2, Corrosion resistance
Oil resistant rubber goods
Hydrostatic pressure limitations
Hole angle limitations
Hole size versus tool size
DIMENSIONS
Length, OD, ID of tool
Weight and grade
Connection type
Special make up torque requirements, thread dope
Stress relief features
Connections compatible with other down hole equipment
Will tool work with other equipment
OPERATING PARAMETERS
Minimum / maximum flow rate
Minimum / maximum operating pressure
Torque / tension limitations
Recommended operating hours
Is a tool operator needed / provided
Special handling tools required
Are special operating instructions required/provided
Operating manual provided
Safety recommendations
Settings / calibration data
Maintenance requirements
FISHING TOOL METHODS

FISHING
Tool dimensions diagram provided
Required fishing tools / ease of fishing
Fishing records available
Tool lost-in-hole consequences

SUPPORT

QUALITY
CONTROL

COST

LIMITATIONS

Back up tools readily available / delivery time

Are spare parts needed / readily available
Transportation problems / hazardous cargo
Air transportable
Required deck space / deck load
RELIABILITY OF TOOL
New or rebuilt tool
Hours since last rebuilt / inspection records
Performance record of tool on offset wells
Performance record of tool worldwide
Operating/standby rental rates / repair agreements
Lost-in-hole charges / insurance
Success/failed performance rate
Depth / external pressure limitation
Yield strength
Drilling fluid - Oil, LCM, Hematite
Battery packs

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DOWN HOLE EQUIPMENT FAILURE

Following a standardized check list when the tool arrives insures the right tool has been shipped and was not damaged in transit

RIG-SITE TOOL INSPECTION CHECK LIST

ITEM
PAPER WORK

CHECK POINTS
Verify equipment quantities and types

Ensure serial / model numbers on the tool agree with the order form, cargo manifest and
inspection report

Locate the operating manual, special instructions (if any), settings and calibration sheet, tool
dimensions diagram and parts list

Damaged containers may indicate damaged tool

PHYSICAL
CONDITION

Missing or damaged parts and spare parts

Thread protectors installed on tools and crossovers

Thread and sealing shoulder damage

Tool bore and other circulating ports are free of debris

Explosive / corrosive tools and materials are clearly marked

Correct connections size, type and BSR

COMPATIBILITY
Connection stress relief features match features of the drill string

Handling / operating tools are compatible with rig equipment

Plugs / wireline tools will pass through tool

Bolt pattern, bolts, gaskets are correct

OPERATION

Function test values, flappers, etc. before running tool in hole

Cross-over subs are correct, BSR's are checked

Identify and mark new technology tools

TOOL FAILURE PREVENTION

RECOMMENDATION

TOPICS
UNFAMILIAR /NEW
TECHNOLOGY
TOOL
OPERATING
MANUAL
AWARENESS /
REFRESHERS

Hold a pre-job safety meeting focused on the safe and proper operation of the tool.

If an operator

is provided, allow the specialist to make the presentation

Make available to the Driller, an operations manual for each tool that requires special operating
procedures (i.e., jars)

Pre-tour safety meetings with written Tour Operations Plan,

current/next operations section.

Driller Hand Over Notes with

Discuss operation of unfamiliar / new technology tools

.
TOOL FAILURE
REPORT
SERVICE /
EQUIPMENT

When tool failure occurs, file a Tool Failure Report to share knowledge of the failure and
preventive action taken.

A statistical data base can be built with this information

Inferior service and tools provided by supply companies can account for a substantial number of
tool failures,
ratings,

Included in the Tool Failure Report, is a section on supply company performance

An alternative supplier should be considered if ratings indicate high tool failure rate

and/or poor service

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