Customer Challenges
Cement head management:
- The customer in Indonesia was required to demobilize the cement head after every job for onshore inspection and redressing, resulting in operational inefficiencies
- During previous campaigns, residual cement debris was repeatedly found inside the cement head, rendering it unfit for immediate reuse and contributing to project delays
Dart reloading capability:
- The customer needed a cement head design that allowed darts to be reloaded on location without removing pup joints, enabling faster, safer job preparation • In an earlier operation, the cement head became detached when the rig inverted it to break out the upper pup joint, causing one fully day of non-productive time (NPT)
Safety improvements:
- A key customer priority was to reduce personnel exposure within the Red Zone by adopting equipment and processes that enhanced operational safety
Expro Excellence
Enhanced safety:
- The Blackhawk Cement Head with Skyhook system removes the need for personnel to enter the Red Zone at any stage of the cementing operation
- By integrating hands free handling and controlled tool positioning, Expro’s solution significantly reduced physical exposure and improved overall operational safety
Improved Operational Efficiency:
- The proprietary QuikLock™ connection, which is included on all of Expro’s Blackhawk Gen-II & Gen-III cement heads enabled, fast, on location dart reloading without having to break out pup joints
- This streamlined process reduces rig floor activity, shortened job preparation time, and enhances both safety and workflow efficiency
Reliable Internal Cleaning:
- Our purpose built cage design ensured continuous mud flushing through the cement head’s internal diameter
- This eliminated the need to stop circulation to clear bypass channels - an issue common with previous cement head designs - ensuring reliable, repeatable performance across runs
Reduced Logistics & Cost Savings:
- Expro’s cement head was designed to remain offshore between jobs, eliminating the requirement for onshore redress or cleaning
- This reduces logistics handling, minimizes vessel movements, and lowers both planning and operational costs for the customer
Value to Client
Faster preparation for subsequent operations:
- Our solution saved 2 hours on cement head preparation for each job
- We had no requirement to invert the cement head to break out pup joints, reducing operational steps and simplifying the workflow
- Minimized the risk of damage to rig equipment and removed unnecessary personnel exposure on the rig floor
Reduced cement line handling:
- Expro’s Skyhook system enabled rapid connection and disconnection of cement lines, saving around 1.5 hours per operation
- Workflow becomes significantly more streamlined, reducing manual handling and improving efficiency
Enhanced personnel safety:
- Cementing operations could be completed with personnel fully removed from the Red Zone, supporting the highest safety standards
- We eliminated the need for man riding activities, significantly decreasing the likelihood of safety incidents
Contact
For further information, please contact wellconstruction@expro.com.
