Rigless Deployment Solutions - Home - Caledyne Ltd Deployment Solutions Wellhead interface solutions to suit any application Caledyne has developed a portfolio of unique patented technologies

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Wellhead interface solutions to suit any application

Caledyne has developed a portfolio of unique patented technologies to enable the rigless installation of all types of artificial lift in existing wells.

Rigless deployment of artificial lift has many benefits:

• Significantcostsavings• Bringingwellsbackonproductionquicker• Enhanceproductionfromexistingwells• Delayingabandoningofdepletedwells

The Caledyne enabling technologies are available in multiple sizes and include:

• TorusInsertSafetyValve• SelfSetlock• Clamp-onGasliftMandrel• DownholeBarrierValve• CoilTubingConnector• FullWellheadInterfaceSolution

Typical applications:

• CoiltubingdeployedESPsystems• Insertcoiltubinggasliftsystems• Capillarystringfordeliquification• InsertPCPsystems

Introduction

CaledyneInsertESPWellheadInterface

CaledyneInsertGasLiftWellheadInterface

3

Contents

5

Torus 06

CT Connector 14

ClamponGasLiftMandrel 18

DSBV 22

Self-SetLockMandrel 26

StuffingBox 30

Stinger 34

HEST 38

CompanyProfile 42

Contents

CaledyneSelf-SetLockMandrel

TorusTheCaledyneTorusvalveisafailsafeclosedInsertSafetyValve, which offers a permanent conduit through thecentre of the valve. The valve is installed in the safety valve nipple profile and operated by the existing hydraulic control line.

The valve utilises a sliding sleeve mechanism to shut in production operated via a power spring and piston arrangement, akin to industry standard flapper typesafety valves.

Thelowersubcanbeconfiguredtofitcapillarytube,fibreoptic or electrical penetrators or rotary seals for insert PCPs applications, where there is a requirement for asafety barrier.

Tubing mounted versions are also available.

TheTorusValvemainbodyisindependentlytestedtoAPI14A.EachcompleteTorussystemisthoroughlytestedinhouse to meet specific customer requirements.

Overview

Design optimised to reduce part count and complexity.

Minimal number of pressure seals and hence potentialleakpaths.Thereare3dynamicsealsand3staticsealsinthe entire assembly.

Modular design allows the same basic valve to beconfigured to accept the particular penetrator for the application.

Installedasper industrystandardwire line insertsafetyvalves.

Easily installed on coil tubing for hanger applications, suchasinsertESPs.

KeyBenefits

Conduit passes through Torus valve

Torus in closed position

7

When safety and well

stimulation are key issues

Wellsthatrequiresafetyvalves installed incombinationwith the following:

• Capillarytubeinstallations• Velocitystringterminatedatthehanger• InsertGaslift• Foamorchemicalinjection• InsertPCPcompletion• InsertESPcompletion• Retrofitpermanentmonitoring,eitherelectrical

or fibre optic

Application

Consult your Caledyne representative for details on type approvals.

Certification

9

TheTorusValveisextremelyversatile,bysimplychangingout thebottomsub itcanbeutilisedformanydifferentapplications

Versatility

PCPpumpscanbeinstalledinwellsrequiringsafetyvalvesby installing a bottom sub with rotational seals. Utilising theTorus valve allows PCP pumps to offer an artificialliftsolutiontotheoffshoremarketinparticularinharsh,sandy,morematureenvironments.

PCP

Utilising theTorusValve in capillary string applicationsallows for a permanent or semi-permanent capillaryinstallation through the existing TRSSSV withoutcompromising safety.With checkvalves in the injectionstring the Torus system presents a full fail safe closed barrier. Capillary string installations are ideal solutions for deliquificationandchemicalinjection.

Capillary String

TheBalancePumpisahydraulicallyactuatedreciprocatinglowvolumepump,whichmaybeusedtoremovewaterfrom gas producing wells. The pump is operated by two hydrauliclines,oneoilfilled,theotherwaterfilled.

BalancePump

PCP

Capillary String

BalancePump

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TorusTechnical

Data

ListedbelowaretypicalapplicationswherebytheTorusInsertSafetyValve,canenhance production saving both time and money:

Liquid LoadingWatered out gas wells can be brought back to production by injection ofa foaming agent through a capillary string. Utilising a Torus valve with a permanent capillary string installation allows wells to be stimulated on a regularbasis, reducing theneed for interventionworkonwellswithahighlevel of water ingress. Should further deliquification be required the Caledyne BalancePumpcanbeusedforthefinalstagesingasproduction.

Insert ESPElectricalSubmersiblePumpsareoneofthemosteffectivemethodsofartificiallift.UtilisingtheCaledyneTorusvalve,ESP’scanbeinstalledinexistingwellseliminating expensive workovers while still maintaining full safety valveintegrity. The Torus valve can accommodate coil tubing deployed and cable deployedinsertESPsystems.

MonitoringBothsemi-permanentandpermanentinstallationofrealtimedataacquisitioncan be achieved by installation of a gauge or fibre optic cable through the centre of the Torus valve providing operators with valuable downhole well performance information.

Insert Gas LiftEnhancing production through gas lift typically requires installation of gasliftmandrels during thecompletion installationphase. Insertgas liftat theoptimum depth can be achieved through the Torus safety valve with minimal down time thus enhancing production.

AvailableSizesSize 2-7/8” 3-1/2” 4-1/2” 5-1/2” 7”

SealBore 2.313” 2.813” 3.813” 4.562” 5.950”

Capillary X X X X X

Coil Tubing X X X

FibreOptic/Electrical X X X X X

PCP X X X

ESP X X X

12

Other sizes available on request.

CTConnector

The Caledyne Coil Tubing Connector utilises internal slips to securely lock the coil in place. It also incorporates akeyedlockringthatensuresthesliphousingcannotbackoffanddoubleO-ringswithbackupsmaintainapressuretight seal on the coil.

Overview

Fieldredressable.Thedesignallowsthetooltobestripped,redressed and reassembled without the aid of specialist tools or personnel.

Tensile rating in excess of that of the coil.

Minimalpartcount,thusallowingforquickandeasymakeup.

Lockringthatensuressliphousingcannotbackoff.

Coupling of coil tubing to down hole accessory tools.

KeyBenefits

Application

15

CTConnectorTechnical

Data

Certification

Technical Information

Parameter 1-1/4” Coil

MaximumOD 2.48”(63.0mm)

MinimumID 1”(25.4mm)

Length 14.57”(370mm)

FlowArea 0.785in2

Upper Connection 2.094”8TPI3GSTUBACMEBOX

LowerConnection 1-1/4”CoilTubingConnector

Metallurgy AISI42013%CrperNACEMR0175

Elastomer Viton®

Temperature Rating 0-250°F

Tensile Rating 60,000lbs

PressureRating* 5,000psi

Consult your Caledyne representative.

*Thepressureratingisthroughthehousing.Asthedesignisbasedabound80ksimaterial,13%Cr.maybesubstitutedfor9%Cr.orL-80,withoutanysizeorratingchanges.


The Caledyne Coil Tubing Connectors is available in a wide range of sizes between1/4”and2-3/8”.Belowisthetechnicalinformationforatypicalsize,for further information and sizes contact Caledyne.

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Clamp On Gas Lift Mandrel

TheCaledyneCoilTubingClamponGasLiftMandrel isused to install standard Gas Lift Valves on Coil Tubingwithout the requirement to cut the tubing.

TheGLMutilisesavalvehousingthatisclampedagainstthe coil tubing. A communication hole is drilled intothecoiltubing.Asealinsertisassembledintothevalvehousing which is then clamped against the coil tubing. This compresses the seal insert against the tubing creating a metal to metal seal. Upper and lower bumper subsprovide themechanical connection to the tubing,lockingaxialandrotationmovementandprotectingthevalve housing. Lockingwashers are used to ensure thetorqueboltscannotbackoff.

Overview

Metal-To-Metal primary seals and elastomeric back-upseals.

Can be attached at any place on the coil tubing.

Multiplevalvescanbe installedonthesamecoil tubingstring.

Accommodatesstandardgasliftvalves.

Design optimised to reduce part count and complexity.

Tested in situ prior to deployment.

Coiled tubing gas lift system.

KeyBenefits

Application

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Clamp on Gas Lift Mandrel

Technical Data

Certification


Parameter 1.25”


Length 25.630”(813mm)

Coil Tubing Size 1.25”CoilTubing

Metallurgy AISI420MperNACEMR0175/ISO15156

Elastomer Viton®

MinimumWellTemperature 40°F

MaximumWellTemperature 250°F

MaximumWellPressure 6,500psi

MaximumGasInjectionPressure 4,000psi



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TheCaledyneClamponGasLiftMandrelisavailableinawiderangeofcommoncoiltubingsizes.Belowisthetechnicalinformationforatypicalsize,for further information and sizes contact Caledyne.

Deep

Set

Barrier

Valve

The Caledyne Deep Set Barrier system is a slick-lineretrievable tool, which is deployed into a down-holenipple profile. The system consists of a lock mandrel,sliding sleeve type valve and an actuator tool housing. Itmaybeused in conjunctionwith theCaledyneTorussafetysystem,wheretheinsertstringisusedtoopenandclosetheDSBV.

The system is installed on slick-line using standardtechniques.Oncethelockissetinthenippleprofile,therunning tool is withdrawn, automatically shutting thesliding sleeve valve.

The valve is opened and closed with a shifting tool,mounted at the end of the insert string. When theinsert string is installed, the shifting tool interactswiththe double acting collet, automatically opening thesleeve.Whentheinsertstringiswithdrawn,thesleeveisautomatically closed.

The shifting tool housing below the valve allows the entire insert string to be manipulated without closing the sleeve. The maximum length of the housing is defined by themaximumallowablestackupheightofthetool-stringin the lubricator. The shifting tool has an emergency shear release facility that allows the insert string to be recovered; in the event the sleeve does not fully close.

Overview

Slick-linedeployabledeep-setbarrier.

Installedusingstandardslick-linetechniques.

Non-elastomericsleeveseals.

Operation independent of the final position of the insert string.

KeyBenefits

23

DSBVTechnical

Data

Application

Certification


Parameter 3.688”


MinimumID 1.890”(48.01mm)

Length 29.8ft(9080.47mm)

SealBore 3.688”BOT‘AF’Profile

Upper Connection 4”GSFishingNeck

LowerConnection BullNose

Metallurgy 80ksi13%Cr.PerNACEMR0175

Elastomer Viton®

Sleeve Seals PEEK/PTFE

PressureRating 7,500psi

Temperature Rating 0-150°C

TensileRatingAtFishingNeck 140,000lb

Isolationoflowercompletion.



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TheCaledyneDSBVisavailabletosuitmoststandardnippleprofiles.Belowisthetechnicalinformationforatypicalsize,forfurtherinformationandsizescontact Caledyne.

Self-Set Lock Mandrel

The Caledyne Self-Set Lock Mandrel for Torus valveapplications is a rest on the no-go Lock. The lock isinstalledaspartoftheTorussystem,sodoesnotrequirea dedicated running tool. Once the Torus valve is installed in the SV nipple profile, application of tubing pressureactsonthe lock’s internalpiston,shearingoutatapre-determined hydrostatic pressure. The piston then allows the expander mandrel to expand the locking keys,securingthelockintheprofile.

When theTorusupperumbilical is removed, the lock isretrievedusingaGSpulling tool andprong.TheProngshifts the expandermandrel before the GS latches theneck. Once the GS is latched upward pull removes thelockfromtheprofile.

Overview

Simple and robust design for reliable operation.

Idealforflowingsituationsastheinnermandrelisbiasedinthedirectionofflowwhenlockedintheprofile.

Thepackingbarrelispartoftheaccessorytoolreducingpossibleleakspaths.

Wiper protects the nipple throat from debris ingress,minimisingthepotentialfortheLocktostick.

Nojarringrequiredtoreleaserunningtool.

KeyBenefits

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Self-Set Lock

MandrelTechnical

Data

Certification

Application


Parameter 2.750” 3.750” 3.812” 4.312” 4.562”


3.738”(94.95mm)

3.870”(98.30mm)

4.372”(111.05mm)

4.641”(117.88mm)

Length 23”(584.2mm)

28.9”(735.0mm)

23.4”(595.0mm)

28.5”(725.0mm)

28”(711.2mm)

FishingNeck 3”GSProfile 4”GSProfile 4”GSProfile 4”GSProfile 5”GSProfile

LowerConnection STUBACME

Metallurgy AISI42013%Cr.18-22Rc80ksiasperNACEMR0175

Shear Setting Pressure Variablein500psiincrements

Staticpressuretestto10,000psi.

Restonno-goLockMandrelforTorusValveapplications.


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TheCaledyneSSLMisavailabletosuitmoststandardnippleprofiles,between1.937”to5.950”.Belowisthetechnicalinformationforsometypicalsizes,forfurther information and sizes contact Caledyne.

Stuffing Box

TheCaledyneStuffingBoxisthelowerpartoftheTorusvalve assembly used to seal and suspend the conduit that is installed through theTorusvalve. InESPapplicationstheStuffingBoxenablestheTorustobedeployed‘piggybacked’ on the pump, once the assembly reaches theTRSSSVtheTorussystemcanbelandedoff.Thepumpcanthen be unlatched from the Torus and run to the desired depth.

Overview

J-slot mechanism allows easy engagement anddisengagement on to the pump.

Incorporatesacoiltubingconnectorthatisstrongerthanthe coil tubing.

TestedinaccordancewithISO14310

TorusESP.

TorusPCP.

Torus insert gas lift.

Torus capillary.

KeyBenefits

Application

31

Stuffing Box

Technical Data

Certification


Parameter 1-1/2” Coil Tubing


MinimumID 1.516”(38.5mm)

Length 28.900”(734.05mm)

Upper Connection 3.125”8TPI2GStubACMEBox

LowerConnection 1-1/2”CoilTubingConnector

MetallurgyAISI4140-4518-22RC80ksi/AISI42018-22RC

80ksi13%Cr/Super13Cr(UNSS41426)/Inconel718(UNSN07718)/perNACEMR0175

Elastomer Viton



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TheCaledyneStuffingBoxisavailableforawiderangeofconduitsmatchingavailableTorusvalves.Belowisthetechnicalinformationforatypicalsize,forfurther information and sizes contact Caledyne.

StingerThe Caledyne Stinger is designed to engage with a shiftingprofileinadownholetool.Thespring-loadedkeyscollapse through restrictions and fully expand to engage therelevantprofile.Oncethetoolhasbeenshifted,thekeysauto release fromtheprofile.The toolhasa shearout facility in the event that the downhole tool cannot be actuated.The large throughbore allows for fluid tobecirculatedthroughthetool,makingitidealforuseonwash strings.

TheBi-DirectionalStingerisdesignedtooperateinOtisB style profiles, but keys can be provided for alternateprofiles.

Aselectivekeysetcanalsobeusedonthetooltoengagea single shifting operation.

Overview

Single trip to operate downhole profile.

Emergencyshearreleaseincasethetoolcannotshiftthedown-holetool.

Shear rating can be set in the field up to 40,000lbs,dependant on operation.

Mechanically shifting down hole valves, such as theCaledyneFluidLossValve(FLV)andMechanicalIsolationValve(MIV).

Other manufacturers down hole tools may be operated usingBi-DirectionalStinger.

KeyBenefits

Application

35


CertificationContact Caledyne representative.

Shifting Profile Size 2.312” 2.812” 2.948” 3.312”

MaxOD 2.19"(55.5mm)

2.67”(68mm)

2.88”(73mm)

3.12”(79mm)

MinID 0.61”(15.5mm)

1.65”(42mm)

1.57”(40mm)

1.96”(50mm)

Overall Length

11.54”(293mm)

13.60”(345mm)

Shear Rating(Brass)

(2x)5,660lbs-(12x)33,960lbsShearScrews

Shear Rating(Steel)


Top Connection

1.75”8TPIStubAcme

Box

2.375”8TPIStubAcme

Box


Box


Box

BottomConnection WirelineentryHalfMuleShoe

No.ofKeys Six (6)

Shifting Profile Size 3.812” 4.562” 4.562” SP 4.750”

MaxOD 3.69”(93.6mm)

4.25”(108mm)

4.52”(115mm)

4.62”(117.4mm)

MinID 2.11”(53.6mm)

2.36”(60mm)

2.75”(70mm)

3”(77.4mm)

Overall Length

18.50”(470mm)

Shear Rating(Brass)


Shear Rating(Steel)


Top Connection


Box


Box


Box


Box

BottomConnection WirelineentryHalfMuleShoe

No.ofKeys Six (6)


StingerTechnical

Data

36

High

Expansion

Shifting

Tool

TheCaledyneHighExpansionShiftingTool (HEST) is anultra slim shifting tool, which may be used to operatedownholetoolshavingasignificantlylargerIDthantherestriction above.TheHEST is run andoperatedon coiltubing.

Various key sets may be used to configure the tool tooperate in common sizes of profiles.

Overview

Ultraslimforinstallationthrough2-7/8”bypasstubing.

Bi-directional key sets. No need to modify the tool foropen/closeoperations.

Field replaceable choke nozzle to vary pump pressurerequiredtoactivatekeys.

Emergency shear facility to collapse keys if the keysdonot retract.

OtisBprofileinterfaceasstandard.

CT deployed shifting tool.

KeyBenefits

Application

39

HESTTechnical

Data

40

Parameter Size: 2” Size: 2.2” Size: 3”

To set in casing size

41/2”(3.81”

ProfileMax)

51/2”(4.562”

ProfileMax)

7”(5.953”

ProfileMax)Metallurgy AISI4140

MaximumOD 2”(50.80mm)

2.2”(55.88mm)

3”(76.2mm)

MinimumID N/A

Length 52.8”(1342mm)

56”(1422mm)

Temperature Range 22-250°F(0-121°C)

Tensile Rating 40,000lbf(177kN)

90,000lbf(400kN)

76,000lbf(338kN)

Elastomer Viton®

Top Connection 1/2AMMTBottom

connection Bullnose



CertificationContact Caledyne representative.

Over 300 artificial lift installations complete

Caledyne Limited is a dynamic, innovative servicecompany with an extensive engineering resource. Headquartered in Aberdeen, Caledyne specialises inproviding production equipment and engineering services for the oil & gas sector. In addition to theAberdeen office, Caledyne utilises a global network ofdistributors and agents, ensuring optimum support toour rapidly expanding worldwide client base.

Caledyne is recognised as a solutions provider with an extensive portfolio of patents and patents pending. They have successfully won multiple awards including the NationalBusinessAwardsforScotlandandtheHartsE&PmeritoriousawardforIOR(IncreasedOilRecovery).

Caledyne is accredited to ISO9001:2008 by QASInternational for “Provision of Mechanical EngineeringDesign Services and Downhole Tools” and registeredontheFirstPointAssessment (FPAL)database, suppliernumber10049792.

Caledyne’s wide range of products and services havebeenextensivelyutilisedbymajoroperatorsandservicecompanies in the Eastern and Western Hemispheresestablishingaproventrackrecord.

Examplesinclude:

- ArtificialLiftrelateddownholevalveswithover 300 installations completed. - Arangeofcompletionisolationvalvesandfluid lossvalvesformanymajoroperatorsincluding theNorthSea,Brazil,SaudiArabiaandRussia. - Arangeoffibreoptic,artificialliftandgaswell dewatering products. - Interventionproductsincludingflowcontrol, bridgeplugs,straddles,coiltubingtoolsinstalled atvariouslocationsintheNorthSea,MiddleEast, NorthAfricaandAsiaPacific.

- ConsultancyEngineeringservicesandproject management,foranextensiveclientbaseinthe areasofsubsea,wellcontrol,wellintervention and downhole monitoring.

CompanyProfile

OperationalExperience

43

Caledyne Torus and StuffingBox

CaledyneLtdUnit24,TwinSpiresMugiemossRoad

AberdeenAB219BG

Tel: +44(0)1224826827Email:[email protected]: www.caledyne.co.uk

Copyright©2015CaledyneLtd

Documents

Rigless Deployment Solutions - Home - Caledyne Ltd Deployment Solutions Wellhead interface solutions to suit any application Caledyne has developed a portfolio of unique patented technologies