Hello everyone. My name is Jose Chapa and this is my FE1 local review presentation. (NEXT)
The outline for this presentation is as follows:
I will talk a little about my academic background and work history
The safety culture I have adopted with Baker Hughes
The engineering and operational aspect of my job
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We begin with my education. I received Bachelor of Science in Biology in 2004 from Texas A&M International, a small school in Laredo, TX. While working as a middle school science teacher, I went back to school and received my Master of Science in Biology in 2010.
After graduating, I was offered the opportunity to teach at my alma mater. I was assigned Biology lectures and labs for two semesters before the grant that paid my salary was lost.
Soon after that, Halliburton hired me to test drilling fluid samples in their Laredo, TX laboratory. I would test rig samples and compare results with mud engineers, and I would test mud that would be reconditioned and sold back to the customer. During that time, I would also assist with routine testing for cement samples.
I used what I learned in cement to get a job as a cement technician for Superior Energy Group (their pressure pumping division is now Warrior Energy) out of Yancey, TX. As their only cement tech I was forced to quickly learn how to troubleshoot equipment and efficiently pilot test slurries. Being one of two contacts for the lab, I worked closely with the bulk plant and the engineers whenever problems arose (i.e. short blend sampling).
About two years ago, I joined the Baker Hughes team as a cement technician in the San Antonio lab. I used what I learned at previous jobs to help organize the lab and to train the other lab techs to perform cement tests new to San Antonio. One of those was the infamous dynamic settling test. Again, I worked closely with the lab coordinator, bulk plant, and engineers, always making suggestions to increase efficiency and safety.
About a year later, I received the opportunity to be part of the LEAD program for engineers. Since then, I have spent a lot of time training in Tomball, out on the field, and in the lab working to meet the requirements for promotion to an FE2. (NEXT)
The one element that kept popping up in training, regardless of where this was, was safety. Baker Hughes has a safety culture unlike any I have seen before. Of course, other companies have safety trainings, but it is encouraging to know that the majority of Baker Hughes employees take safety seriously and that they are looking out for you.
One of the initiatives I was introduced to was aiming for a “Perfect HSE Day”. Zero recordable injuries, zero motor vehicle accidents, zero serious environmental spills or releases.
The “Life Rules” are important reminders of the top critical hazards that help every Baker Hughes employee to make every day a Perfect HSE Day.
These were meant to reduce the possibility of serious injury or death, understand potential workplace hazards, use proper precautions to manage risks, and work together safely and go home healthy. (NEXT)
Some other Life Rules include securing tools to prevent them from falling, always using Lockout-Tag-Out process, never entering a confined space without a permit, and being fit to perform your duties.
The other seven Life Rules include:
Secure tools and equipment to prevent them from falling or being dropped
Use “bow-tie” risk analysis for each job; focuses on People, Process, Equipment
Always use Lockout-Tag-Out (LOTO) process
Position yourself in safe zones in relation to moving objects
Never enter confined space without authorization
Work with a valid work permit when required
Be fit to perform duties assigned to you (NEXT)
Let us focus on that last Life Rule for a quick safety moment.
It is important for our safety and the safety of the ones around us to be fit and well for the job that is assigned to us.
(read bullets)
If we are out on the field, we need to remember to stay hydrated and take breaks when possible.
It is not ever easy to get good rest in this type of work, but we need to know our limitations and ask for help if necessary.
We should also be able to recognize our co-worker’s limitations and offer help.
I remember not too long ago, Edgar needed to drive to Houston but he hadn’t slept. Steve stepped in and drove him. (NEXT)
Other HSE programs are targeted to more specific hazards, like dropped objects and pinch points.
Focusing on hand safety is important because (read bullet).
The upstream safety process is a systematic approach to minimize the likelihood of an event that could lead to loss of well control.
Things like preparing Hazard and Risk Assessments, being familiar with policies and procedures on BHOS, and reporting near misses through the SOS observation system can prevent such events. (NEXT)
The outline for the technical part of the presentation is as follows:
(Read bullets)
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A wellbore is drilled from the top down in several stages. Each stage is deeper and narrower than the one above it. Each stage of the wellbore is lined with casing and that casing is set in place with cement. This is done by circulating cement slurry down the inside of the casing, out the bottom, and into the annulus between the casing and the borehole or two different casings.
This is considered Primary Cementing.
Secondary or Remedial cementing consists of repairing primary cementing jobs with squeezes and plugs.
The idea, of course, is to cement the wellbore right the first time and avoid remedial cement jobs.
Cementing the casing is beneficial because it:
Isolates water and hydrocarbon zones from each other
Protects well casing from formation pressure and corrosives
Establishes a base for mounting well control equipment (NEXT)
Regardless of the customer’s well condition, Baker Hughes has the technology and expertise to deliver high-quality, efficient cement operations.
A good cement job starts with good cementing practices, and good cementing practices begin with designing a slurry that matches the characteristics of the wellbore.
Customer provides us with…(read bullets)…and other information relevant to the design
When designing the slurry…(read bullets)
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Once a slurry design is chosen, we can simulate pumping the slurry downhole using the CemFACTS software.
Historical data for the fluids can be used, but the simulation works best when the actual fluids have been tested and the
rheology data is input into the software.
This software:
Monitors and analyzes multiple fluids, as well as pump rates and shutdowns
Hydraulic simulator calculates pressures at surface, bottom, and critical depths (ECD)
Provides a mud cleaning indication based on fluid friction hierarchy
Shares data with the WellTemp software application (NEXT)
This software:
Calculates the wellbore and formation temperature profile during fluid circulation and cement placement operations
Considers multiple fluid properties
Shows multiple formation layers (NEXT)
Other software not commonly used:
Isovision
Calculates the initial and induced stresses on the cement sheath
Displays results graphically along with a pass/fail indication
Plug Cement Wizard
Allows the user to input wellbore and fluids information to accurately identify where a balanced cement plug should be placed
Cover sheet
Customer information
Job at a glance
TVD, MD
Hole size
Casing size
Fluids
Well Data
Volume calculations
Landing collar
Top of lead and tail
Fluid specifications
Spacer
Cement slurries
Displacement
Cement properties
Price estimate (NEXT)
The lab takes the lab request, inputs it into the cement database, and prints out a weigh-up sheet.
The sheet will let the lab know, in grams, how much of each bulk product or additive to mix.
Every cement product is properly labeled and updated as soon as new lot numbers or grind dates are available.
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(Discuss typical production slurry)
TVD: total vertical depth
MD: measured depth
BHST: bottom-hole static temperature
FF: free fluid
FL: fluid loss
CS: compressive strength
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(Testing Process)
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(Testing Process)
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(Testing Process)
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(Testing Process)
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Once pilots are tested, the bulk plant will blend a short blend and take sample to the lab. If the short blend tests meet the same criteria as the pilots, the bulk plant blends the entire job.
The bulk plant stores all of the bulk product, like cement and fly ash, in the silos on the left. They stores additives that come in sacks on pallets in the warehouse on the right.
The bulk plant has two separate plants each with its own scale tank and holding tanks. Meaning that two separate blends can be mixed simultaneously.
Bulk trucks can be driven up next to the silos and either loaded or unloaded.
The bulk plant is a vacuum system plant and it is controlled with top-of-the-line digital controls. It also has an automatic sample catcher that can be programmed to catch
cement at varying intervals during transfer to a bulk truck. (NEXT)
Bulk Truck
The bulk truck is composed of a tractor trailer with two pods and an air compressor.
Each pod holds approximately 250 cubic feet of cement.
Usually a little less is loaded to allow for proper circulation of air.
Cement Pump
Designed to mix and pump different types of cement slurries at specific densities
Main components include:
Mixing module
Mixing tub and agitator
Density control valve
Mixing water control (NEXT)
Batch Mixer
The purpose is to combine water and a dry product and create a slurry with consistent density before pumping downhole.
We use it to mix spacers but it could be used to mix cement slurries.
The first thing cement operators do is spot the equipment when they arrive at the rig. It is important to spot the equipment correctly and safely
to facilitate the cement job.
Field Silo/Field Bin
Field silos can hold about 1800 cubic feet of material
Field bins (not shown) can hold about 425 cubic feet of material in each of its four compartments. (NEXT)
Once the equipment is properly spotted, the iron and hoses are connected.
Connecting iron and hoses is similar to each other:
The threads are cleaned and oiled
The iron or hoses are pressed together
The wing is hammered to make up the connection
The process is easier when done as a team. (NEXT)
This is a simplified version of the placement of the bulk truck, the pump truck, service supervisor.
During the cementing job, measured amounts of water and dry blended cement are mixed together on the pump truck.
The slurry is then pumped down the casing and up the annulus.
The service supervisor records the job using JobMaster by either connecting a cable directly to the mixing module or by LAN data acquisition. (NEXT)
Cement head functions:
Holds the wiper plugs
Connects cement high pressure line to the casing
Launches the plug during various stages of the cementing operation
Holds back fluid pressure coming up the casing
Common procedure includes:
Break circulation with fresh water
Drop bottom plug with 3 bbls of fluid
Shut down and load top plug
Pressure test
Pump spacer, lead, tail
Stop and drop top plug
Displace
Bump plug (NEXT)
JobMaster records all data, which can be displayed as an x/y chart.
The most typical parameters chosen are Pressure (psi), Discharge Rate (bpm), and Density (ppg) over time.
(Describe chart)
These Job Master charts are sent to the customer along with the proposal, field receipt, and lab report.
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