Saudi Aramco

Drilling Technical Department

July 2021
The Alerts are provided to all Drilling and Workover Operations Foremen and Liaisonmen so that we all learn from the
experiences of others. The knowledge of this incident could prevent similar ones from happening in the future. Saudi Aramco
policy requires the information in this Alert to be communicated to all crew members and documented on morning reports.

What happened?

On July 11, upper completion BAKER S-3 Packer with tail pipe was run to
11,441 ft (30 ft above Top of 4-1/2” Liner). While reverse circulating, pressure
increased suddenly from 970 PSI to 1700 PSI. String was free. Reverse
circulation was resumed with 1 BPM and 2600 PSI. Attempted to RIH upper
completion, tagged 4-1/2” TOL. After spaced out, packer prematurely partially
set at 11,468 ft, had 15K of slack off weight down and free up. POH with upper
completion. Checked equipment on surface and found one part from lower slips
of packer left in hole.

Consequences:

Lost Time of 157 hrs and still ongoing.

Why did it happen?

Initial investigation showed that the packer specification is for 7” 32 PPF

casing/liner. The maximum OD of the packer is 5.875” while the drift of the 7” 35
PPF casing/liner is 5.879”. The clearance is very tight for the S-3 packer to be run
in 7” 35 PPF casing/liner.

What should be done to prevent reoccurrence?

Service company representative, operation along with drilling engineering should

have reviewed the packer specification prior to run it in the well with 7” 35 PPF
casing/liner. Baker S-3 packer with its specification should not be run in 7”
casing/liner higher than 32 PPF. Alternative packer to 7” 35 PPF casing/liner can
be Halliburton THT Packer or Weatherford OPTI Packer.