Xpress-ESP™ - Coiled Tubing Completion System

INNOVATIVE ENGINEERING SYSTEMS LIMITED 14 RUBISLAW TERRACE LANE ABERDEEN AB10 1XF UK

TEL: +44 (0)1224 658695 FAX:+44 (0)1224 658696 E-MAIL [email protected]

INNOVATIVE ENGINEERING SYSTEMS LIMITED

IES

L

Xpress-ESP™

Coiled Tubing Completion System

Technologies Technical Brochure

February 2004

Version 2.0

TABLE OF CONTENTS

This document contains CONFIDENTIAL and PROPRIETARY INFORMATION of INNOVATIVE ENGINEERING SYSTEMS LTD (IESL). This document and the information disclosed herein shall

not be reproduced in whole or in part to others for any purpose including conceptual design, engineering, manufacturing or construction without the written permission of IESL. IESL 2003

VERSION 2.0 Xpress-ESP™ FEBRUARY 2004 3

1. INTRODUCTION........................................................................................... 5

2. XPRESS-ESP™ - SYSTEM DESCRIPTION................................................ 7

3. SYSTEM COMPONENTS............................................................................. 9

3.1 Cable/coiled tubing assembly ............................................................... 9

3.2 Subsurface assembly........................................................................... 11

4. WELL CONTROL & SAFETY SYSTEMS ................................................ 13

4.1 Circulation and Release System – E-Scape™ .................................... 13

4.2 Flow Control & Isolation TOOL - FS-Valve™ .................................. 14

5. TRACK RECORD – CT COMPLETIONS.................................................. 15

6. CONTACT INFORMATION....................................................................... 17

Table of Content

This document contains CONFIDENTIAL and PROPRIETARY INFORMATION of INNOVATIVE ENGINEERING SYSTEMS LTD (IESL). This document and the information disclosed herein shall not be reproduced in whole or in part to others for any purpose including conceptual design, engineering, manufacturing or construction without the written permission of IESL. IESL 2003

4 FEBRUARY 2004 Xpress-ESP™ VERSION 2.0

Section 1

INTRODUCTION 1




1. INTRODUCTION

P r o b l e m s

Are your wells subject to expensive workover rig costs or remote locations

for ESP completions?

Do you have problems where you can’t run a conventional ESP pump

assembly?

Do you have to pull the pump because of cable seal failure?

Are you unable to circulate your well and release cleanly from the BHA?

B e n e f i t s

Deploy ESP pumps on Coiled Tubing, quickly and efficiently even in

remote locations!

Innovative cable seal provides low impact, high resistance seal!

Dedicated flow control and safety systems prevent damage to motor during

shutdown and clean release from BHA!

Xpress-ESP™ is a completion system that utilises electric-ubmersible pumps as the means of liftinging hydrocarbons and/or water from underground reservoirs. The system comprises the surface and subsurface assemblies required to complete the wells with the exception of the ESP. The system is configured for use in wells that require inverted pumps (i.e. motor located at the top of the ESP assembly).

Xpress-ESP™ offers the following advantages:

Reduce cost and minimize downtime by avoiding the use of rig and by allowing faster installation/recovery of the completion

Extends run life and improves reliability by isolating the electrical parts from the production fluids.

Minimize formation damage by allowing live well deployment and retrieval.

Introduction 1



Xpress-ESP™ is the only completion system that allows well intervention without retrieving the completion.

Xpress-ESP™ systems incorporate subsurface flow control system for well safety and reservoir isolation.

Xpress-ESP™ provides a release and circulating system that allows safe well circulation & control, disconnect and effective retrieval of the completion.

Xpress-ESP™ components have been thoroughly tested in order to ensure that problems encountered with other commercial system such as cable slippage, internal and external damage to the Coiled Tubing and installation failure are avoided.

Section 2

XPRESS-ESP™ - SYSTEM DESCRIPTION

2




2. XPRESS-ESP™ - SYSTEM DESCRIPTION

Xpress-ESP™ Completions are composed of two main assemblies. The subsurface assembly comprises of elements from the bottom of the Coiled Tubing string to the pump assembly depending on the configuration selected. The following paragraphs describe in more detail the system specifications and operating principles.

The Xpress-ESP™ system has been designed to be utilised in wells that require the use of inverted (Bottom Intake) ESP’s. The sub-surface assembly is composed of cable termination and isolation devices located at the top of the pump assembly and a release/circulation device that allows well neutralization and release (disconnect) from the ESP assembly.

The system allows flow control and formation isolation by locating the deep-set safety valve at the intake side of the pump. The subsurface assembly incorporates a pump discharge sub whose design is based on packer technology, this removes the complication and problems associated with existing discharge heads. This flow diverter placed between the pump and the motor (or seal) provides isolation between the suction and discharge sides of the pump assembly, takes the torque generated by the pump unit and allows flow to cross from the internals of the pump into the annular space. The system does not require a sacrificial tubing string to be used and does not impose depth setting limitations; the pump can be set at any particular depth since it does not rely on fixed seating devices.

Xpress-ESP™ utilises Mag-CLAMP™ technology for the suspension of the cable inside the Coiled Tubing string. This patented technology permits effective cable suspension without indenting and damaging the walls of the Coiled Tubing string. Engineered cable load distribution avoids slippage and excessive tensile/compressive loads associated with installation failures in wells utilizing the anchor or welded type of suspension devices. The figure on the following page illustrates a typical completion system.

Xpress-ESP™ - System Description 2



Xpress-ESP™ - Subsurface Assembly Item Description

1 Coiled Tubing

2 Circulating & Release System

E-Scape™ 3 Control Line

4 Adjustable Setting & Discharge System

Section 3

SYSTEM COMPONENTS 3




3. SYSTEM COMPONENTS

Xpress-ESP™ is composed of three main assemblies, the surface part of the system, the cable/Coiled Tubing section and the subsurface assembly. The following pages illustrate these sub-systems in more detail.

3.1 CABLE/COILED TUBING ASSEMBLY

The cable / Coiled Tubing assembly utilises the patented Mag-CLAMP™. This technology allows effective suspension of the electrical power cable without damaging either the cable or the Coiled Tubing. Conventional anchor mechanisms used to date have presented a number of problems that have lead to completion failure. Poor gripping, CT wall indentation and cable slippage are some of the main problems. The indentation caused is beyond the acceptable tolerances set by the Coiled Tubing manufacturers. Such damage leads to crack initiation that under typical operational conditions could result in a parted string. Mag-CLAMP™ is a patented technology and does not require external or internal deformation or indenting of the string. Cable suspension systems for wells using Mag-CLAMP™ are designed based on well deviation, orientation, depth and cable weight. The following figure illustrates the cable / coiled tubing assembly.

System Components 3



Item Description

1 Coiled Tubing 2 Electrical Cable 3 Mag-CLAMP™ Body 4 Suspension Assembly

CABLE SUSPENSION ASSEMBLY - Mag-CLAMP™

1

2

Patent Pending

3

4

System Components

3



3.2 SUBSURFACE ASSEMBLY

Subsurface equipment for the Xpress-ESP™ system is for use in wells requiring an inverted pump configuration. There are three key components utilised in this system - the circulation and release tool (E-Scape™); and adjustable setting, isolation and discharge unit – the key components of the Xpress-ESP™ system and a formation isolation valve (FS-Valve™). The following schematic and table illustrate the main characteristics of the subsurface assembly for Xpress-ESP™ equipment.

ADJUSTABLE SETTING, ISOLATION AND DISCHARGE – Xpress-ESP™

System Components 3



Sub Assembly Max. O.D.

(in) Min. I.D.

(in) WP Rating

(psi) Remarks

E-Scape™ 6.00 2.75 5000 Allows circulation of fluids above the motor and disconnect from the BHA

Xpress-ESP™ 5.50 3.25 5000 Located between the motor and pump, provides both isolation and discharge of

produced fluids.

FS-Valve™ 6.00 3.50 5000 Hydraulically activated valve to minimise damage to formation by preventing flow

back during pump shutdown.

SUBSURFACE ASSEMBLY - GENERAL SPECIFICATIONS

More details concerning the safety and control systems are included in the following section.

Section 4

WELL CONTROL & SAFETY SYSTEMS

4




4. WELL CONTROL & SAFETY SYSTEMS

Xpress-ESP™ well control and safety systems have been designed to avoid the uncontrolled release of hydrocarbons to the environment and to allow safe and effective release of the Coiled Tubing string from the pump assembly during deployment or retrieval operations. Two control and safety systems are incorporated in these type of completions, E-Scape™ (circulation and release tool), and FS-Valve™ (flow control and isolation tool)

4.1 CIRCULATION AND RELEASE SYSTEM – E-SCAPE™

E-Scape™ provides three main functions. Firstly to neutralize the well by allowing circulation via the internals of the Coiled Tubing, secondly to allow safe and effective release of the Coiled Tubing string from the pump assembly and finally to severe the electrical power cable and hydraulic conduits passing through the main mandrel. Two of these functions are independent.

E-Scape™ is pressure activated via the internals of the CT string and energizes a cam/slot system that will allow communication between the internals of the CT and the annular space in order to circulate the well. This function can be operated as many times (open/close cycles) as required and does not impact the release and cutting functions.

The release function is vital in cases where it is impossible to unseat the packer or the ESP assembly is jammed (e.g. pump sanded). In this case, the pulling capacity of the injector head and/or the strength of the CT string limit the options available to retrieve the completion. As a result, the string has to be released. The E-Scape™ system will allow an effective release/disconnect from the jammed section, the link is broken at the bottom of the CT string and it requires straight pull. It is during the releasing/disconnecting that the third function is activated. E-Scape™ allows the electrical cable and hydraulic conduits to be cleanly severed without leaving any debris on the top of the "fish". They are cut as the CT string is being pulled after releasing from the stuck assembly.

The completion can then be recovered using a larger size CT or with a rig using tubing/drill pipe. The following sketch illustrates a E-Scape™ system for a 7.0" completion in its circulating position.

Well Control & Safety Systems 4



4.2 FLOW CONTROL & ISOLATION TOOL - FS-VALVE™

The FS-Valve™ is for all practical purposes a deep set downhole safety valve. Located at the discharge of the ESP assembly and below the packer, it is hydraulically closed from surface via a control line. FS-Valve™ is opened using the pump discharge pressure. The forces created by the flow of fluids through the valve locks the sealing body of the FS-Valve™ ensuring that a large flow area is available minimizing the risk of erosion. Once the pump fails or is temporarily shut down, pressurising via a dedicated control line at surface closes the valve.

Test results have characterized pressure losses of fluids flowing through the valve. These results confirm initial CFD simulations that indicated minimum losses even for very high flow rates.

Section 5

TRACK RECORD – CT COMPLETIONS 5




5. TRACK RECORD – CT COMPLETIONS

Since its foundation IESL has been at the forefront of CT Completions, based on over 25 years of technical, managerial and operational experience the company has been involved in many projects worldwide. Some of the milestones include managing the first two CT ESP completions using an internal cable assembly, a summary of some of the main projects completed to date is presented in the following table.

Operator Field Year Type of Work Activity SHELL UK Dunlin, UK 1995 Engineering Recompletion, 1 well

EEC Stockbridge, UK 1994/1995 Management,

engineering and supervision

2 installations, CT ESP completions

STATOIL Siri, Norway 1996 Engineering Completion design, 1 well NORSK HYDRO

Hermod, Norway 1996 Engineering Completion design, 1 well

w/CT ESPs

CENTRILIFT North Sea 1997 Equipment development

Development of complete CT ESP system

STATOIL YME, Norway 1997 Engineering Completion Design, 2 wells w/CT ESPs

SHELL UK Brent, UK 1996 Engineering BPW project, CT ESPs

BP Thistle, UK 1997 Engineering Recompletion design, 1 well w/CT ESPs

SHELL Brunei Magpie, Brunei 1997 Engineering Recompletion, 2 wells

REDA YME, Norway 1998 Equipment development

Development of safe disconnect system

PDVSA CEPRO 1998 Engineering Test installation

IESL's PROJECT PORTFOLIO SUMMARY

Track Record – CT Completions 7



Section 6

CONTACT INFORMATION 6




6. CONTACT INFORMATION

U N I T E D K I N G D O M

14 Rubislaw Terrace Lane,

Aberdeen AB10 1XF

Scotland

Telephone 01224 658695

Facsimile 01224 658696

Email [email protected]

Woodfalls,

Hythe Road

Marchwood

Hants, SO40 4WU

England

Telephone 02380 849074

Facsimile 02380 849083


U N I T E D S T A T E S

10375 Richmond Avenue

Suite 1300

Houston

TX 77042

USA

Telephone 713 974 0634

Facsimile 832 251 6691


Contact Information 8



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Xpress-ESP™ - Coiled Tubing Completion System