Addressing Complex Well Conditions: Batch of 9-5/8″ 5000psi Double-Plug Cement Heads Shipped for Middle East Cementing Operations

Recently, a batch of twelve 9-5/8″ double-plug cement heads and associated accessories, commissioned for a cementing service project in the Middle East, has successfully completed in-house quality inspections and pre-assembly testing at our facility. The units have been crated and dispatched this week for deployment in surface casing cementing operations targeting high-pressure gas wells in the region.

The client imposed stringent requirements regarding pressure ratings, sealing integrity, and on-site operational efficiency due to the complex geological structures, fluctuating bottom-hole pressures, and narrow operational windows characteristic of the block. Designed and manufactured in strict compliance with API Spec 6A and API Spec 10A standards, these units are rated for a working pressure of 5000psi. Key design optimizations were implemented to meet specific operational challenges:

Structural Optimization:​ To facilitate frequent make-and-break operations on site, the upper connection features an ACME trapezoidal thread integrated with a Quick Latch mechanism. Field trials indicate this design reduces wing valve change-out time by approximately 40% compared to conventional flanged connections. Additionally, we supplied custom 9-5/8″ crossover subs (VAM TOP Box x ACME Pin) to ensure seamless integration with the client’s existing tubular string configuration.

Material Selection and NDE Protocols:​ The cement head bodies were forged from high-strength alloy steel, with post-heat-treatment hardness controlled within the 285–341 HB range to ensure resistance against sulfide stress cracking and impact. Quality assurance protocols mandated 100% Ultrasonic Testing (UT) and Magnetic Particle Inspection (MT) on all pressure-containing components, with a focused review of thread roots and high-stress areas for micro-defects. Sealing elements utilized Hydrogenated Nitrile Butadiene Rubber (HNBR) for enhanced oil and temperature resistance. Prior to shipment, each unit underwent a hydrostatic test at 7000psi ambient temperature, maintaining pressure for 30 minutes with zero recorded drop, verifying sealing reliability.

Pre-shipment Verification and Documentation:​ To mitigate on-site operational risks, each cement head underwent a “dry-run” pre-assembly to validate thread engagement and the smooth operation of the slip-jaw mechanism. Detailed Thread Usage and Maintenance Manuals accompanied each unit. Beyond standard Certificates of Conformance (CoC) and inspection reports, the documentation package included a supplementary Field Operation Notice, highlighting recommended torque values for makeup and prescribed maintenance intervals for the Quick Latch assembly.

The batch is currently en route to the port of destination. Project communications indicate the first four units are expected to arrive at the rig site in early next month. Our technical support team has established a coordination protocol with field service engineers to provide remote assistance during running operations. Following the completion of the initial well, we will collect performance data and wear analysis to further refine future design iterations and maintenance schedules.

This delivery not only validates our manufacturing capabilities but also lays the groundwork for deeper collaboration with the client regarding subsequent downhole tool supply contracts.

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Contact :Jessie Zhou

Mobile/Whatsapp:+0086-18109206861

Email: energy@landrilltools.com

Web:http://www.landrilloiltools.com