4 day. Bypass _ Dual Systems oil gas.pptx
- 1. 1 Y-tool & Dual Systems Novomet Application Engineers School
- 2. 2 Y-Tool Y-Tool (Bypass) systems originally provides the ability to access the formation below the ESP for different purposes. For example: you can change the settings of a flow control system, you can stimulate your formation with coiled tubing, you can run a production logging test (PLT) with the ESP in operation, you can use it in multiple system for multi reservoir production in the same well.
- 3. 3 Y-Tool Applications Wire line Logging operations Coil tubing Logging operations Free-flow production bypassing the ESP while ESP shutdown Activation/deactivation of Flow Valves located below the Bypass System Holding the equipment located below. In this case, it is necessary to use Load-Carrying Y-Tool Configuring for Dual ESP Systems Tubing Pressure testing
- 4. 4 Y-Tool Benefits Access to down hole zone without ESP pulling out ESP system protection during natural flow or bullheading Well survey during ESP system operation with changing of operation modes Operation in casings starting from 5他 (146 mm) and bigger
- 5. 5 Y-Tool Design Pressure test sleeve Y-block assembly Pressure test plug Pup-joint of Y-block assembly Bypass tubing Bypass clamp (Pump-Pump) Bypass clamp (Motor-Protector) Support assembly ESP swivel Clamp Y-block Blanking plug Logging plug (geophysical)
- 6. 6 Y-Tool Components Pressure test plug Pressure test sleeve Pup joint of Y-block assembly Y-block assembly, including: ESP Swivel Y-Block Clamp Blanking plug Bypass tubing Bypass clamps Support assembly Logging plugs: for smooth logging cable for non-smooth logging cable for coiled tubing Replaceable parts kit Y-Tool installation tools and accessories CHECK VALVE (usually bypass is used without check valve. That means that all flow will fall back through the ESP when it is shut off. But it can be installed under the Customers request)
- 9. 9 Y-Tool Glossary Novomet Bypass System can be designed in different sizes and modifications. Please see the Novomet Bypass System glossary for easy Bypass Selection. Y-TOOL X-X/X" X.XX" XXXFT TYPEX CRX Y-tool Casing OD, inches Minimum bypass passage ID, inches (see Table 1) Bypass tubing length, ft Logging plug design (see Table 2) Corrosion resistance (see Table 3) e.g., Y-TOOL 7" 1.77" 118FT TYPE1 CR3
- 10. 10 Y-Tool Glossary Table 1 - Bypass tubing size Min bypass passage ID Casing OD ESP system OD inch mm inch mm inch mm 1.38 35 53 /4 146 3.19 81 1.45 37 65 /8 168 3.78 96 1.50 38 7 178 4.06 103 1.61 41 7 178 4.06 103 1.77 45 7 178 3.78 96 2.05 52 65 /8 168 3.19 81 2.24 57 7 178 3.19 81 2.44 62 95 /8 245 5.62 143 Table 2 - Logging plug design Seal type Logging plug design Logging plug ID/ Nominal cable OD inch mm Chevron seal* Taper seal** Type0 X 0.315" 8.0 Type1 X 0.236" 6.0 Type2 X 0.248" 6.3 Type3 X 0.394" 10.0 Type4 X 1.000" 25.4 Type5 X 1.500" 38.1 Type6 X 0.343" 8.7 Type7 X 0.402" 10.2 Type8 X 1.752" 44.5 * - Chevron seal is rubber-fabric seal for coiled tubing. ** - Taper type is bronze seal with small clearance. It is used for non-smooth logging cable.
- 11. 11 Y-Tool Glossary Table 3 - Corrosion resistance Abbr. Full name Fluid Max chemical content, g/l pH Description H2S CO2 Cl CR1 Corrosion Resistant 1 Moderately aggressive fluid 0.01 1.25 1.45 0.01 200 4.0..8.5 All components except Bypass tubing are from Stainless Steel. Bypass tubing is from Carbon Steel. CR3 Corrosion Resistant 3 Highly aggressive fluid 1.25 1.45 200 3.0..9.0 All components are from Stainless Steel.
- 12. 12 Y-Tool Specification Y-TOOL variants Casing OD ESP system OD Min bypass passage ID inch mm Inch mm inch mm Y-TOOL 5-3/4" 1.38" 53 /4 146 3.19 81 1.38 35 Y-TOOL 6-5/8" 1.45" 65 /8 168 3.78 96 1.45 37 Y-TOOL 6-5/8" 2.05" 65 /8 168 3.19 81 2.05 52 Y-TOOL 7" 1.5" 7 178 4.06 103 1.50 38 Y-TOOL 7" 1.61" 7 178 4.06 103 1.61 41 Y-TOOL 7" 1.77" 7 178 3.78 96 1.77 45 Y-TOOL 7" 2.24" 7 178 3.19 81 2.24 57 Y-TOOL 9-5/8" 2.44" 95 /8 245 5.62 143 2.44 62
- 13. 13 Y-Tool Selection 1. First of all you should select the ESP System. 2. Then in accordance with selected ESP series and Casing size ID you may select Bypass series. 3. Taking in consideration Customers Logging tool OD correct selected Bypass series if necessary. For example: The 319 series pump was selected. So Y-TOOL 5-3/4" 1.38 can be taken. But if Customers Logging tool size is more than 1.38 so we should change Bypass System to the next Y-TOOL 6-5/8" 1.45. But in this case we must check Casing ID.
- 14. 14 Y-Tool Selection 4. Then you should select length of bypass tubing using table below. ESP System length Conditional length of bypass tubing Actual length of bypass tubing Number of bypass tubing pipes Number of bypass clamps between pump sections + bypass clamp between lower pump section and protector ft m ft m ft m 31.2-44.3 9.5-13.5 49 15 44.3 13.5 3 1+1 44.3-59.1 13.5-18 59 18 59.1 18 4 2+1 59.1-73.8 18-22.5 72 22 73.8 22.5 5 3+1 73.8-88.6 22.5-27 89 27 88.6 27 6 3+1 88.6-103.4 27-31.5 105 32 103.4 31.5 7 4+1 103.4-118.1 31.5-36 118 36 118.1 36 8 4+1 118.1-132.9 36-40.5 131 40 132.9 40.5 9 4+1 132.9-147.6 40.5-45 148 45 147.6 45 10 5+1 147.6-162.4 45-49.5 164 50 162.4 49.5 11 5+1 162.4-177.2 49.5-54 177 54 177.2 54 12 6+1
- 15. 15 Y-Tool Selection 5. Select Logging plug design using Table2 from Y-Tool Glossary. Depending on using type and size of logging cable or coiled tubing different seal type in logging plug can be selected. 6 . The last parameter for selection is corrosion resistance. Using Table3 from Y-Tool Glossary you can choose CR1 or CR3 modification. Table 2 - Logging plug design Seal type Logging plug design Logging plug ID/ Nominal cable OD inch mm Chevron seal* Taper seal** Type0 X 0.315" 8.0 Type1 X 0.236" 6.0 Type2 X 0.248" 6.3 Type3 X 0.394" 10.0 Type4 X 1.000" 25.4 Type5 X 1.500" 38.1 Type6 X 0.343" 8.7 Type7 X 0.402" 10.2 Type8 X 1.752" 44.5 * - Chevron seal is rubber-fabric seal for coiled tubing. ** - Taper type is bronze seal with small clearance. It is used for non-smooth logging cable.
- 16. 16 Load-Carrying Y-Tool Load-Carrying Y-Tool is designed to keep the equipment located below.
- 17. 17 Dual systems Dual ESP System is a combination of ESP and Y-Tool Systems. Dual System can be used for: Multi-reservoir production from the same well; Long-term operation of two ESP Systems (one ESP as back-up); Separated flow control from the different zones.
- 18. 18 Dual Benefits Increased oil production Increased equipment durability and run time Concentric or parallel double tubing for separate flow control without ESP system shutdown
- 19. 19 Dual Features Selective control of each ESP system operation Measurements of flow rate of produced fluid from each zone Available for Casings from 5- 3/4 up to 9-5/8 (from 146 to 245 mm)
- 20. 20 Dual Configurations Dual ESP system configuration for multi-zone production in casings from 5 他(146mm) Can be used when distance between reservoirs more than 260ft (80m) Dual ESP system configuration including leakproof POD system for multi-zone production in casings from 5 他 (146mm) Can be used when distance between reservoirs from 16 to 260ft (from 5 to 80m)
- 21. 21 Dual components Sub Y-Tool Pup joint of valve Pup joint of ESP Load-carrying tube Clamps Movable assembly Spare parts kit Tool and equipment set Leakproof rod (only for concentrical type of tubing lift)
- 22. 22 Dual System Glossary SD XXX - XX - XX / X X Dual System Casing OD, mm Load-carrying tube OD, mm Conditional length of system, m Type of lift (0 - conventional, 1 - concentrical) Corrosion resistance e.g., SD146-41-40/00
- 23. 23 Dual System Selection 1. Depending on distance between reservoirs you should select type of configuration: Lower ESP between perforation zones (if distance more than 260ft/80m); Lower ESP in shroud (if distance between perforations less than 260ft/80m)
- 24. 24 Dual System Selection 2. Based on chosen ESP series and Casing size select Dual System size. Dual System Casing OD ESP series Load-carrying tube OD Type of tubing lift inch mm Inch mm inch mm SD146-41-XX/0X 5 他 146 3.19 81 1.61 41 conventional SD168-56-XX/0X 6 5/8 168 3.19 81 2.2 56 conventional SD168-56-XX/1X 6 5/8 168 3.19 81 2.2 56 concentric SD178-56-XX/0X 7 178 3.38 86 2.2 56 conventional
- 25. 25 Dual System Selection 3. Determine length of dual system taking in consideration the total length of two ESP Systems working together. 4. Select type of tubing lift (conventional or concentric) depending on the Customers needs. 5. Select corrosion resistance (the same way as for Y-Tool: CR1 or CR3 respectively)
- 26. 26 Dual Systems options 1. Systems for simultaneous/separate reservoir operation 2. Systems for simultaneous/separate reservoir operation and injection 3. Systems for simultaneous/separate production and in-well pumping 4. Systems for simultaneous/separate reservoir operation with flowrate controller 5. Completions to increase MTBF
- 27. 27 1. Dual configurations Cut-off valve Safety sub Upper ESP Anchor Lower ESP Packer with cable penetrator Dual system with hermetic bypass line Upper ESP Leakproof pod with penetrator Mechanical packer Safety sub Cut-off valve Anchor Lower Perf Upper Perf Upper Perf Lower Perf Dual system with hermetic bypass line
- 28. 28 1. Different combinations of Dual ESPs Casing OD 5-3/4 6-5/8 7 9-5/8 Upper ESP Series 319 319 319, 338 Up to 406 ESP OD, mm 122 142 152 210 Bypass tube diameter (OD/ID), mm 42 / 26 56 / 40 56 / 40 73 / 50 Flowrate, Bpd/day 2500 2500 2500 1250 Up to 5000 Lower ESP Series 362, 406 362, 406 362, 406 535 Flowrate, Bpd/day 5000 5000 5000 Up to 6300
- 29. 29 1. Different combinations of Dual ESPs Casing OD 5-3/4 6-5/8 7 9-5/8 Upper ESP Series 319 319 319, 338 Up to 406 ESP OD,mm 122 142 152 210 Bypass tube diameter (OD/ID), mm 42 / 26 56 / 40 56 / 40 73 / 50 Flowrate, Bpd/day 2500 2500 2500 1250 Up to 5000 Lower ESP Series 319 319 319, 338 Up to 406 Shroud diameter (OD/ID), mm 121 / 100 121 / 100 121 /100 140 / 117 190 / 140
- 30. 30 2. Different combinations of Dual completions (production/injection) Casing OD 5-3/4 6-5/8 178 9-5/8 Upper- production with ESP Series 319 319 319 338 Up to 406 ESP OD 122 142 152 210 Bypass tube diameter (OD/ID), mm 41/26 56 / 40 56 / 40 73 / 50 Flowrate, Bpd/day 2500 1750 1750 1250 Up to 5000 Lower- injection Flowrate, Bpd/day Up to 2800 Up to 6300 Up to 6300 Up to 9400
- 31. 31 Different combinations of Dual completions (production/injection) Casing OD 5-3/4 6-5/8 178 9-5/8 Upper- injection Flowrate, Bpd/day 2800 6300 6300 9400 Lower- production with ESP Series 319 319 319 338 Up to 406 Shroud diameter (OD/ID), mm 121/100 121 / 100 121 /100 140 / 117 190 / 140 Flowrate, Bpd/day 2500 2500 1750 1250 Up to 5000
- 32. 32 2. Dual completions (production/injection) with concentric lift for 6-5/8 casings Production through upper reservoir Injection through lower reservoir Production through lower reservoir Injection through upper reservoir Outer tubing 102 mm Internal tubing 60mm Dual ESP with hermetic bypass line Outer tubing 102 mm Internal tubing 60mm Packer Packer Packer Safety Sub Safety Sub Cable penetrator ESP inside leakproof shroud Upper reservoir -injection Upper reservoir - production Lower reservoir - injection Lower reservoir Hydraulic anchor Landing unit
- 33. 3. System for simultaneous/separate production and in-well pumping 33 Overall flowrate up to 5000 bpd/day In-Well water pumping with flowrate control opportunity Oil production through upper reservoir ESP with one motor and two side shaft
- 34. 34 3. Advantages of simultaneous/separate production and in-well pumping Separate oil production and injection of required fluid volume for formation pressure maintenance CAPEX reduction (no new well drilling for production or injection); Insulated operation of 2 reservoirs and control and regulation of injection and production rates Differential reservoir influence with opportunity to regulate production/injection flowrates; Insulated operation of 2 reservoirs and control and regulation of each reservoir separately
- 35. 35 4. Systems for simultaneous/separate reservoir operation with flowrate controller Disconnecting of reservoirs by packer Reservoir disconnection from casing during RIH operation with cut-off valve Operation of 2 reservoirs with different pressures Flowrate control during operation Bottom hole pressure control in each reservoir Separate reservoir research Flowrate measure. Regulation of flowrate
- 36. 36 5. Completion to increase MTBF Applications: In the case of first ESP failure, second ESP can be started without workover crew Long distance and remote control oilfields Offshore wells
- 37. 37 Practice
- 38. 38 Y-TOOL Selection Example Casing OD 7 (ID 6.184) Required the pump series is 406 ESP length is 17 m (56 ft) logging tool OD is 1.6 logging cable OD is 0.25 (6,3 mm) Highly aggressive fluid What Y-TOOL should be used?
- 39. 39 Y-TOOL Selection Example Solution: 1. Y-TOOL Size Selection (ESP series) Considering the ESP series determine the Y-TOOL Size: Y-TOOL 7" 1.61" XFT TYPEX CRX Y-TOOL 7" 1.50" XFT TYPEX CRX 2. Min bypass passage ID Selection Considering the logging tool OD determine the min bypass passage ID: Y-TOOL 7" 1.61" XFT TYPEX CRX
- 40. 40 Y-TOOL Selection Example 3. Seal Type Selection Considering the logging cable OD (coiled tubing OD) determine the seal type. Type2 is for 0.25 logging cable: Y-TOOL 7" 1.61" XFT TYPE2 CRX
- 41. 41 Y-TOOL Selection Example 4. Y-TOOL Length Selection Considering the ESP length determine the Y-TOOL length. Y-TOOL 7" 1.61" 59FT TYPE2 CRX 5. Bypass clamp Selection Bypass clamps are installed on the groove of protector and pump section base.
- 42. 42 Y-TOOL Selection Example 3. Corrosion resistance Selection Considering the fluid properties determine the corrosion resistance. Y-TOOL 7" 1.61" 59FT TYPE2 CR3
Editor's Notes
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