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