SPE Applied Technology Workshop :

Coiled Tubing : Expanding the Operating Envelope 6 8 February 2012, Dubai, UAE

Recent Developments in Coiled Tubing Pressure Control Equipment and Specifications

Bill Taylor
NOV Texas Oil Tools

Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012.

Fit For Purpose

What is Changing ?
Focus on PCE performance and qualification testing, BOPs

Strippers less focus accepted dynamic performance.

Regulations : International vs Regional approach. Revision

Training and Competency.

Extension of operational requirements 20,000 psi CT; 350 Deg F gas; (30,000 psi WP for WL) . The future : what is required / acceptable ?
Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

Stripper Packers
Various configurations but accepted dynamic performance. On higher pressure wells use of a secondary stripper in tandem to provide back up different philosophies : use to finish the job, or secondary annular seal while changing out worn packer. Two Door : position indicators to estimate packer life : avoid need to change out insert safety and time considerations.

Add image (S) to illustrate.

Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

Coiled Tubing Shearing and Sealing

Most queries in recent times are in relation to shearing : Can my BOP shear X and will it seal ? What is the hydraulic pressure ? Is there documented proof ? Shearing at temperature ? Will it seal in gas ? Note X may not be what the BOP was designed to shear e.g. Coiled tubing > to shear jointed tubing or stem or sinker bar.

Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

SHEAR vs SHEAR / SEAL

BLIND

SHEAR

SHEAR/SEAL (Combi)

QUAD 3.06x 10,000 Psi WP; 1,600 Lbs

SLIP

SLIP RAM
PIPE

PIPE/SLIP (Combi)

DUAL COMBI 4.06 x 15,000 Psi WP; 1,600 Lbs

Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

Coiled Tubing Shearing

Shear Testing and calculation of appropriate shear pressure. Previous empirical testing > Conservative Calculation of shear pressure (+ 200 to 400 psi) Recent events have led regulators to require confirmation of shearing ability witness tests; and more accurate calculation of shear pressures (+ 100 to 150 psi). Calculation can act as a guide but no substitute for empirical test.

Need this data to size accumulators to ensure fit for purpose standard : close / open / close plus 25% (is this enough ?)
Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

Typical BOP Actuator

Piston Rod Hydraulic Piston

Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

BOP Pressure Balanced Piston Rod Actuator

Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

CT Shear and Shear Seal

4.06 Multi Cut Shear Blades Shear Actuator: 18.15 in2 Shear Area 5.00 Main Piston, 1.38 Rod, 4.06 Size Specific Shear Seal Blades Shear Seal Actuator w/ Booster: 29.23 in2 Shear Area 5.00 Main Piston, 4.00 Booster Piston, 1.38 Main & Booster Rod, WBR 19.69

1.75 x .156 wall 144k MYS. 1,598 hyd psi to shear 0 psi WBP

2.38 x .188 wall 110k MYS 2,859 hyd psi to shear 0 psi WBP

1.75 x .156 wall 144k MYS. 1,788 hyd psi to shear 0 psi WBP

2.38 x .188 wall 110k MYS 2,336 hyd psi to shear 0 psi WBP

Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

New Low Force Shear Blade Design

LFS Shear Blades V150 2 7/8 Drill pipe .400 wall 2,600psi (8.50 piston) : 40 - 50 % less hydraulic psi than current designs

Video

Shear data and Blade Factor

Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

Blade Factor and Shear Calculations

Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

Safety Head BOP : Norsok D002, Annexe B Shear Samples

200 psi Low Pressure Test and 15K High Pressure Test (Liquid)
Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

Safety Head Testing

Rated to 15,000psi WP Passed Fluid test at 15,000 psi 300 F Passed 12,500 psi gas test on rams from 34F 295F Gas test on stem seals per API 6A

Ram tested to API 16A HSN/HNBR ram seals Metal x Metal Bonnet gasket Will hold 2500psi from above Bonnet gasket as been tested to 10,000 of water depth for external pressure.

Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

Other CT Queries Shearing with pressure in the BOP / in the coiled tubing ? Shearing under flowing well conditions per ISO 13628-7 ? How long does it take to close the rams ? Regulations : less than 30 seconds, accumulator sizing; hose ID, hose length. API RP 16ST accumulator calculations and verification of performance at different ambient temperatures. Slip Ram performance
Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

Slip Ram Testing Pipe Heavy Pipe Light

Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

INDUSTRY STANDARDS AND SPECIFICATIONS

INTERNATIONAL API 6A : Specification for Wellhead and Christmas Tree Equipment API 16A : Specification for Drill Through Equipment API RP 16ST : Recommended Practice for Coiled Tubing Well Control Equipment Systems
ISO 13628-7 : Petroleum and Natural Gas industries

Design and operation of subsea production systems Part 7: Completion/workover riser systems REGIONAL HSE : UK : Duty of Care Third Party OSPRAG NORSOK D002 : Norway : System requirements well intervention equipment. BOEMRE : US Bureau of Ocean Energy Management, Regulation and Enforcement : Increased Safety measures for Energy Development on the OCS
Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

Training and Competency Currently frequent requests for training of maintenance personnel. Needs to be more than just a certificate. Potential litigation issues. We see many companies developing systems to demonstrate that equipment is fit for purpose ie complies with relevant regulations / internal requirements : Verification / validation / qualification OEM Training OEM Re-certification Important to avoid complacency systems, and people, are not infallible.
Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

Future Developments : Integrity ? HPHT 311 350 F Testing to be performed in the near future on Shear/Seal Rams and Grip/Seal Rams 5 ID 20K designs for CT; 30K in manufacture for Wireline 15K and 350F and Gas Elastomer : Confirmation of fluids compatibility. Low Force Shear Blade Design. Increase shearing capacity Or reduce hydraulic pressure / accumulator volume

Autolocks for Surface Equipment

Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

Automatic Locks ?
Surface BOP - Manual Lock

Subsea BOP Autolock

Minimise Risk ?
Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012

PCE : The Future

Safety Head BOP (LFS Blades) on all CT and Wireline Ops ? End Connections : Elastomeric vs Metal : Quick Union / Flange / Hub ? Subsea specifications for surface equipment ? With AutoLocks ? Remote ram position indication plus flow measurement ? 3,000 psi or 5,000 psi hydraulic control system ?

Q&A

Session 1 : Progress in CT Pipe and Equipment Manufacturing and Performance. 6 February 2012