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 Fn

Page 2
 1.2a - The Principals of POS-GRIP Technology

Type 1 Design Type 2 Design Type 3 Design

(Split Flange) (One Piece) (Connector)

Current Configurations - Open

Page 3
 1.2b - The Principals of POS-GRIP Technology

Type 1 Design Type 2 Design Type 3 Design

(Split Flange) (One Piece) (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 BOPs
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

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

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 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
 12.3 Other Applications - Risers

Drilling Riser Connector

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
 12.6 Other Applications - Subsea

Reduced Bore Systems

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

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