From "Wired" magazine-2007
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Dropping a drill down through more than 1 mile of water and 4 miles of earth isn't easy either. The drill string is composed of hundreds of 90-foot sections known as joints that are dropped into the water by an automated mechanical arm and successively screwed into each other. It took more than three days to assemble all the joints in the drill string that pierced the Jack field.
Once the rotating drill bit begins its journey down through miles of sediment and pierces the seafloor, it encounters another set of problems caused by the changing terrain. The test well for the Jack field drilled through nearly a dozen geological layers — ranging from hard bedrock to sandy sediment to empty voids. These rapid shifts from one level of pressure to another can disturb the rotations of the drill, causing it to get stuck or veer off course. Pressure is good — it's what naturally forces the liquid crude up the length of the well and into the barges and pipelines that send it back to shore. (The layer of shale over the oil-bearing sands acts like a brick on top of a water balloon — the fluid wants to surge upward.) But, at the very bottom, farther below sea level than Mount Everest is above it, there's enough pressure to implode a human head — or, more pertinently, to crack iron casings.
Moreover, the closer you get to Earth's core, the higher the temperature of the rocks. At 20,000 feet below seabed, the oil is hot enough to boil an egg. At 30,000 feet, it can reach more than 400 degrees Fahrenheit, hot enough to cook off into natural gas and carbon dioxide. Meanwhile, the water at the bottom of the deep sea is at near-freezing temperatures — between 32 and 34 degrees — creating a dangerous interaction: When the boiling-hot oil hits the freezing-cold water, it could solidify and block the flow, rupturing the pipes. The machinery on the seafloor, therefore, has to be well insulated. Engineers on the Cajun Express have been relying on a fairly primitive method — pumping the casing and substations with antifreeze — but much more sophisticated systems are in the works.
Because so many of the challenges that engineers encounter in the ultradeep can't be anticipated — or found anywhere else — the Jack test rig was populated with so-called Serial Number 001 technologies: one-of-a-kind innovations ranging from perforation guns that are triggered at well bottom inside the casing, creating holes that let the oil gush in and flow upward, to electrohydraulic systems that seal the wells in emergencies. And yet sometimes the solution is plain old creative thinking and duct tape. For example, when a tool got stuck down the hole during one well test, someone suggested just banging a giant hammer against the casing, sending vibrations down that jarred the tool loose.
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Read More
http://www.wired.com/cars/energy/magazine/15-09/mf_jackrig?currentPage=3#ixzz0mrxrEULlAnd they wonder why it failed???