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ReelDirection
Spring 2011
NOV ASEP Elmar has now designed, manufactured and tested its first fully electronic remotely
operated well intervention equipment. NESSIE, which stands for NOV Electric Smart System
Intervention Equipment, is set to revolutionise the field of wireline intervention control by
enhancing the efficiency, accuracy and reliability of operations, resulting in optimised production
from wells and maximizing return on investment. NOV ASEP Elmars engineering director CarlWood and Keith Dempsie, principal engineer of NOV ASEP Elmar, explain the thinking behind
this exciting innovative system.
The technology behind wireline pressure control equipment (WPCE) has come along way since
NOV ASEP Elmar designed and introduced the very first wireline valves (formerly referred to as
wireline BOPs) in the 1950s under the Bowen name. The latest electric generation of WPCE,
which is designed in-house by NOV ASEP Elmars engineering team, will change the way that
offshore wireline operations are conducted worldwide by primarily improving the safety, flexibility
and control of well intervention activities. (see page 7)
...produces new Recessed Reel Bodyload CTUs
Worlds Leading Equipment Supplier for: Coiled Tubing Units Snubbing Nitrogen Pumping Fracturing Cementing
Pressure Pumping Wireline Pressure Control Data Acquisition
NOV Well Intervention and Stimulation Equipment
www.nov.com
A PUBLICATION OF
Electrical technician testing one of the
WLV control skids.
Its no myth: fully electronic solutions for improved well
intervention control can cut costs
NOV Hydra Rig has just completed manufacture of two recessed reel truck mounted CTUs thatare destined for Russia. The Terberg chassis utilizes a Volvo cabin, controls, transmission, and
a Volvo Euro 5, 440hp engine. The unit is winterized to -50C for operation in Arctic conditions
in Siberia. These particular chassis are 10 X 8, but 10 X 10 units are available. The split
frame design enables NOV Hydra Rigs Patented DID designed reels to fit thru the frame. The
split frame design significantly increases the capacity of a bodyload coiled tubing unit while
maintaining a road legal height, and at the same time lowers the CG of the unit for more stable
handling in off road conditions. This DID has a capacity of 14,500 of 1-3/4 tubing. A HR560
Injector is mounted on a hydraulic tilt stand for leaving the tubing stabbed during transport.
Page 1
Page 2 Stackable Offshore Units
N2 Vaporizer Automation
System
Page 3 MicroCoil Capillary Units
Page 4 CT Support Pumpers,
Fracturing Equipment
Page 5 New BOP and Two DoorStripper Packer
Page 6 Cerberus Software
Page 7 NESSIE
Page 8 2011 Trade Shows
Contents
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NOV Hydra Rig and NOV CTES has developed an Automated Discharge Temperature Controller for NOV Hydra Rigs Direct
Fired Nitrogen Vaporizers. The Merlin Nitrogen Vaporizer Automation System has been developed to allow the operator to input the
desired discharge temperature on a touch screen HMI and let the controller operate the vaporizer to control the discharge temperature,
thus allowing the operator to focus on rate and pressure control. The system is available on the full range of models of NOV Hydra Rig
Direct Fired Nitrogen Vaporizers and can be included on new build units or retrofit onto existing units with NOV Hydra Rig Direct Fired
Nitrogen Vaporizers. To date five automation systems have been supplied and are in operation in the field.
NOV Hydra Rig Nitrogen Division and NOV CTES introduces new Merlin - Nitrogen Vaporizer Automation System
Merlin - Nitrogen Vaporizer Automation SystemFEATURES BENEFITS
Automatically maintains operator preset discharge temperature Reduces temperature variations during rate and/or pressure changes
Automatic fuel and fan control improves vaporizer efficiency Provides cleaner emissions and improved fuel ef ficiency
Built in data acquisition system Provides data for job analysis and customer reports
Auto re-ignition on flame out System monitors for flame out and reacts quickly to maintain preset
temperature
Built in self diagnostics Pinpoints problem area and provides potential solutions
Safety warnings and system shutdown to protect critical components Reduces costly repairs and downtime
Remote monitoring Provides real time data to control center and/or of fice location
www.nov.com
Suitcase Mount for Retrofit Applications Integrated into Main Control Panel on New Build
NOV Hydra Rigs Stackable Offshore Units
The NOV Hydra Rig stackable CT skid is another development based on specific customer requirements for a small footprint unit
suitable for limited space on an offshore platform. The control cabin skid can be mounted on top of the power pack skid or it may be
used side by side where space is not limited.
Two of these stackable units have been delivered by NOV Hydra Rig
Canada and are now in operation.
NOV Hydra Rig UK has produced the stackable unit
above, with sound enclosed power pack, DNV and ATEX
certified, with CE markings.
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www.nov.com
NOV Hydra Rig introduces MicroCoil capillary units
The NOV Hydra Rig MicroCoil Compact Well Intervention unit has a combined power pack and operator cabin, integrated into a single
fully-enclosed offshore-style container. The power pack and operator cabin drives and controls a number of alternate well-intervention
systems such as slickline, capillary tubing or small coiled tubing. The unit can be operated with or without the optional wire-line module
attached. The functionality of the wireline module and capillary components are independent of each other.
The containers power pack compartment (sound reduced to 83 DbA average) contains the major diesel/hydraulic assembly. If required
the unit can be ATEX/ Zone 2 certified for offshore use.
The operator cabin compartment is fitted out with the control panel and operator chair. The control console is a designed for ease
of use and maintenance. It features direct hydraulic controls and instrumentation is provided for weight and depth. A NOV data
acquisition system or customer supplied system is integral to the control console. The cabin compartment is double-insulated and is
provided with heating and ventilation.
Together, the combined power pack and operator cabin container and secondary open-frame container form a complete capillary tubing
spread. Capillary coiled tubing may be used for placement of well treatment chemicals and can be appropriate for nitrogen injection for
well kick-off.
There is a standard option to install a slickline winch module. This is supplied as a separable container, bolted to the front of the
combined power pack and operator cabin when in use. When separated for transport or storage, the slickline winch module is fully
enclosed, damage resistant and weatherproof.
The combined power pack and operator cabin is designed to fully utilise the NOV Hydra Rig HR420 capillary injector.
The compactly designed HR420 capillary injector has a rated pull of 20,000lbs, a rated snub of 10,000lbs and weights just 1500lbs
(700kg). Two fixed displacement motors drive heavy duty chains with precision cast gripper blocks to suit capillary tubing, cable and or
coiled tubing from OD to 1 OD.
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www.nov.com
For equipment operators, shale completion is synonymous with tough on equipment. In response, NOV Rolligon has developed
new robust designs for Coiled Tubing Support Pumpersspecifically geared for high pressure/high rate shale applications. These
higher rated twin pump units provide the capability of 1600 bhp to 1900 bhp on a single trailer mounted Coiled Tubing Support unit with
pressure capability to 15,000 psi. As the industries requirements change, NOV Rolligon will continue to lead the way with products to
meet those needs.
NOV Rolligon continues to expand its offshore fracturing
equipment market with innovation and fit for purpose engineering
designs. The applications can range from fit for purpose units
on custom design fracturing boats to modular designs for rapid
installation on the deck of more conventional vessels. The
engineering design can not only meet special fit for purpose
applications, but also the varied safety regulation requirements
such as DNV 2.7-1, CE marking, and ABS certified. The NOV
Rolligon fracturing package can be engineered to meet the
changing demands of the service industry.
NOV Rolligon Engineering Responds to the New Shale Completion Demands
Twin Quintuplex Trailer Mounted Coiled Tubing Support Pump
NOV Rolligon Expands Presence in Offshore Fracturing Market
Romania Spread for the Black Sea
Below Deck Blending System for an Integrated Frac Vessel
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www.nov.com
NOV Texas Oil Tools has recently completed the manufacturing and qualification
testing for a new 6 3/8 Model ES64 BOP stack. The stack has two unique
tools that were a first for Texas Oil Tools.
1. New Model ES64 Triple BOP
6.375 bore, 10,000psi working pressure
Hydraulic Quick Ram Change
Larger shear seal actuator
Metal x Metal Bonnet gaskets
Shearing capabilities:
o Coiled tubing All sizes up to 3.50 .204 120K yield
o Wireline, braided wire, electric line
Holding capabilities
o Pipe heavy mode 100,000lbs
o Pipe light mode API 16st requirements
2. Two Door Stripper Packer
4.06 bore 10,000psi working pressure Capable of running up to 2.875 coiled tubing
Slip Bowl capabilities in the upper housing
Rotating Bottom Flange assists in rigging up and making up flanges
External visual indicator for packer monitoring
Electronic indicator capabilities for packer monitoring
New 6.375 Triple BOP and 4.06 Two Door Stripper Packer
The Improvements in the BOP will decrease the time required to conduct regular maintenance on the equipment with the addition of
the hydraulic ram change system. This system has been used before on smaller BOPs and it has been improved for the 6 3/8 ES
to make it easier to assemble. The shearing capacity has increased with a larger piston on the shear seal actuator. The BOP has
passed all of the API 16A qualification requirements, and additional requirements from API 6A, NORSOK, and ISO. Our qualification
testing includes a gas test.
The Two Door Stripper Packer improvements is the addition of
an external visual indicator. The indicator is attached directly
to the main piston, as the stroke of the piston increases the
indicator will show percentage of packer wear. As you approach
the stroke of the piston the packer assembly will be worn to
levels that is must be replaced. The system also allows for
an electronic LVDT to be attached so that the wear can be
monitored inside the control cabin.
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Field operations with high angle or wellbores with long
horizontal sections can present a unique set of challenges.
Successful outcomes are dependent on the use of advanced
technology.
In these scenarios, gravity can no longer be used to deploy theBottom Hole Assembly (BHA), and the coiled tubing (CT) must
be used to push the BHA to the desired working depth.
Friction forces (acting between the CT surface and the
surrounding tubulars) increase as push is sustained, resulting
in helical buckling of the tubing. If pushed far enough, the CT
will eventually experience lockup, preventing any additional
forward movement of the BHA and potentially limiting the
success of the field operation.
Fortunately, there are several methods of reducing friction
forces in long horizontal wellbore sections. One of these ourfocus here is the application of gentle downhole pulsation, or
vibration energy, on the CT string (by way of devices such as
the NOV Downhole Agitator), to gently oscillate the BHA to
reduce friction for the purpose of delaying the onset of lockup,
thereby allowing further penetration into an extended-reach
well.
This friction-reduction technique also helps to mitigate the
slip/stick movement of the CT that occurs in some situations,
allowing for more constant weight on bit (WOB) when
performing milling or drilling operations.
Key challenges encountered when using a downhole pulsation
device are: 1) accurately predicting the additional depth of
penetration that is achievable with the use of the tool, and 2)
accurately predicting the additional amount of available WOB
that is deliverable as a result of reduced friction. Its important
that these predictions are made correctly prior to mobilization
of the equipment to ensure that no opportunities are missed; or
conversely, that the field operation is successfully performed.
NOV CTESs Cerberus softwares modeling capabilities can be
used to answer both of these challenges. Within the software,the friction-reducing properties of various downhole tools are
definable by user inputs. These user inputs are then used to
provide an analysis of the friction reduction achievable by use
of the pulsation tool. More importantly, the pre-job analysis
provides an estimate of the additional CT penetration depth
that can be achieved as a result of the friction reduction
provided by use of the pulsation tool.
www.nov.com
According to a 2009 SPE paper presented by Ken Newman et
al.1, Case histories show that the [Cerberus forces] model gives
reasonable results when compared to measured field data.
The figures below represent the Cerberus modeling results
obtained in a case study described in the referenced SPE paper.
Bottom line: Downhole pulsation tools can help delay the onset
of CT lockup and can extend the reach of the BHA in wellbores
containing long horizontal sections, and Cerberus software canprovide effective modeling of these types of operations.
1 Kenneth Newman et al., Modeling the Affect of a Downhole
Vibrator, SPE 121752, 2009 SPE/ICoTA Coiled Tubing and Well
Intervention Conference and Exhibition, The Woodlands, Texas
USA, 31 March 1 April 2009.
Intervention with pulsation tool: lockup at 14,370 ft.
Intervention without pulsation tool: lockup at 13,463 ft.
NOV CTESs Cerberus software effectively models downhole pulsation devices
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www.nov.com
NESSIE Technology
The NESSIE system is designed to ensure that even the most delicate adjustments to pressure control or grease injection can be done
instantly from the safety and comfort of the winch cabin, without a diesel engine. The essence of the technology is incorporation of an
NOV ASEP Elmar SmartMonitor realtime computer-generated interface in the winch control cabin which instructs the units on a fully
automated basis. Out-with the winch unit, NOV ASEP Elmar CAN-bus technology eliminates hydraulic control up to the point of the
wireline valve (WLV) control skid.
By replacing hydraulic connections with CAN-bus technology and integrating SmartMonitor technology within each unit, the end result
is a complete electronic well control and winch package consisting of an e-drive winch system, a WLV control skid, a grease injection
skid and a wellhead pump master valve unit.
The SmartMonitor hardware is a touch screen computer that controls all aspects of the wireline operation including; wire lubrication and
tension, the display of real time imagery from cameras as well as controlling safety protocols. The result is a quieter, more controlled,
environmentally friendly product that can be operated remotely from anywhere in the world.
Technical challenges
One of the biggest challenges encountered during the design process was developing a method to synchronize the automatic controls
of the SmartMonitor with the manual controls of the WLV control skid. The intelligent process advanced, named physical feedback
by the companys engineering team, ensures that in the event of an emergency where manual control is required to override theSmartMonitor control, the handles are in the correct position for an engineer to operate instantly.
NOV ASEP Elmar carried out an intense program of testing to ensure high performance and reliability of the new electronic solutions
and techniques. Cold weather testing was conducted in a test chamber to temperatures as low as -20C in order to verify the systems
reliability, even in the harshest conditions.
Cost-effectiveness
With rig costs running into millions of dollars a day, developing cost sensitive technologies without compromising safety or performance
is paramount.
When it comes to service life and maintenance checks, NESSIE technology is longer lasting and more effi
cient. The SmartMonitorsinitiate regular health checks scheduled according to actual usage time rather than calendar based scheduling, which is less efficient.
Maintenance costs are therefore much lower than hydraulic power equipment resulting in a cost-effective method for intervention
activities.
Conclusion
NESSIE is indeed a major step forward in using software and electronics to drive innovative, reliable and cost-effective intervention
equipment during oil and gas exploration worldwide.
Quiet, environmentally friendly, safe, reliable, cost-effective and high performing electronically driven equipment is the new direction of
well intervention pressure control technology and NESSIE is set to revolutionise the field of well intervention control.
SmartMonitor on the grease injection skid.
NOV ASEP Elmars Electric Smart System Intervention Equipment
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316 marine grade stainless steel pressure test skid.
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Technical Handbook Update:
NOV Group Coiled Tubing Handbook is available on CD by contacting
NOV Group Wireline Handbook is available on CD by contacting
Manufacturing Locations
NOV Hydra Rig
USA Ft. Worth, Texas
Phone: 817 985 5000
E-mail: [email protected]
USA Duncan Oklahoma
Nitrogen Division
Phone: 580 255 4433E-mail: [email protected]
United Kingdom
Phone: 44 1493 651801
E-mail: [email protected]
Alberta - Canada
Phone: 403 279 6430
E-mail: [email protected]
Texas Oil Tools
USA Conroe, Texas
Phone: 936 520 5300
E-mail: [email protected]
USA - Broussard, Louisiana
Phone: 337 839 0024
United Kingdom
Phone: 44 1224 331 200
Rolligon
USA, Anderson, Texas
Phone: 936 873 2600
E-mail: [email protected]
CTES
USA Conroe, Texas
Phone: 936 521 2200Technical Support: 936 521 2200
E-mail: [email protected]
United Kingdom - Aberdeen
Phone: 44 1224 748797
Dubai Middle East
Phone: 971 481 0132
Fidmash
Minsk, Belarus
Phone: +375 17 298 24 11
E-mail: [email protected]
Manufacturing Locations
NOV ASEP Elmar
United Kingdom
Phone: +44 1224 740261
E-mail: [email protected]
Netherlands
Phone: +31 184 608 700
E-mail: [email protected]
United States
Phone: + 1 713 983 9281
E-mail: [email protected]
Middle East
Phone: +971 4 810 0100
E-mail: [email protected]
Singapore
Phone: +65 6546 0928
E-mail: [email protected]
NOV ASEP Elmar Sales,
Rental and Service Location
Macae, Brazil
Phone: +55 22 2773 3328
E-mail: [email protected]
Perth, Australia
Phone: +61 8 9456 0999
E-mail: [email protected]
Veracruz, Mexico
Phone: +52 229 937 2890
E-mail: [email protected]
Representative Offices
Beijing, China
Phone: +86 10 8485 1973
Bogota, Colombia
Phone: +57 1602 0414
Edmonton, Canada
Phone: +1 780 986 6063
Fidmash, Minsk, Belarus
Phone: +375 17 298 24 11
Istanbul, Turkey
Phone: +90 262 679 0500
Louisiana, USAPhone: +1 337 839 0024 ext 201
Moscow, FSU
Phone: +7 495 258 1473
NOV Corporate Headquarters
7909 Parkwood Circle Drive
Houston, Texas 77036
United States
Phone: 713 375 3700
Fax: 713 375 3994
Well Intervention and
Stimulation Equipment
Headquarters
1020 Everman Parkway
Ft. Worth, Texas 76140
United States
Phone: 817 985 5000
Fax: 817 985 5297
NOV WISE Sales
Far East
Phone: 86 10 8485 1973
E-mail: [email protected]
Mexico South America
Phone: 86 10 8485 1973
E-mail: [email protected]
Middle East
Phone: 971 4 883 0414
E-mail: [email protected]
Russia and EuropePhone: 971 4 883 0414
E-mail: [email protected]
NOV Well Intervention andStimulation Equipment
2011 Trade Shows
-CIPPE Beijing, China
March 22 - 24
-SPE/ICoTA
Woodlands, Texas
April 5 - 6
-ICOTA Well Intervention Seminar
Stavanger, Norway
May 31
-OTC
Houston, Tx.
May 2 - 5
-OGU
Tashkent, Uzbekistan
May 17 - 19
-Brazil Offshore
Rio, Brazil
June 14 - 17
-MIOGE
Moscow, Russia
June 21 - 24
-Offshore Europe
Aberdeen, Scotland
September 6 - 8
-KIOGE
Almaty, Kazakhstan
October 5 - 8
-LAGCOE
Lafayette, Louisiana
October 25 - 27
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www.nov.com 2011 National Oilwell Varco
D392001760-MKT-001 Rev. 05