5-1/2” HWDP HARDBAND & 5-1/2” G105 DP

WASHOUT FAILURE
 UNPLANNED EVENT REPORT (UER) # RIG-GERD

DESCRIPTION:

- WHILST DRILLING THE 8.5” SECTION ON 5-1/2” G 105 DP & 5-1/2” HWDP W/FH DSTJ
CONN, OBSERVED PRESSURE DROP IN THE STRING & UPON POOH OBSERVED 1 JT
OF 5-1/2” G105 DP WASHED OUT ON THE RECESS AREA. ALSO OBSERVED THE
ARNCO 350XT HARDBAND ON THE 5-1/2”HWDP ERODED/FAILED.

CAUSE:

- AT THIS INITIAL STAGE OF INVESTIGATION, THE ROOT CAUSE COULD BE

ATTRIBUTED TO ABRASIVE WEAR DUE TO FRICTION BETWEEN THE PIPE BODY
AND OPEN HOLE FORMATION.
- THE WASHOUT INCIDENT COULD BE A RESULTANT OF MECHANICAL FATIGUE &
DOWNHOLE DRILLING CONDITIONS (HIGH PRESSURE, FLUCTUATED WOB, RPM,
TORQUE, H2S)
UNPLANNED EVENT REPORT (UER) # RIG-GERD

WASH OUT HARDBAND ERODED

UNPLANNED EVENT REPORT (UER) # RIG-GERD

WASH OUT HARDBAND ERODED

 SUGGESTED CORRECTIVE ACTIONS

SUGGESTED CORRECTIVE ACTION AS BELOW:

- RECALL THE WASHED OUT 5.5” DP & HWDP (HARDBAND FAILED) BACK TO
CONTRACTORS BASE - DONE.

- PERFORM FULL 3RD PARTY INSPECTION & DETAILED ELEMENTAL ANALYSIS,

MICROSTRUCTURAL CHARACTERIZATION (TO REVEAL & IDENTIFY CRACKS ON PIPE
MATERIAL, HARDBAND & DIFFUSION ZONE), FACTOGRAPHY OF FAILED SPECIMEN- TO
REVEAL THE NATURE OF THE FAILURE AND MECHANICAL ANALYSIS (TENSILE, CHARPY
IMPACT TEST)– 3RD PARTY INSPECTION DONE, DETAILED ANALYSIS-PENDING
 DETAILS OF THE EVENT

OGI RENTED 5-1/2’’ DP X 350 JTS & 5-1/2’’ HWDP X 27JTS.

CAT 3-5 INSPECTION WAS PERFORMED ON THE HWDP & DP (CAT-5) TUBULARS
PRIOR TO SENDING TO THE RIG SITE ON BOTH 5-1/2“ DP & 5-1/2" HWDP

CLIENT REPORTED THAT THE FOLLOWING INCIDENT OCCURRED DURING

DRILLING OPERATIONS DOWNHOLE, RESULTED IN DOWN TIME IN OPERATIONS;

“WHILST DRILLING THE 8.5” SECTION ON 5-1/2” G 105 DP & 5-1/2” HWDP W/FHDSTJ
CONN, OBSERVED PRESSURE DROP IN THE STRING & UPON POOH OBSERVED 1 JT
OF 5-1/2” G105 DP WASHED OUT ON THE RECESS AREA. ALSO OBSERVED THE
ARNCO 350XT HARDBAND ON THE 5-1/2”HWDP ERODED/FAILED.

NOTE: DDR-DAILY DRILLING REPORT FOR THE DAY OF THE INCIDENT IS YET
TO RECEIVE FROM THE CLIENT
 INTERNAL INVESTIGATION & NCR DETAILS

SEQUENCE OF EVENTS :

- BASED ON THE CALL OUT RECEIVED FROM CLIENT-BORR AS PER RENTAL CONTRACT OGI-RC-
0823- 0194, 3RD PARTY INSPECTION (TUBESTAR) PERFORMED ON THE PIPE ON 24TH OCT 2023

 EQUIPMENT DELIVERED TO RIG AS PER DELIVERY NOTE # OGI-SE-0866 & OGI-SE-0929

 UER NOTIFICATION FROM THE CLIENT RECEIVED ON 22ND JAN 2024.

 INTERNAL NCR OPENED IN OGI SYSTEM 10TH FEB 2023 ( NCR/01/1023)

 INITIAL VISUAL INSPECTION FINDING RESPONSE CONVEYED TO THE CLIENT ON FEB 6TH
2024

 HAD DETAILED INSPECTION BY 3RD PARTY INSPECTION COMPANY (TUBESCOPE) AND

DISCUSSED WITH THE INSPECTOR & QAQC INVOLVED IN THE INCIDENT- REPORT YET TO
RECEIVE, SUMMARY RECEIVED ON FEB 9TH 2024.

 SINCE THE INCIDENT IS VERY CRITICAL- DETAILED ELEMENTAL, MICROSTRUCTURAL AND

MECHANICAL ANALYSIS WILL BE PERFORMED TO FIND OUT THE ROOT CAUSE.
 INTERNAL INVESTIGATION & NCR DETAILS

ROOT CAUSE ANALYSIS

AT THIS STAGE, IT IS IDENTIFIED THAT THE PRIMARY CAUSE FOR THE HARDBAND
FAILURE IS ABRASIVE WEAR DUE THE FRICTION BETWEEN THE PIPE BODY & THE
OPEN HOLE FORMATION.

- THE DRILL STRING IS SUBJECTED TO SEVERE STRESS & ABRASION IN OPEN HOLE
FORMATIONS. DOWNHOLE DRAG, TORQUE & DOG LEG/INCLINATION PLAYS A VITAL
ROLE IN STRESSING THE PIPE BODY, AS THE PIPE CONTINUOUSLY WORKS AGAINST
THE WALL OF THE FORMATION (ECCENTRIC ROTATION & VIBRATION).

- DOGLEGS & HIGH INCLINATION ZONES INDUCE SEVERE CYCLIC LOADS, BENDING OF
THE PIPES THROUGH BOREHOLE FORMATIONS. THE ALTERNATING TENSION AND
COMPRESSION CYCLES SEVERELY IMPACT THE PIPE LIFE AND CAN LEAD TO
PREMATURE FAILURE, THE HOLE INCLINATION ON THIS CASE BEING 73DEG.
 INTERNAL INVESTIGATION & NCR DETAILS

ROOT CAUSE ANALYSIS

- EROSION TO TUBULAR TOOL JOINTS CAUSED BY MUD OR HIGH VELOCITY DURING

DRILLING IS COMMON IN DRILLING OPERATIONS, PARTICULARLY WHERE FASTER
DRILLING METHODS ARE USED. THE TOOL JOINT CAN WEAR AT THE LOCATION OF THE
18-DEGREE TAPER. THIS TYPE OF WEAR CAN BE CAUSE FOR DOWNGRADING OF DRILL
PIPE AND HWDP.

- WEAR AT THE TAPER IS CAUSED BY EROSION AND ABRASION FROM DRILLING IN HIGH
ANGLE/DOG LEG ZONES, HARD FORMATIONS, CUTTINGS AND/OR SAND IN THE
ANNULUS IMPINGING UPON THE EXTERNAL UPSET OF THE TOOL JOINT. THE
CUTTINGS IN THE ANNULUS ARE TRANSPORTED TO THE SURFACE BY THE MUD. THE
VELOCITY OF THE MUD MUST BE SUFFICIENTLY HIGH TO ADEQUATELY TRANSPORT
THE CUTTINGS. THE HIGH VELOCITY OF THE CUTTINGS STRIKING THE BOTTOM OF
THE TOOL JOINT CAUSES EROSION OF THE METAL.
 INTERNAL INVESTIGATION & NCR DETAILS

ROOT CAUSE ANALYSIS

THE WASHOUT INCIDENT IS ATTRIBUTED TO FATIGUE & DOWNHOLE DRILLING

CONDITIONS, A WASHOUT IS THE MOST COMMON MODE OF FAILURE ENCOUNTERED IN
DRILL PIPES, MOSTLY DUE TO MECHANICAL FATIGUE DAMAGE & CORROSION. AS WE ARE
AWARE THAT THE DRILLSTRING CONTINUOUSLY UNDERGOES TENSION, COMPRESSION,
BENDING & TWISTING STRESSES DURING DRILLING OPERATIONS PARTICULARLY AT
COMPLEX GEOLOGICAL CONDITIONS & CONTINENTAL DEPOSITION ENVIRONMENTS, THE
DOWNHOLE DRILLING PARAMETERS BHT- BOTTOM HOLE TEMP, SOLID CONTENT & WELL
INSTABILITY SEVERELY IMPACTS THE DRILLING STRING

- A WASHOUT IS A LEAK, CRACK OR A SMALL OPENING IN THE PIPE BODY, CAUSED BY A

HIGH PRESSURE OF DRILLING FLUID/MUD. THE HIGH PRESSURE THAT DRIVES THE
FLOW OF MUD FROM PIPE BORE TO ANNULUS WIDENS & PROPAGATES THE SMALL
OPENING THRU THE PIPE BODY LEADING TO A CATASTROPHIC FAILURE I.E TWIST OFF.
 INTERNAL INVESTIGATION & NCR DETAILS

ROOT CAUSE ANALYSIS

- WASHOUT FAILURES ARE ATTRIBUTED TO PIPE FATIGUE- AS THE STRING UNDERGOES

FLUCTUATED WOB, RPM, ROP & TORQUE, DUE TO BOREHOLE FRICTION- HIGH LEVEL
OF STRESS CONCENTRATION OCCURS AT THE UPSET TRANSITION AREA. THE
TRANSITION ZONE & SLIP AREAS ARE THE WEAKEST ZONES OF THE WHOLE DRILL
PIPE.

- MAJORITY OF WASHOUT FAILURES OCCUR NEAR THE SLIP AREA I.E THE CASE ON
THIS OCCASION, MOREOVER-DIE MARKS FROM SLIPS & TONGS ARE ALSO CAPABLE
OF GENERATING STRESS CONCENTRATION ON THE TRANSITION/DIFFUSION ZONE (I.E
BETWEEN THE TJ TO SLIP AREA) LEADING TO FRACTURE/WASHOUT.
 CORRECTIVE PREVENTIVE ACTIONS

CORRECTIVE & PREVENTIVE ACTIONS

OGI WILL SEND THESE TUBULARS FOR DETAILED TESTING & ANALYSIS. MAKING SURE
ALL RELEVANT DOCUMENTS SUCH AS INVESTIGATION REPORTS & COC AVAILABLE
WITH PROPER TEST RECORD AS PER INDUSTRY STANDARD TO AVOID ANY POSSIBLE
REOCCURRENCE.

- THE INSPECTION COMPANY IS AN APPROVED RENOUNED VENDOR- TUBESCOPE

OGI WILL CONDUCT THE BELOW TESTS

1) ELEMENTAL ANALYSIS

2) HARDNESS TEST- ELECTROMECHANICAL TESTING- TO ANALYSE YS-YIELD STRENGTH,

UTS-ULTIMATE TENSILE & HARDNESS VALUES.

3) MECHANICAL PROPERTY EVALUATION (TENSILE TEST, CHARPY-IMPACT TEST)

4) FACTOGRAPHY OF THE FAILED SPECIMEN TO REVEAL THE NATURE OF THE FAILURE

5) MICROSTRUCTURAL CHARACTERIZATION- TO REVEAL AND IDENTIFY CRACKS ON THE

PIPE MATERIAL, HARDBAND AREA & DIFFUSION ZONE.
 CORRECTIVE PREVENTIVE ACTIONS

CORRECTIVE & PREVENTIVE ACTIONS

- INTERNAL MEMO IS ISSUED TO ENSURE ON SHOP INSPECTION IS DONE AS PER
DS-1 & API STANDARDS, THE 350XT HARDBAND IS DONE AS PER API STANDARDS
FOLLOWING PROPER SOP’S TO MAKE SURE HARDBAND IS 100% BONDED WITH
THE BASE METAL .

NOTE: THROUGH INVESTIGATION, ROOT CAUSE ANALYSIS & CPAR SHALL BE

COMPLETED ONCE RECEIVED THE TUBULARS BACK (TESTED) AND SAMPLES
TESTED.
Tuboscope findings for 5-1/2” G105 DP Washed out Jt
EMI Chart for 5-1/2” G105 DP Washed out Jt
UT/WT for 5-1/2” G105 DP Washed out Jt
Investigation findings
Investigation findings
Tuboscope Findings for 5-1/2” HWDP Hardband eroded
Pre dispatch Inspection report for 5-1/2” g105 21.9# DP
Tubescope inspection reports on backloaded HWDPs

5 1/2”OD R-2, HWDP with 5 ½” FH DSTJ Connections (25 Joints).

Serviceable joints 07 Joints

IPC - Nil

Repairable Joints 17 Joints 05

PIN Recut
Conn’s

12
Damaged Beyond Repair (DBR) 01 Box Recut
Conn’

BOX HEW Nil

07
BOX HBD
Ends
DBR (Rejected due to Strap Welding& Cracked on Tool joint 16”Away from Pin Shoulder). 05
PIN HBD Ends

BENT Nil
Total Joints Inspected. 25 Joints
 Forward Plan

 120 joints of 5 ½” have been inspected at Tuboscope to DS-1 Cat -5 and ready to be mobilized to the rig.
 192 joints of 5 ½” were back loaded and are currently being inspected. We should receive summary for first
batch of 60 joints later today.
 225 joints (75 stands ) of 5 ½” will be kept in the derrick for spud and top hole section on EB-56.
 54 joints of 5 ½” backloaded to be sent for inspection at Tuboscope.
 320 joints of 5 ½” ( brand new ) will be in UAE on 10th April.
 With 120 inspected joints, 320 new joints and additional 46 joints from drill pipes being currently inspected
we will have required 486 joints of 5 ½” drill pipes with FH DSTJ connections.
 25 joints of HWDPs were inspected, 7 joints with hardband issues will be replaced.