R & D SOLUTIONS
Chapter 1 INTRODUCTION
R & D SOLUTIONS
R & D SOLUTIONS
R&D Solutions is a privately owned oil, gas, and renewable energies equipment and services provider.
Based in Perth Western Australia, R&D Solutions prides itself on providing a broad spectrum of equipment and technology solutions. From the remote outback of Australia to offshore Asia and Europe.
We are available around the clock to assist service and support your operations.
OUR PRODUCTS
We are the representative agents for a range of suppliers of proven drilling, completion and monitoring technology. Whether your requirements are for geothermal renewable energies, or traditional oil and gas, locally and internationally, our track record proves we will deliver on time and to budget.
In addition to product supply our locally based engineering group is well positioned to assist you with one off tool requirements that may arise during operations.
We also facilitate heavy industry machine repairs of damaged equipment or refurbishment. R&D Solutions prides itself on being able to take on special build items and turn these round in a timely manner from concept to delivery.
TOOL DESIGN
TRAINING AND FACILITATION
In alliance with independent training providers, R&D Solutions provides industry training on all of the following:
• Slickline Operations
• Well Completion
• Basic Completions
• Overall production & exploration overviews
• Induction type courses for new hires
• Slickline course for supervisory personnel
OUR EXPERIENCE
Our customers engage us for our proven history of delivering responsive and cost competitive solutions. R&D Solutions’ Directors bring significant local and international experience. Russell Furner is formerly of BBL Bits and Doug Gillespie is exWeatherford Completions.
Our history of continued repeat business from our client base of major oil and gas companies is testament to our commitment to outstanding service, including Apache Energy, Chevron, Esso Exxon, Hess, Horizon Energy, Inpex, Santos, Shell, Vermilion Oil and Gas, Weatherford and Woodside.
Local highlights since establishment include the award of the Chevron Wheatstone contract for the supply of drill pipe protectors and service, the Shell prelude contract for the supply of Matrix Low Friction centralisers, drill pipe protectors and service and a Master Services agreement with Santos to provide Packers Plus technology and services.
WAREHOUSE STORAGE
Inventory Management and Warehousing
The bigger, new R&D Solutions warehouse is conveniently located at Welshpool near Perth City airport to provide accountable Equipment Storage and Inventory Management with prompt receipt and delivery to and from customer’s mobilisation point or workshop.
R&D WORKSHOP
4 Riversdale Road Welshpool Western Australia 6106
FEATURES INCLUDE:
• Full service Office with access 24/7
• 2000m² fully enclosed, high truss, air conditioned warehouse and workshop
• Double overhead cranes
• 2000m² outside hardstand
• 30 minute drive from Perth CBD. 15 minutes from Perth airport.
• Fully equipped workshop with hand tools
• Total Inventory management
• All good stored under cover
• Fully fenced, secure yard with parking and lay down area
• Monitored alarm and security cameras
• Forklifts and qualified staff to conduct equipment load outs and receivals
SHIPPING & TRANSPORTATION
For small shipments R&D Solutions can deliver to customer’s facilities at short notice. For larger goods R&D Solutions use local transport and shipping specialists to ensure quality service at a competitive cost.
WAREHOUSE VIDEO
Welshpool Facility
Chapter 2
SEALING TECHNOLOGY
Section 1 KCI LTD
KCI LTD
KCI was established in 2002 to respond to the unique and challenging specialist requirements of brownfield and greenfield developments.
KCI offers a range of unique products and services specifically designed to reduce costs and minimise downtime, whilst maintaining or increasing production across:
• Sub sea
• Surface
• Refinery
• Down hole
• Topside
• Pipeline
• Other applications
Kinetics Controls & Innovation Ltd
Service & Product Awareness
Integrity Solutions Supporting Ageing facilities
Gate Valve Isolations with Mac-Pac
Background
❑ KCI were requestedbya major Oil andGas Operator in the UK to provide isolations for Christmas Tree Valves on a Water InjectionWellwhere all three inline Gate Valves have failed.
❑ The Isolations are requiredto breakcontainment to enable the installation of a secondarySwab Valve. This wouldallowWell InterventionandWellAbandonment operations to continue.
❑ With all inline Gate Valves closed theyhada recordedleakrate of 10 Litres per minute of fluid& a PBU (Pressure BuildUp) of 540psi.The Valves had been greasedwith Clare 601 & 701 but still leaked at 10 Litres per/ min.
PlannedOperation
❑ DeployKCI’s Mac-Pac Sealant throughthe standardGrease fittingon the Bonnet. Displace the existing Grease from the Valve cavities andreplace it with Mac-Pac to provide an effective andrepeatable Valve isolation.
❑ Allowthe Well to be preparedfor future safe Intervention Operations.
Kinetics Controls & Innovation Ltd
Established in 2002
Office, Workshop and Manufacturing facility in Dyce, Aberdeen, UK
Specialising in Well Integrity Engineered Leak Solutions
Gate Valve Isolations with Mac-Pac
Actualoperation
❑ Connect KCI deployment toolingto the SWAB Valve. Inject 1.5 Litres of Mac-Pac andwitnesseda PBU. FunctionedValve and tested. ZeroPBU or leakrate above.
❑ Connect KCI deployment toolingto the LMV. Inject 5.5Ltrs of Mac-Pac andwitnesseda PBU. Functioned Valve andtested. Zero PBU above however, a verysmallfluidleakage was witnessedat the vent point. An extendedPBU test was carried out overnight and a goodresult was confirmed.
❑ The HMV’s Actuator Springwas brokenso the Valve could not be functioned.
❑ The well will remainsafelyclosedin until the planned interventionworkbegins.
* Objective Achieved*
Our customer was extremelysatisfiedwithour Safe, Effective & Efficient Isolationof the Well. This Value Adding, Rigless Isolation Operationsavedthe Well owner from a potentially time consumingandcostlyWellKill or Freeze operation.
Advanced Leak Sealing Technology
Sectors of Operation
Wellhead, Christmas Tree Valve & Topside Valve Isolations
Annulus & Downhole Isolations
Subsea Well Isolations
Production & Pipeline Applications
Well Decommissioning & Abandonments
Wellhead Isolations Gate Valve Isolations
Subsea Applications Well Abandonment Downhole Isolations
KCI Product Description Applications
Mac-Seal:
A variety of “Time Activated” viscosity compounds
MS-Sealant:
A variety of “Time Activated” viscosity compounds
Isolation Barrier System (IBS)
Time Activated Compound and Breaker
Mac-Pac:
Non-Activated Sealant Compound
Leak Sealing Solutions High Pressure
Leak Sealing Solutions
Medium to High Pressure
Flexible non-porous gel with high compression load limits
High Viscosity Sealing & Lubricating Compound
MHS-Protect:
Paint on Anti-Corrosion Product
Corrosion & Erosion
Protective Coatings
Seals, Wellhead Voids & Pack Offs
Wellhead Seals, Tubing & Casing Hanger
Wellhead Seals, Tubing & Casing Hanger
Seals, Wellhead Voids & Pack Offs
Formulated for Hotter Climates & Regions
Isolation Solutions including:-
Production Pipelines, Ball Valves & Hybrid solutions
Downhole Annulus Isolation of Packers & Casing Shoes
Ideal for leaking Gate Valve Isolations
Energise Wellhead Seals as a more stable replacement for Plastic Packing
Protect Injection Fittings, Nuts, Bolts,
Threaded Equipment & Splash Zones etc.
Kinetics Controls & Innovation Ltd
Mac-Seal & MS-Sealant
Wellhead Isolation & Control Line
Product and Application Review
Mac-Seal & MS-Sealant provide a static seal between existing damaged sealing areas. Deployed as a time activated viscous fluid, Mac-Seal & MS-Sealant convert to a resilient self-bonding, pressure energised, solid but flexible material to re-establish a pressure retaining barrier without shrinkage.
Part Fill of Hanger Void
Hybrid Full Fill of Hanger Void with 2 Sealants
Damaged Ring Groove repair
Sealing face very badly damaged by Grinder
Damaged Ring Groove repair
Damaged Ring Groove repair
Control Line Isolation
Mac-Seal or MS-Sealant is used to permanently Plug & Isolate DHSV Control Lines, Chemical Injection Lines, Capillary Strings etc.
Used when well pressure is witnessed at surface in the Control Line, Workover or Abandonment. This would indicate that the well is down to one barrier from the reservoir pressure.
Control Line Isolation
Valve
KCI
Deployment Manifold
MS-Sealant 02 in Control Line
120ft Long Isolation
Tubing Hanger Void
• Can regain Well Integrity if in-line Check Valves or Control Line structure fails.
• Safer, Faster & more Economical compared with Traditional Intervention operations.
• Negates the need to set a Straddle Plug in the DHSV nipple for an isolation.
• The cured isolation can be Pressure tested & Leak-Off tested.
• Just 500mls of Sealant required to fill a ¼” Control Line to a depth of 120ft.
Kinetics Controls & Innovation Ltd
Mac-Pac
Gate Valve Isolation
Product and Application Review
Mac-Pac
Gate Valve Isolation
Mac-Pac is a dynamic product that sits within the valve and reacts to any leaks.
Ideal for isolating leaking Stem Seals
Mac-Pac coats scored
Gate Valve internals
It is a repeatable solution
NOT just a one time isolation
Mac-Pac
Gate Valve Isolation
Mac-Pac is easily pumped
Will displace grease and plastic packing An alternative to plastic packing due to stable structure at Low & High Temperatures
Mac-Pac seals leaking Gate
Valves
Mac-Pac is a Sealant + High Temp Lubricant which remains in the valve pocket much longer than grease
Commenced pumping Mac-Pac through “Model D” grease injection fitting on valve
Mac-Pac has displaced the Clare 601 grease from the valve cavity
Kinetics Controls & Innovation Ltd
Isolation Barrier System – (IBS)
Surface & Downhole Isolations
Product and Application Review
IBS (Isolation Barrier System) Gels
Ball Valves & Pipeline Isolations
Deployed as a fluid and transforms to a gel to provide a seal / barrier directly into or between leaking production ball or gate valves, on surface or subsea.
IBS can be converted back into a fluid and dispersed within the system or pigged out as solid.
Valve
Gas Manifold
Mac-Pac
Inject IBS into the Spool by directional isolation
Mac-Pac
Short or Long Term
Isolations
Temperatures: +5 to +120°C
Ideal for:
• Gate Valves
• Ball Valves
• Production Pipelines
• Surface or Subsea
Direct access Isolation When Possible
IBS Rigless Well Integrity
Deployed from surface as a fluid, transforms to a solid flexible membrane when it reaches the target depth to provide a seal directly at the problem area - Packer Element, Casing Shoe or Casing Hanger.
Annulus Isolations
Ideal for: Rigless Low Cost Well Intervention – Behind Pipe, Micro Annuli, Cement Porosity & Hanger Seal Issues
IBS – SB (bottom IBS layer)
Heavier than Oil, Seawater and most Brines
Layers from top down:
IBS-SX
Oil
IBS-S
Seawater
IBS-SB
Dry sand & cement mix
IBS – SB
Micro Porosity Issues within the Annulus
IBS – SB
Leaking Packer Isolated
IBS-SX Packer Isolation
From Below
Leaking Packer Element
/ Well Fluids Brine
Nipple WEG
IBS-SX Being deployed
IBS-SX Floats on Oil
Flush Line with water Leak Reduced
IBS-SX Cured Isolating Packer Leak From below Maintain Well Pressure
IBS-SB Packer Isolation From Above
Deployment of IBS-SB Fluid State
Packer
Element
Leak
Top up with heavy fluid or apply fluid pressure and hold until IBS is cured
IBS-SB Cured Isolating Packer Leak from above
Hydrostatic pressure compressing the IBS
Annulus and Wellhead Isolation
Advantages
• Maintains balanced pressure in the annulus
• Protects wellhead from harmful well fluids and gasses
• Protects wellhead seal structures from constant exposure to well pressure
• Prevents gas escape to atmosphere
• Sealant can be broken back to fluid state when required (surface only)
• Allows monitoring of annulus pressure
• Allows venting of annulus pressure when required
Tubing Perforations
Micro
Porosity Issues
Position the IBS-SX below the Hanger to protect the casing hanger seals with communication to the tubing
VR hose mandrel to allow annulus pressure monitoring
Cement Treatment of IBS-SB Heavy Fluids Seawater
Thread Leak
IBS-SX
Protection and Repair Solutions for Your Valves
to Play
Wellhead Isolation Animation
R & D SOLUTIONS CERTIFICATES
CONTACT DETAILS
4 Riversdale Road, Welshpool, Perth, WA 6106 Australia
Website: www.randd-solutions.com
Welshpool & Canning Vale Australia
Mobile: +61 450 663 908
Office: +61 8 9486 8350
allan.paterson@randd-solutions.com
