working for the future – posgrip™ technologydea-global.org/wp-content/uploads/2009/11/dea... ·...

October 2008

Working for the future – POSGRIP™ Technology

A Request for

Joint Industry Support

to enable roll-out of a new method

of wellhead design

A New Method for Wellhead Engineering

1.1 - The Principals of POS-GRIP

• POS-GRIP is a patented

method for wellhead design

• External force deforms the wellhead to grip and seal hangers within the elastic range

• Setting force is equally distributed

around seal perimeter

• Hangers are held rigid

and concentric

• Seal movement (fretting)

is eliminated

• Hangers are adjustable

• The design tolerates

stack-up and dimensional variations

• Leak paths are eliminated

• Landing shoulders are not required

• Seals can be externally

tested, and from both directions

Load Capacity = A μ

Fn

1.2a - The Principals of POS-GRIP Technology

Current Configurations - Open

Type 1 Design(Split Flange)

Type 2 Design(One Piece)

Type 3 Design(Connector)

Current Configurations - Closed

Type 1 Design(Split Flange)

Type 2 Design(One Piece)

Type 3 Design(Connector)

1.2b - The Principals of POS-GRIP Technology

2 –

Typical POS-GRIP Wellhead System

Hydraulic Jack System

• Single Piece Hangers

• Thru BOP Technology

• Elegant Design

• Simple yet better

• Maintenance Free

2 - “HG” Technology for Exploration Wellheads

• Rental Product• Tested to 20,000 psi• Qualified to API PR2 Appendix F• Available out of Inventory• Thru BOP Technology• Multiple Metal Seals• Re-useable Metal Seals• Tested to WP from all directions• Continuous Control Lines• Simple Design• Installation Time Savings• Adjustable Hangers• 8” Space-out Capability • Full Bore Design• Only available from Plexus• One Design - All applications ANIMATION

3.1 -“HG” Technology for Production Wellheads

• POS-GRIP used on critical hangers• Qualified to 20,000 psi• Multiple integral metal seals• Minimum number of Leak Paths• Individual landing shoulders• Adjustable emergency tie-back hangers• Through BOP Liner Top Completions• Maintenance free production• Continuous control lines• Full external WP testing• Full internal WP testing (all directions)• Minimal number internal components• Reduced installation time

Drill-Through Application

ANIMATION

3.2 - “HG” Technology for Tie-back Wellheads

• Standard housing• POS-GRIP hangers• 6 inch adjustability • Multiple metal seals• Maintenance free • Continuous control

lines• External testing• Full WP testing• No adjustment

Subs

Adjustable Hangers

Tie-Back Application

3.3 - “HG” Technology for Emergency Hangers

• “HG” Metal Hanger Seal• Disconnect Sub at 400ft• Metal Tie-back Seal• 8” Adjustability• Installed thru BOP’s• External testing• Multiple Seals• Tension control• Predictable Technology• Maintenance Free

POS-GRIP Emergency Solutions match Primary Capability

“HG” ADJUSTABLE SURFACE WELLHEAD CASING HANGER

4 – POS-GRIP for Conductor Load Management

• Thru BOP Installation• 6 inch adjustability • Mudline Hangers• Riser Tension control• Free Standing

Conductor• Metal seal technology• Environmental loading

resistant• Platform Tie-back• Subsea X-over

Adjustable Surface Hangers for Casing Support at Mudline

5 – POS-GRIP for HP/HT Subsea Tie-Back

• POS-GRIP used for HPHT mudline tieback

• “HG” seals enable fully loaded metal to metal sealing

• Zero torque – zero sliding enabled CRA materials to be used

ANIMATION

6 – POS-GRIP “HG” Seals for Corrosive Environments

• Single Piece Housings• Resistant Seal Areas• Multiple Metal Seals• Extended Contact Area• Low Stress Bump Seals • Damaged surface Tooth Seals• Resilient non extrusion Seals• Tailored to Conditions• One Design all applications• 22,500 psi tested• Used Seals Qualified

7.1 – Standards for Wellhead Seals Inferior to Couplings

Deficiencies:• Seals qualified from a single sample, ignoring manufacturing tolerances• Limited test cycles are not representative of field conditions• Make or break tests are required to prove serviceability• Not testing to destruction, obscures the point of failure• Wellhead seal are subject to loading. API tests should incorporate the effect• Extrapolating results that take multiple “tweaks” to achieve, is nonsenseConclusion:• API 6A Appendix F test standards are not based on good science

API 6A App F Plexus API 5C5 CAL II API 5C5 CAL IV(Current “Extended (Casing (Tubing

wellhead Field Life” coupling test) coupling test)standard) Testing

No of Samples 1 1 4 8Thermal Cycles 6 23 25 50Make / Break Test No Yes Yes YesTest to Failure No Possible Yes YesTesting under load No Possible Yes YesExtrapolation Yes No No No

7.2 - POS-GRIP Standards Compared

Facts:• “HG” Seal tested to 15,00psii, API 6A Appendix F at first attempt• “HG” Seal passed testing with the first design• Used seal parts re-assembled and tested again for extended field life• Used Seals passed complete API 6A Appendix F at first attempt• POS-GRIP “HG” Seals designed for multi sample testing• “HG” Seals can match stringent coupling test requirementsConclusion:• POS-GRIP HG Seals have achieved a New Standard

POS-GRIP vs API

8 - POS-GRIP Capability Explained

The Fundamental Difference – Elimination of Movement

9.1 Simple Design – Lower cost

Cost Estimate: £5,465 DD TRIM £13,445 DD TRIM

9.2 One Design – Linear Costs

9.3 Thru BOP – Time SavingsTime Advantage

Conventional Installation hrs POS-GRIP Installation

Weld on Starter Head 6 Fre-lok installed POS-GRIP wellheadInstall low pressure BOP n/a Install 18-3/4" BOPDrill, run 13-3/8" casing Drill, run 13-3/8" casingN/D low pressure BOP 5Cut casing and set slips 4Install A-Section 4Install high pressure BOP 8

-1 Activate “POS-GRIP” device-1 Install and test Annular Seal

Test BOP 6Drill, run 9-5/8" casing Drill, run 9-5/8" casingSecond Intermediate Casing BOP lift eliminated 9Cut casing and set slips 5Install B-Section 4


Test BOP 6Drill, run 7" casing Drill, run 7" casingProduction Casing BOP lift eliminated 9Cut and machine Production casing and set slips 9Production and test spool installation 5


Test BOP 6

Elimination of casing cuts during abandonment 6

TOTAL TIME SAVINGS PER WELL 86

10 – API and Proprietary Technologies

• API is recognized as a mark of Quality• Quality is a combination of process and design• API Standards cater for open technology• Suppliers influence API Committees• API Standards are directed by suppliers• API ignores proprietary technologies• POS-GRIP™ represents a new Standard• The HP/HT Frontier needs a new Standard• Plexus needs a JI assistance

POS-GRIP Technology – “QUALITY by DESIGN”

11 – Joint Industry Proposal

• POS-GRIP Technology is disruptive• Plexus gets no help to develop POS-GRIP• API will not recognize proprietary technology• HP/HT Frontier needs improved technology• Conventional Seals are at their limit• POS-GRIP is field proven, 140 wells• POS-GRIP is uniquely capable• Can this be left to Plexus? 85 employees• Should POS-GRIP be pulled into the market• Enabling ideas deserve JI support

12.1- Other Applications - TLP

• Unlimited adjustment stroke

• Through the BOP installation

• Integral HG seals• Exact tension control• Rigid design• Substantial time savings• Maintenance free• HP/HT Capability

Test Prototype - Aberdeen

Dry-Tree Systems

12.2 Other Applications - Connectors

• Re-usable• Low torque • High strength• Radial pre-load• Metal sealing

Riser Connectors

12.3 Other Applications - Risers

• Light weight• High strength• Low contact stress• Pressure enhanced• Quick make-up

Drilling Riser Connector

12.4 Other Applications - Wellhead Connectors

• Integral metal seals• High strength/weight ratio• Low contact stress• Pressure enhanced• Quick makeup• High stab angle• Bending capacity independent

from pressure

High Strength/Weight Ratio

12.5 Other Applications - Work Over

• Adjustable• Through BOP• HG sealing• Tension control• Re-useable• Rental Product

Tubing Space-out

12.6 Other Applications - Subsea

• Slim bore design• Subsea casing tension• Integral HG metal seals• Casing drilling friendly• Multi-ported Tubing Hangers

Reduced Bore Systems

12.7 Other Applications - Surface BOP Systems

• Adjustable metal sealing riser joint

• Full bore access to wellhead• BOP test facility• Remedial inner string capability• Rental Product

Space-out Joints

13 POS-GRIP Wellheads Installed to date

• Exploration wells – 112• HG Production Wellheads – 8• HP/HT Production Wellheads - 5

14.1 Appendix 1

45 hours savings

14.2 Appendix 2

72 hours savings

14.3 Appendix 3

14.2 Appendix 4

working for the future – posgrip™ technologydea-global.org/wp-content/uploads/2009/11/dea... ·...

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