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Transcript of Y-tool
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Presented by – Ismail Mohamed
North Africa Manager
MIDDLE EAST ARTIFICIAL LIFT FORUM 19 - 21 February 2007, Muscat Pre-conference training workshop - 18 February 2007
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Agenda
• Introduction to Zenith
• Zenith By-pass System new Technology
• Zenith Auto Flow Valve
• Zenith Monitoring Systems
• PCP monitoring new Technology
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Introduction to Zenith
Improving performance through innovative solutions
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Zenith Oilfield Technology Ltd.
• Specialist provider of leading edge technology and services related to:
– Gathering and analysis of downhole data– Design of generic and bespoke completions
• Formed in 2003• Ex Phoenix Petroleum Services managers• 110 years combined oilfield experience
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Our Locations
● Office
● Agent
● Working in country
© Zenith Oilfield Technology. Patents and patents pending worldwide.
GREG DAVIE
Managing Director
LES JORDAN
Engineering Director
RICHARD HAMILTON
Finance Director
SANDY SKINNER
Development Manager
KEITH KETTLEWELL
Sales Director
KAREN GRANT
Marketing Manager
ED JAMES
Production Engineer
IAN LOW
Operations Manager
MARGARET ROBERTSON
Document Control
MIKE DONALD
Stores/ Wkshp. Asst.
STEVE BEATTIE
Manager(Gulf Region)
FUAD AL-BATASHI
Field Engineer(Gulf Region)
KHALID AL-ARAIMI
Sales & Operations(Kuwait)
IAN McCONNACHIE
Support Engineer
DAVE ANDREWS
Sales & Operations(North America)
HAMAD AL-BATASHI
Field Engineer(Gulf Region)
RAJI CHAD
Sales & Operations(Saudi)
SAID ADAWI
Field Engineer(Gulf Region)
ABDULLAH RAIDAN
Field Engineer(Sudan)
MALCOLM MACKIE
Production Mgr.
ANDY RIACH
CompletionTechnician
JULIAN CUDMORE
New Technology Manager
DONALD JAAMIESON
Development Engineer
FRANK ZHANG
Sales & Operations(China)
GAYLE SKINNER
Purchasing
EUAN GRAY
Accounts
ABDULLAH TOUWAIYA
Field Engineer(Gulf Region)
Ismail Mohamed
Sales & Operation (North Africa)
NUTALIA AL RIYAMI
Administrator
(Gulf Region)
The Zenith Team
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Product and Services PortfolioZenith
Monitoring Completions
Artificial Lift Monitoring
Gas Lift
Beam Pump
Bypass
Total Protection
Data Analysis
E-SeriesComms on Power
C-SeriesCable to Surface
Diagnosis & Design [PSI]
Production Optimisation
Specialist Completions
Auto Flow Valves
Data Interpretation Training
ESP
9 5/8” System
7” System
Jet Pump
PCP Protection System
R-SeriesReservoir Monitoring
© Zenith Oilfield Technology. Patents and patents pending worldwide.
New ESP bypass technology simplifies installation & reduces rig time
Presented by – Ismail Mohamed
North Africa Manager
MIDDLE EAST ARTIFICIAL LIFT FORUM 19 - 21 February 2007, Muscat Pre-conference training workshop - 18 February 2007
© Zenith Oilfield Technology. Patents and patents pending worldwide.
IntroductionESP Logging Bypass Systems
• Technology introduced in 1987.
• Y-tool offsets the ESP in the well bore.
• Bypass tubing provides a conduit to access the reservoir below the ESP.
• Bypass clamps hold the bypass tubing to the ESP assembly and provide clips to protect cables.
• Blanking plug set in nipple below the Y-tool prevents fluids circulating through the bypass tubing.
Handling Sub
Y-Tool
Pump Sub
Bypass Tubing
ESP
Teleswivel Nipple
Bypass Clamp
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Thermal Expansion of the ESP• Bypass clamps grip the bypass
tubing to the ESP assembly
• The addition of a pump support under the motor requires the bypass tubing to match the length of the ESP
• These methods do not allow the ESP to freely expand and contract with changing temperatures Pump Support
© Zenith Oilfield Technology. Patents and patents pending worldwide.
An Example of Thermal Expansion
• A 30ft long steel object will expand 0.2268 inches in length with a 100F rise in temperature.
• If the ends of the object are held firmly the object will bow with a deflection of
5-1/2”.
θ
b = 5.534
L=360
x =2924.4658”
r =2930”
LE=360.2268
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Solution• Thermal expansion will place undue
stresses on the bypass clamps and ESP
– Give the bypass clamps freedom to slide along the bypass tubing.
– The ESP can now expand and contract freely, as it would in a free hanging ESP installation.
– The clamps grip the ESP necks maintaining alignment of the ESP and bypass tubing.
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Assembly on the rig floor
Standard bypass
• Method of assembly depends on derrick height vs. assembly length
• If assembly length is less than the pick of height of the rig the bypass tubing and ESP can be built independently (Method 1)
Pick up height sufficient to enable fitment of the lower bypass clamp
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Assembly on the rig floor
Standard bypass
• If assembly length is greater than the pick of height of the rig the bypass tubing and ESP must be assembled in parallel (Method 2)
Pick up heightinsufficient to enable fitment of the lower bypass clamp
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Bypass Saddle
The saddle assembly simplifies the installation procedure by:-
– Allowing both bypass string and ESP assembly to be lifted in the elevators in one operation regardless of ESP length.
– Removing the need to space out the bypass tubing with ESP.
– Removing the need for a friction clamp to support the flush joint tubing during assembly.
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Zenith Saddle Assembly
Saddle Bypass Regular Bypass
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Saddle Bypass Regular Bypass
Flush jointtubing held only with friction clamp
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Saddle Bypass Regular Bypass
Flush jointtubing held only with friction clamp
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Saddle Bypass Regular Bypass
Flush jointtubing heldwith friction clamp
© Zenith Oilfield Technology. Patents and patents pending worldwide.
ESP BYPASS WITH SADDLE COMPLETE
Saddle Bypass Regular Bypass
© Zenith Oilfield Technology. Patents and patents pending worldwide.
ESP BYPASS WITH SADDLE COMPLETE
Saddle Bypass Regular Bypass
© Zenith Oilfield Technology. Patents and patents pending worldwide.
ESP BYPASS WITH SADDLE COMPLETE
Saddle Bypass Regular Bypass
© Zenith Oilfield Technology. Patents and patents pending worldwide.
ESP BYPASS WITH SADDLE COMPLETE
Saddle Bypass Regular Bypass
© Zenith Oilfield Technology. Patents and patents pending worldwide.
ESP BYPASS WITH SADDLE COMPLETE
Saddle Bypass Regular Bypass
© Zenith Oilfield Technology. Patents and patents pending worldwide.
ESP BYPASS WITH SADDLE COMPLETE
Saddle Bypass Regular Bypass
Space out critical
© Zenith Oilfield Technology. Patents and patents pending worldwide.
ESP BYPASS WITH SADDLE COMPLETE
Saddle Bypass Regular Bypass
Space out critical
© Zenith Oilfield Technology. Patents and patents pending worldwide.
ESP BYPASS WITH SADDLE COMPLETE
Saddle Bypass Regular Bypass
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Results
OperatorRegularBypass & ESP
(Hours)
New TechnologyBypass & ESP
(Hours)
Time Saved
(Hours)
KOC 12 5 7 GNPOC 12 5.5 6.5 Oxy 8 3.5 4.5Perenco 17 9.5 7.5
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Conclusions
• The sliding bypass clamps allow the ESP to expand and contract with changes in operating temperature.
• The saddle simplifies rig floor assembly– Reduces engineer time required on site– Reduces rig time during installation– Reduces the risk of dropping equipment
downhole
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Zenith Valve Systems
Increase production with enhanced pump protection.
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Zenith Auto Flow Valve
• Prevents Sand Settling in the ESP
• Enable Free flow to bypass the ESP
• Prevents Back Spin
• Wireline Retrievable Option
• ESP Bypass Option (Total Protection System)
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Zenith Auto Flow Valve
Ports to Annulus
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Zenith Auto Flow Valve
Two StageValve Mechanism -Prevents Recirculation1. Pressure from the pump
is applied to bottom of valve mechanism
2. The 1st stage of the mechanism pushes a sleeve upwards to first close the ports.
4. The mechanism is held in place by the pressure from the pump, keeping the ports closed.
3. The 2nd stage of the mechanism is released which allows flow to pass upwards through the valve only when the ports are closed. This prevents recirculation of fluid through the ports during operation
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Zenith Auto Flow Valve
• Increased pump protection: ESP shut down– Pump damage prevention on shut down
by avoiding tubing solids descending into the pump
– Fluid column drains through annular ports
– Prevents backspin – immediate restart
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Zenith Auto Flow Valve
ESP start up
– The AFV automatically pilots the annular ports to the closed position
– Pump discharge pressure keeps the ports closed
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Zenith Auto Flow Valve
• Increased production: Naturally Flowing wells– The AFV ports automatically reopen,
allowing natural flow to pass through the annular ports
– ESP is fully protected from scale, wear and debris build up as flow path is through annular ports
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Zenith Monitoring Systems
Safeguard and control your system while optimising production
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Zenith Monitoring Systems
• E Series - Comms on Power– ESP
• PCP Protection System – Torsion and Position
• C Series - Cable to Surface – Gas Lift, Beam Pump, Jet Pump, Observation wells
• R Series - Cable to Surface / Memory– Reservoir Monitoring
© Zenith Oilfield Technology. Patents and patents pending worldwide.
E - Series
Configure the sensor from the following parameters to suit your monitoring requirements
» Intake Pressure» Discharge Pressure» Intake Temperature» Motor Oil temperature» Motor Winding Temperature» Vibration x and y» Current Leakage
© Zenith Oilfield Technology. Patents and patents pending worldwide.
E - Series
SPECIFICATIONS
– Temperature Rating: 150°C / 302°F
– Temperature Survivability: 175°C / 347°F
– Pressure Rating: 400 Bar / 5800 psi
© Zenith Oilfield Technology. Patents and patents pending worldwide.
E - Series
SPECIFICATIONS
• Pressure– Range: 0 - 5,800 psi– Accuracy: 0.2% FS or 0.1% FS– Resolution: 0.1 psi
• Temperature– Range 0 - 150C (250C motor temp)– Accuracy: 1°C– Resolution: 0.1°C
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Zenith Surface Panel
• On screen charts
• SCADA Connectivity
• 4mByte Memory
• Analogue I/Os
• Alarm & Trips
• -40C to +75C Operating range
© Zenith Oilfield Technology. Patents and patents pending worldwide.
ESP High Voltage Interface Choke
Earth Point connected to a brass plate inside the choke.
3 x 1/8 Amp fuses
Surface panel connections
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Durable Design !
• Sensor housing severely damaged
Sensor operational and maintained pressure integrity
© Zenith Oilfield Technology. Patents and patents pending worldwide.
ReliabilityZenith Sensor Survivability
60.0%
65.0%
70.0%
75.0%
80.0%
85.0%
90.0%
95.0%
100.0%
30 90 150 210 270 330 390 450 510 570 630 690 750 810 870 930 990
Days Running
% p
rov
idin
g c
us
tom
er
da
ta
Sensor Survivability
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Survivability in Extreme TemperatureMN 64 Zenith Data Detail
1500
2000
2500
3000
3500
4000
19/09/2006 12:00:00 20/09/2006 00:00:00 20/09/2006 12:00:00 21/09/2006 00:00:00 21/09/2006 12:00:00 22/09/2006 00:00:00
Time
Pre
ss
rue
(p
si)
0
50
100
150
200
250
300
350
400
tem
pe
ratu
re (
F)
Pi psi Pd psi Ti F Tm F
1
2 3
4
5
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Well Analysis: “PSI”
• Unique to the industry
• Operates on Pocket PC or desktop
• Designed by industry leaders
• Can be used at the well site
• Fully supported and backed by Zenith
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Normal operationPump Flow rate around 8000 bpd.
© Zenith Oilfield Technology. Patents and patents pending worldwide.
High Temperature due to blocked pumpPump flow rate drops under 800 bpd and internal pump intake pressure very low.
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Zenith Service
• Zenith offer more than just a sensor!
• Independent analysis
• PSI available for purchase by customers
• Backed by comprehensive training
© Zenith Oilfield Technology. Patents and patents pending worldwide.
An Innovative Approach to Increasing PCP runlife
MIDDLE EAST ARTIFICIAL LIFT FORUM 19 - 21 February 2007, Muscat Pre-conference training workshop - 18 February 2007
© Zenith Oilfield Technology. Patents and patents pending worldwide.
IntroductionTypical PCP Monitoring today
• Surface Drive Readings– Torque – usually derived from current– Surface RPM
• Fluid Level Readings
• Downhole Sensors– Pressure, Temperature & Vibration Gauges
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Common PCP Problems
• Damaged Elastomers
– Swelling
– Hysteresis (Over Pressure)
– Over Temperature
– Wear
• Broken Rods
– Over Torque
– Fatigue
– Tightening of couplings
– Deviated wells
© Zenith Oilfield Technology. Patents and patents pending worldwide.
PCP Monitoring
Existing Downhole Monitoring Technology
• Pressure Temperature and Vibration Gauges
Good for well monitoring
Good for protection against
• Pump Off• Dead heading • Over Temperature• Assessing when the pump has become damaged
Limited information for the route cause of rod and elastomer damage
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Common PCP Problems• Damaged Elastomers
– Swelling • Produced Fluid types
– Hysteresis (Over Pressure)• Closed Valves • Heavy fluids• Improper rotor location (too high)
– Over Temperature• Pump off• Excessive Gas• Improper rotor location (too low)
– Wear• Produced Fluid Solids Content• Speed• Length of operation (total rotations)• Improper rotor location (too high / low)
• Broken Rods
– Over Torque• Produced Fluid types• Improper Rotor location (too low)
– Fatigue• Friction• Rotation and Bending• Excessive cyclic motion caused by
Improper rotor location (too high)
– Tightening of couplings
– Deviated wells
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Installation of PCP Rotor
Rotor position is normally set with an installation space out
1. Run Rotor on rod string until it lands on tag bar
2. Pull back to tension the rod string
3. Pull back distance of tag bar to bottom of pump
4. Pull back a distance calculated to counter operational stretch
5. Clamp polished rod at surface
6. Start pump and rotor should settle in correct position
Tag Bar
Elastomer
Rotor
Rod String
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Installation of PCP Rotor
Too High
•Lost Lower pump stages •Damage to upper elastomer•High Vibration•Possible tubing damage•Rotor fatigue
To Low
•Rotor Binds on Tag Bar•Heat Damages lower elastomer•Stator or tubing unscrewing•Rotor Coupling damages elastomer
Possible errors in space out
• Relies on well data and calculations for rod string stretch
• Relies on correct indication on weight indicator when pulling back from tag bar
© Zenith Oilfield Technology. Patents and patents pending worldwide.
PCP Rotor Outside Stator
Drive started but no pressure change
© Zenith Oilfield Technology. Patents and patents pending worldwide.
• Measure Rotor Position During installation– Measure the rotor position
downhole
– Pull back to counter for operational rod stretch
– Ability to see the results of the operational rod stretch
Gauge
Rods String
¼ “ Instrument line
Carrier
Solution
© Zenith Oilfield Technology. Patents and patents pending worldwide.
• Measure Rotor Position During operation
• Down– Temperature expansion, increased loading,
increasing fluid weight, increasing back pressure
• Up – Decreasing fluid weight, rod wind up, decreasing
back pressure, decreased loading
– Compensate at surface
– Is the rotor moving enough to create wear?
Solution
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Monitoring and tracking PCP wear
• Rotational movement creates wear.– Track total rotor cycles over pump life– Delta Pressure across pump– Vibration
• Axial (vertical) movement. – Is it sufficient to accelerate wear?– Track vertical movement over time
• Meters per hour • Total movement over life of pump
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Rod String Twist
• How much twist occurs in a rod string?
• What happens with the stored energy in the rod?
• What breaks a rod?– Twisting or bending?
• Does twist change rotor position?
TORQUEAPPLIED
Torsional Loadfrom Rod string
Torsional Loadfrom Pump
© Zenith Oilfield Technology. Patents and patents pending worldwide.
Rod String Twist
• When does the rotor start to turn at start up
• What happens to rod twist when you change speed?
Technology exists to monitor Rod Torsion/Twist
How to use torsion effectively
Field Trial Torsion Database
Rod Size
MaterialType
Length TotalCycles
This run
TotalCyclesall runs
Average RodBreak Point
Torsion/MThis Run
Recommended Alarm Level
Recommended Trip level
1.0 Sld 1500M xxxx xxxx X co. 350/1000m 240/1000m 320/1000m 340/100m
1.5 Hlw 2000M xxxx xxxx X co. 290/1000m 270/1000m 260/1000m 280/100m
1.0 Sld 1500M xxxx xxxx Y co. 400/1000m 300/1000m 370/1000m 390/100m
1.0 Sld 1500M xxxx xxxx C co 650/1000m 450/1000m 620/1000m 640/100m
Comments: Monitor Company C, low Torsion Limits
Slow down the pump speed to reduce torsion
Adjust rotor position to minimise rod movement
© Zenith Oilfield Technology. Patents and patents pending worldwide.
CONCLUSION To improve PCP Runlife
• Monitor & Control– Rotor position
• Improve rotor installation• Maintain optimum position with compensation
– Rod string twist• Reduce torsion & associated rod breakage• Control Drive Speed
– Draw down• Control Drive Speed with pressure• Maintain Optimum production
• Monitor– Pressure, Temperature, Vibration– Pump Wear– Rotor cycles & movement for pump life
Rod String Torsion
Rotor Position & Movement
Discharge Pressure & Temperature
Intake Pressure & Temperature
Vibration
Downhole Rotor Speed
Total Rotor Cycles