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ADAPTED PRESENTATION Date : 24 November, 2009 (Week 48) Location: PCSB Kerteh HQ. Review of Zeron ® 100 Failures in Dulang. Iain Rei Technical Director. Background. Parties Operator (OC): Petronas Carigali Sdn . Bhd. Service Provider (SP): Geowell Sdn. Bhd.

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Adapted presentation date 24 november 2009 week 48 location pcsb kerteh hq


Date: 24 November, 2009 (Week 48)

Location: PCSB KertehHQ

Review of Zeron®100 Failures in Dulang

Iain Rei

Technical Director


  • Parties

    • Operator (OC): PetronasCarigaliSdn. Bhd.

    • Service Provider (SP): Geowell Sdn. Bhd.

    • Wire Supplier (WS): Wilco OFS Pte. Ltd.

  • Location: Dulang, PMO

  • Scope of Work

    • SP to provide sand-bailing services

    • WS to provide super-duplex stainless steel Zeron®100 HS

Background timeline
Background: Timeline

  • Timeline

    • First contact: Week 40 (Susp. wire thinning)

      • KSB Visit: Week 41 (Wire inspection)

    • Second Contact: Week 42 (Susp. Inconsistent OD)

      • KSB Visit: Week 43 (Wire inspection)

      • Wire replacement: Week 43 (Inconclusive)

      • Official reply: Week 45 (Mfg. Tolerance)

    • Third Contact: Week 47 (Susp. lower MBL; surface quality; plastic behavior)

      • KSB Visit: Week 48 (now)

Background zeron 100
Background: Zeron®100

  • First used in Dulang: 2003

    • SP: Dimension Bid Sdn. Bhd.

  • Current countries: 6

    • Malaysia, Indonesia, Vietnam, Thailand, Myanmar, Turkmenistan

  • Current mean per annum usage: 60 reels

  • Largest end-user: PetronasCarigali

  • Largest single-user: Chevron Thailand

  • Keywords: high breaking load, quality, consistency, support, service, stockist, fast

Discussion thinning
Discussion: Thinning

  • First issue: Wire thinning

    • Restatement: wire is surface thinning inexplicably causing disruption in service

  • Premise:

    • Wire was said to be unused and new from reel

    • Wire was of poor surface quality

  • Conclusion:

    • Wire was found to be used

    • Wire was found to be significantly stressed mechanically

    • Link to reportfrom UK

Discussion od
Discussion: OD

  • Second issue: Inconsistent OD

    • Restatement: wire OD is inconsistently thick or thin, resulting in uncertainty in quality that could lead to NPT

  • Premise:

    • Wire is said to be new

    • Wire OD was changing rapidly during spooling

    • Operator/helper detected accurately using hands on moving wire from supply to usage reel

  • Conclusion:

    • Wire is new

    • Wire OD seemed to be changing if detected by hand

    • Wire was replaced

    • Subsequent findings from Principal show that OD was fluctuating within normal manufacturing limits of ±0.001”

Discussion od1
Discussion: OD

  • Our findings

    • On 23 Nov., 2009 we performed a series of measurements on a reel that is supposedly problematic with an undulating OD.

    • Using an electronic caliper provided by Geowell, we conducted a series of measurements of theOD of the wire

    • The result is an OD measurement of 0.108”±0.00045”ora breaking load of 2,500lb±25.21lb

    • Error is within manufacturing error of 0.001”

Discussion plasticity
Discussion: Plasticity

  • Third issue: Plastic behavior of Zeron®100 wire

    • Restatement: wire elongates without recovering original length on tension; indication of poor quality

  • Premise:

    • Break load testing methods are normal and common; equipment used to test is approved

    • Wire elongates plastically without returning to original length under load

  • Conclusion:

    • Tested wire had already broken at rope socket but was undiscovered

    • Subsequent “elongation” was due to wire being pulled out of rope socket

    • Cup-cone break-ends of wire indicates wire is of good quality

Discussion plasticity1
Discussion: Plasticity

What is elasticity and plasticity?

  • Elasticity: when a material behaves elastically like rubber

    • On tension an elastic material will elongate proportionately with tension

    • On release of tension, an elastic material will retain its original length

  • Plasticity: when a material does not behave elastically

    • On tension beyond the elastic limit, a material will begin to act plastically

    • The subsequent increase in tension will not result in proportional elongation of length

    • On release of tension, the material will not return to its original length

Plastic return of length

Δx (plastic elongation)


  • Findings

    • Most findings conclusively attest to the quality of Zeron®100

    • Thinning on recent sand bailing activity is not yet examined and as yet outside of our scope of control

    • Thinning is akin to mechanical erosionwhereas stress-corrosion-cracking is a form of chemical erosion (or commonly called corrosion)

    • Problems that have occurred to not seem to be due to the quality of the material or drawn wire


  • Recommendations

    • Shorter runs-between-cut/test cycles

    • Closer surface inspection for scratches and large reductions in OD of wire between run-cycles

  • Wilco have been recommended to:

    • Check for well schematic

    • Check for nipple or SSD profiles, kick-offs, deviation angles, etc. that may lead to high forces of friction

    • Request more supporting information from OC and SP

    • Provide continued support to OC and SP

Case study
Case Study

  • Example: Chevron wire thinning

    • WI/125xx; max pull: 1,350lb; on reel: 21,115'; 271 runs

      • Mobilized in November 2007

      • 25,000ft ZERON®100, 0.125”

    • WI/125xx; max pull: 1,500lb; on reel: 18,545'; 258 runs

      • Mobilized in March 2009

      • 20,000ft ZERON®100, 0.125”

Case study1
Case Study

  • Example: Chevron wire thinning

    • Chevron runs in the northern and southern offshore fields

    • 20,000+ runs per year

    • Typical measured depth of wells: 14,000-16,000ft

    • Typical ordered slickline: ZERON®100, 0.125”

    • Typical ordered length: 20,000ft

    • Typical service company junk length:

      Remaining on drum ≥ 1.5 x Well MD

    • Shows great belief in their program and our wire

Wilco website preview
Wilco Website Preview

  • Surface information

    • History

    • Work history

  • Technical information

    • Material data sheets

    • Test certificates (private access)

    • FirstLook Calculator

  • Contact point

    « »

Contact us
Contact Us

Wilco Oilfield Services Pte. Ltd. (estd. 1982)

No. 9, Kaki Bukit Road 3, East Point Terrace, Singapore 417829

Tel: +65(6)482-3666; Fax: +65(6)482-4782

Visit us at:

Email us: [email protected]

For a full technical presentation, please contact us. Focus group: well & production engineers