POSGRIP™ Technology - Drilling Engineering Association

Working for the future – POSGRIP Technology
A Request
for
Joint Industry Support
to enable
roll-out of a new method
of
wellhead design
October 2008
Page 1

1.1 - The Principals of POS-GRIP
A New Method for Wellhead Engineering
• 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 F n
Page 2

1.2a - The Principals of POS-GRIP Technology
Type 1 Design
(Split Flange)
Type 2 Design
(One Piece)
Type 3 Design
(Connector)
Current Configurations - Open
Page 3

1.2b - The Principals of POS-GRIP Technology
Type 1 Design
(Split Flange)
Type 2 Design
(One Piece)
Type 3 Design
(Connector)
Current Configurations - Closed
Page 4

2 – Typical POS-GRIP Wellhead System
• Single Piece Hangers
• Thru BOP Technology
• Elegant Design
• Simple yet better
• Maintenance Free
Hydraulic Jack
System
Page 5

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
Page 6

3.1 -“HG” Technology for Production Wellheads
Drill-Through Application
• 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
ANIMATION
Page 7

3.2 - “HG” Technology for Tie-back Wellheads
Tie-Back Application
• 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
Page 8

3.3 - “HG” Technology for Emergency Hangers
“HG” ADJUSTABLE SURFACE WELLHEAD
CASING HANGER
• “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
Page 9

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
Page 10

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
Page 11

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
Page 12

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 nonsense
Conclusion:
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 8
Thermal Cycles 6 23 25 50
Make / Break Test No Yes Yes Yes
Test to Failure No Possible Yes Yes
Testing under load No Possible Yes Yes
Extrapolation Yes No No No
• API 6A Appendix F test standards are not based on good science
Page 13

7.2 - POS-GRIP Standards Compared
POS-GRIP vs API
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 requirements
Conclusion:
• POS-GRIP HG Seals have achieved a New Standard
Page 14

8 - POS-GRIP Capability Explained
The Fundamental Difference – Elimination of Movement
Page 15

9.1 Simple Design – Lower cost
Cost Estimate: £5,465 DD TRIM
£13,445 DD TRIM
Page 16

9.2 One Design – Linear Costs
Page 17

9.3 Thru BOP – Time Savings
Time Advantage
Conventional Installation hrs POS-GRIP Installation
Weld on Starter Head 6 Fre-lok installed POS-GRIP wellhead
Install low pressure BOP n/a Install 18-3/4" BOP
Drill, run 13-3/8" casing
Drill, run 13-3/8" casing
N/D low pressure BOP 5
Cut casing and set slips 4
Install A-Section 4
Install high pressure BOP 8
-1 Activate “POS-GRIP” device
-1 Install and test Annular Seal
Test BOP 6
Drill, run 9-5/8" casing
Drill, run 9-5/8" casing
Second Intermediate Casing BOP lift eliminated 9
Cut casing and set slips 5
Install B-Section 4
-1 Activate “POS-GRIP” device
-1 Install and test Annular Seal
Test BOP 6
Drill, run 7" casing
Drill, run 7" casing
Production Casing BOP lift eliminated 9
Cut and machine Production casing and set slips 9
Production and test spool installation 5
-1 Activate “POS-GRIP” device
-1 Install and test Annular Seal
Test BOP 6
Elimination of casing cuts during abandonment 6
TOTAL TIME SAVINGS PER WELL 86
Page 18

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”
Page 19

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
Page 20

12.1- Other Applications - TLP
Dry-Tree Systems
• 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
Page 21

12.2 Other Applications - Connectors
Riser Connectors
• Re-usable
• Low torque
• High strength
• Radial pre-load
• Metal sealing
Page 22

Drilling Riser Connector
12.3 Other Applications - Risers
• Light weight
• High strength
• Low contact stress
• Pressure enhanced
• Quick make-up
Page 23

12.4 Other Applications - Wellhead Connectors
High Strength/Weight Ratio
• Integral metal seals
• High strength/weight ratio
• Low contact stress
• Pressure enhanced
• Quick makeup
• High stab angle
• Bending capacity independent
from pressure
Page 24

12.5 Other Applications - Work Over
Tubing Space-out
• Adjustable
• Through BOP
• HG sealing
• Tension control
• Re-useable
• Rental Product
Page 25

Reduced Bore Systems
12.6 Other Applications - Subsea
• Slim bore design
• Subsea casing tension
• Integral HG metal seals
• Casing drilling friendly
• Multi-ported Tubing Hangers
Page 26

12.7 Other Applications - Surface BOP Systems
Space-out Joints
• Adjustable metal sealing riser
joint
• Full bore access to wellhead
• BOP test facility
• Remedial inner string capability
• Rental Product
Page 27

13 POS-GRIP Wellheads Installed to date
• Exploration wells – 112
• HG Production Wellheads – 8
• HP/HT Production Wellheads - 5
Page 28

14.1 Appendix 1
45 hours savings
Page 29

14.2 Appendix 2
72 hours savings
Page 30

14.3 Appendix 3
Page 31

14.2 Appendix 4
Page 32