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


Agenda

• Introduction to Zenith

• Zenith By-pass System new Technology

• Zenith Auto Flow Valve

• Zenith Monitoring Systems

• PCP monitoring new Technology


Introduction to Zenith

Improving performance through innovative solutions


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


Our Locations

● Office

● Agent

● Working in country


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


RAJI CHAD

Sales & Operations(Saudi)

SAID ADAWI


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


Ismail Mohamed

Sales & Operation (North Africa)

NUTALIA AL RIYAMI

Administrator

(Gulf Region)

The Zenith Team


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


New ESP bypass technology simplifies installation & reduces rig time

Presented by – Ismail Mohamed

North Africa Manager



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


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


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


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.


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


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


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 Saddle Assembly

Saddle Bypass Regular Bypass



Flush jointtubing held only with friction clamp



Flush jointtubing heldwith friction clamp


ESP BYPASS WITH SADDLE COMPLETE





Space out critical


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


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 Valve Systems

Increase production with enhanced pump protection.


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)



Ports to Annulus



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



• 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



ESP start up

– The AFV automatically pilots the annular ports to the closed position

– Pump discharge pressure keeps the ports closed



• 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 Monitoring Systems

Safeguard and control your system while optimising production


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


E – Series System


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


E - Series

SPECIFICATIONS

– Temperature Rating: 150°C / 302°F

– Temperature Survivability: 175°C / 347°F

– Pressure Rating: 400 Bar / 5800 psi


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 Surface Panel

• On screen charts

• SCADA Connectivity

• 4mByte Memory

• Analogue I/Os

• Alarm & Trips

• -40C to +75C Operating range


ESP High Voltage Interface Choke

Earth Point connected to a brass plate inside the choke.

3 x 1/8 Amp fuses

Surface panel connections


E - Series


Durable Design !

• Sensor housing severely damaged

Sensor operational and maintained pressure integrity


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


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


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


Normal operationPump Flow rate around 8000 bpd.


High Temperature due to blocked pumpPump flow rate drops under 800 bpd and internal pump intake pressure very low.


Zenith Service

• Zenith offer more than just a sensor!

• Independent analysis

• PSI available for purchase by customers

• Backed by comprehensive training


An Innovative Approach to Increasing PCP runlife



IntroductionTypical PCP Monitoring today

• Surface Drive Readings– Torque – usually derived from current– Surface RPM

• Fluid Level Readings

• Downhole Sensors– Pressure, Temperature & Vibration Gauges


Common PCP Problems

• Damaged Elastomers

– Swelling

– Hysteresis (Over Pressure)

– Over Temperature

– Wear

• Broken Rods

– Over Torque

– Fatigue

– Tightening of couplings

– Deviated wells


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


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


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


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


PCP Rotor Inside Stator


PCP Rotor Outside Stator

Drive started but no pressure change


• 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


• 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


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


Rod String Torsion (twist)


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


Rod String Twist

• When does the rotor start to turn at start up

• What happens to rod twist when you change speed?


Typical Start – Rod Twist

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


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


THANK YOU

• Questions…

Y-tool

Documents

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