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Advancing Well Construction Performance in the Caspian...
- Mar 2
- 4 min read
How Vulcan’s Patented PROBE™: BORG and Non‑Rotating Plug System Delivered a Zero‑Downtime Casing and Drill‑Out Operation.
In the Caspian region, operators continue to face increasingly complex wellbore conditions where equipment reliability is not optional, it is fundamental to maintaining operational efficiency and controlling risk. As wells extend deeper and encounter more challenging formations, the performance of casing accessories becomes a decisive factor in whether operations proceed smoothly or face costly delays.
A recent 9‑5/8" casing run in a 12¼" open hole section has provided a clear demonstration of how Vulcan’s engineered solutions deliver consistent, measurable value in these demanding environments.
A major operator successfully deployed 9‑5/8" casing to 3,856 m MD using the PROBE™: BORG Reamer Shoe, paired with Vulcan’s API 10F‑certified Non‑Rotating Float Collar and Dual Non‑Rotating Cement Plug system. The casing was run to depth without incident and cemented in place using Vulcan’s NR top and bottom plugs. As the document states, the casing was “run to depth without incident and cemented in place using Vulcan’s non‑rotating top and bottom plugs.”
This operation reinforces the importance of equipment that not only performs its primary function but also supports downstream activities such as cementing, drill‑out, and early formation engagement.
Smooth Casing Deployment and Confirmed Cement Placement.
The PROBE™: BORG Reamer Shoe played a central role in guiding the casing string through the open hole section, reducing drag and ensuring stable run‑in‑hole performance. Once cementing was completed, the BHA tagged top of cement at 3,784 m MD, confirming accurate placement. The cemented interval and NR plug system were then drilled out using a standard PDC bit, with plug debris observed at the shakers, exactly as expected and consistent with the system’s design. The document notes that “plug debris was observed at the shakers as expected.”
Drill‑out performance of plugs and float collar.
The drill‑out sequence demonstrated predictable, controlled behaviour, a key requirement for operators seeking to minimise risk during this critical phase.
• 40–80 rpm at 11–17 kft‑lbs torque.
• 5,000–15,000 lbs WOB.
• 450 gpm at 3,700–4,800 psi.
• 50 minutes to drill out plugs.
• 1 hour to drill out the float collar.
These parameters reflect the drill‑friendly profiles engineered into Vulcan’s NR plug system and float equipment. The document highlights that the float collar was drilled out “with controlled parameters,” reinforcing the system’s predictable behaviour.
Rapid, Clean Drill‑Out of the PROBE™: BORG Reamer Shoe.
Following the plug and float collar drill‑out, the same 8.5" × 9.25" BHA was used to drill out the shoe track to 3,853 m MD. The PROBE™: BORG, complete with internal cement and an API 10F float valve, drilled out in less than one hour, after which the BHA progressed directly into 3 m of new formation. This seamless transition from shoe drill‑out to formation drilling is a strong indicator of the shoe’s structural consistency and drill‑out predictability.
Shoe drill‑out parameters.
• 350 gpm at 2,400 psi.
• 60 rpm.
• 11–15 kft‑lbs torque.
• Low WOB.
The wellbore was subsequently drifted at 200 gpm with no restrictions encountered, confirming a clean, obstruction‑free path. The document states clearly that “the shoe and wellbore were subsequently drifted at 200 gpm with no restrictions encountered.”
This level of drill‑out performance is particularly valuable in wells where time, cost, and BHA integrity are critical considerations.
Engineering That Drives Operational Efficiency.
The performance of the PROBE™: BORG and Vulcan’s NR plug system highlights several engineering advantages that translate directly into operational value.
• High‑strength, thermally stable composite nose supports smooth RIH and rapid drill‑out.
• API 10F‑certified float equipment ensures dependable barrier performance during cementing.
• Non‑Rotating plug design reduces rotational friction, improves displacement efficiency, and drills out cleanly.
• Plug designs exceeding API TR 10TR6 requirements provide enhanced structural integrity and predictable removal.
• Zero unplanned downtime across the entire casing, cementing, and drill‑out sequence.
Vulcan's combination of innovative design, high‑performance materials, and field‑proven reliability ensured seamless casing deployment and highly efficient drill‑out operations.
These attributes are not incidental, they are the result of deliberate engineering choices aimed at reducing operational uncertainty and supporting consistent performance across a wide range of well conditions.
PREMIUM CEMENT PLUGS.
Vulcan offer a complete range of Cement Plugs designed to surpass the requirements of API TR 10 TR6.
Reinforcing Vulcan’s Role as a High‑Value Partner in Complex Wells.
This operation underscores Vulcan’s commitment to delivering equipment that performs consistently in the world’s most challenging wellbore environments.
From the PROBE™: BORG’s smooth run‑in‑hole and rapid drill‑out to the reliability of the NR plug system and float collar, the equipment delivered exactly what the operator required: predictability, efficiency, and confidence.
The editorial conclusion captures this clearly: “This case reinforces Vulcan’s capability to deliver dependable, high‑value solutions for complex wellbore environments, supporting operators in maintaining optimal performance even under challenging conditions.”
As operators continue to push the boundaries of well construction, Vulcan remains focused on developing casing accessories that combine robust engineering, field‑proven reliability, and operational efficiency, ensuring that every component contributes to a safer, more predictable, and more productive well...
Built for reliability. Engineered for results. Contact Sales@Vulcan-CP.com
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