ECN# - N728—04
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`Page 1 of 1
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`RETRIEVABLE PACKERS
`
`Notice: N728~O4
`
`Engineering Change Notice
`Bill of Material Change -
`
`Location: Navigation
`Product Family: H99501
`Product Dueription: 582-337 150 - Frac Packer
`
`
`G.le if:
`t.‘F:
`
` Replaced Packing Element, Lower Cyllnder, Drift Ring, and Upper Piston.
`
`
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`
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`EEC—{3:133 REES
`CELEB [fqi -_ --=i
`_
`Field speclflcations changed and now requires a smaller O.D. U3 .EJJO US. 5 RID
`
`
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`Work in Progress: Manufacture/Rework To Latest
`Plant Inventory -> Parts: Manufacture/Rework To Latest
`
`Plant Inventory -> Assemblies: Manufacture/Rework To Latest
`Field Inventory: Use A515
`
`Ass'y and Test Area -> Parts: Manufacture/Rework To Latest
`Ass'y and Test Area o- Assemblles: Manufacture/Rework To Latest
`
`This ECN has not been released from Engineering yet.
`
`W*
`
`Tech Unit affected:
`
`AsoemblleM Drawing:
`
`Field Notificaton required:
`
`Cost Center I Internal Order No.:
`470310317I
`
`Account Number:
`501600 Scrap
`501550 Jn-House Rework
`689300 Outside Rework
`500900 Obsolete
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`RESTRICTED - OUTSIDE ATTORNEYS' EYES ONLY - TECHNICAL
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`BHOD363809
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`Ex. 2052
`IPR2016-01506
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`ENGINEERING JOB CONTROL CARD
`
`
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`
`
`Estimated Cost: $1m-79
`'3
`
`we re
`Planned Gate 30 Date: 03r05
`Estimated Completion Date: 05105
`Job Name:
`Iso Frac Packe - or Mr “A; 1"“
`
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`‘
`Job Instructions: Develop an 18 in. packing element for the open hole frac. system. Two
`designs will be developed per the attached Brainstorming Meeting Minutes. Ball «A. Steam :1. crIcgiN'w
`
`1. Maximum packer OD: 5.820" for up to 6.250" open hole desired; 5.820" for 6.00 in. open ‘3 at“
`hole and 5.910” for 6.250" open hole acceptable
`“WIFE "
`2. Designed to deploy in 6.500” ID open hole
`“:13
`3. Minimum ID: 3.375"
`‘6”
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`4. Operating temperature of 100°F-250°F
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`5. Differential pressure rating of 10,000 psi desired; 8,500 psi acceptable
`
`6. Torque rating through mandrel: 15,000 ft—lbf
`
`7. Burst 8: collapse rating of 10,000 psi
`8. Non-NACE service
`
`9. Setting pressure: 4,000 psi
`
`10. Desirable to have pistons below element; acceptable to have pistons above the
`element
`,
`.
`l
`, . cg:ng
`_
`_
`WL 153 hillside .3551? pg. unfit-Is. are?»
`11’. Maxtmumnpackegggtjfisqflfis
`I
`. flip—r
`12. See attached test plan foiacceptance criteria
`Milestone Dates:
`PM "-
`
`Prototype Chassis Available to Order: 1i24!05
`
`Commence Prototype Testing: 2f1i05
`
`First Packer Acceptance Test: 2i22i05
`
`Test Plan Completion: 3131105
`
`Estimated Ship Date: Week of 4I4!05
`
`Written By: Gus Weinig
`
`Date Written: 1212132004
`
`Assigned To: Gary Anderson
`
`Manager Assigned To: Gus Weinig
`
`Cost Center: 47031031?
`
`Date Job Closed:
`
`Approved By:
`Enineerin Director
`
`
`Approved By:
`District Manaer or desinee
`
`
`
`Desin Team
`m Department
`Gary Anderson
`Packer Engineering
`Craig Whitler
`Region Manager
`Greg Badke
`Welibore Construction Engineering
`
`Erick Peterson
`(Form: JOB CARD)
`
`Region Engineer
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`CorefPeripheraI
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`Peripheral
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`Peripheral
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`18. Use an atmospheric chamber continuoust energize the element
`
`19. Place a piston between the elements and cover it with rubber
`
`20. Use a steel accordion with variable waves
`
`21. Use a rubber accordion with variable waves
`
`22. Make the center element thinner to reduce friction loss
`
`23. Use a solid core ECP with a secondary setting piston
`
`24. Undercut the element along its length
`
`Each idea was reviewed and several were eliminated. The following two ideas were
`candidates for future development:
`0 Use an expandable element similar to the new Big Bore Permanent packers
`I Use a solid core ECP with a secondary setting piston
`
`After the review, each person voted for the three best designs. The results were:
`
`Six votes for:
`
`0 Set the element system from both ends
`0 Six votes for: Taper the ID of the element and fill the void with Teflon, steel, another
`durometer rubber, or a flexible filler
`- Six votes for: Use an MPAS sleeve under the element
`
`Four votes for:
`
`a Add multiple grooves with varying lengths and diameters
`
`re
`-
`Three votes for:
`o Mold varying thicknesses of continuous strand matting into the element;
`
`Two votes for:
`
`0 Use multiple elements with spacer rings between, but cover the spacers with a thin sheet of
`rubber
`
`0 Two votes for: Extend a long sleeve under the element and shear pin it to the gage rings
`0 Two votes for: Vary the durometer with each element, such as 70-80-90
`
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`4. Add another 500 psi and hold for 15 minutes
`5. Continue applying pressure in 500 psi increments until failure
`Brainstorming Meeting Minutes
`lso Frac Packer Packing Element System
`
`Meeting Date: December 7‘“. 2004
`
`Attendees: Doug Murray, Chuck Pleasants, Jim Doane, Mike Evans, Cliff Mills, Hector
`Mireles. Gary Anderson, Greg Badke. Amy Farrar
`
`Purpose: Choose three packing element concepts to pursue for thelso Frac packer. The
`following constraints were placed on the designs:
`- Compatible with the threaded backup rings off the 7" Premier packer
`Able to hold 10,000 psi water at 250°F in 6.250 in. ID casing
`Element Length: 18 in. continuous (run-in position)
`Maximum Element OD: 5.780 in.
`Mandrel OD: 5.525 in.
`
`Gage Ring OD: 5.890 in.
`Setting Force: 45,000 lbs.
`
`The meeting began with a review of the constraints and a brief description of the application. It
`was agreed that the main challenge was to transfer enough force through the element to set
`the upper threaded backup ring and set the element in sequence to reduce voids and gaps.
`
`Each person at the table presented a design. The following list was generated aflerseveral
`rounds of ideas.
`
`1. Set the element system from both ends
`
`2. Add multiple grooves with varying lengths and diameters
`
`3. Use multiple elements with spacer rings between. but cover the spacers with a sheet of
`rubber
`
`Use two, 6 in. elements with a 6 in. metal spacer covered with rubber
`
`Extend a long sleeve under the element and shear pin it to the gage rings
`
`T4939"? Taper the ID of the element and fill the void with Teflon. steel. another durometer rubber.
`
`Push the element over a metal or Teflon cone
`
`or a flexible filler
`
`8. Use an MPAS sleeve under the element
`
`9. Use an MPAS sleeve on the OD of the element
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`10. Make the backup rings out of wire mesh
`
`11. Use an expandable element similar to the new Big Bore Permanent packers
`
`12. Push through a long ZXP element
`
`13. Use a double-piston with a tapered element
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`14. Shear pin spacers together or to an intermediate mandrel
`
`15. Vary the durometer with each element, such as 70-80-90
`
`15. Mold varying thicknesses of continuous strand matting into the element
`
`17. Design a multiple-ramped ZXP element on a helix (similar to a Fishing spear)
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`Iso Frac Packer Test Plan
`
`Test 1: Simulates loads on lower packer
`
`Casing ID: 6.250”
`Elastomer: Nitrile
`
`Setting Temperature: 250°F
`Test Medium: Water
`
`Acceptance Criteria: Able to maintain the hold pressure with the Sprague pump.
`
`Steps:
`1. Heat fixture to 250°F
`2. Set with 4,000 psi
`3. Pressure below element with 8,500 psi and hold for 30 minutes
`4. Cool down to 100°F with 8.500 psi below and hold for 30 minutes
`5. Reverse to top at 100°F and hold 8,500 psi for 30 minutes
`6. Reverse pressure to below and repeat steps 3 and 5 at 10,000 psi
`
`Test 2: Simulates loads on upper packers
`
`Casing ID: 6.250"
`Elastomer: Nitrile
`
`Setting Temperature: 250°F
`Test Medium: Water
`
`Acceptance Criteria: Able to maintain the hold pressure with the Sprague pump.
`
`Steps:
`1. Heat fixture to 250°F
`. Set with 8,500 psi
`. Cool to 100°F
`4. Pressure below element with 8,500 psi and hold for 30 minutes
`. Reverse to top at 100°F and hold 8,500 psi for 30 minutes
`. Reverse pressure to below and repeat steps 4 and 5 at 10,000 psi
`
`2 3
`
`5 6
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`Test 3: Determine pressure rating in larger ID hole with pressure from below
`Casing ID: 6.500"
`Setting Temperature: 250°F
`Elastomer: Nitrile
`Test Medium: Water
`
`Acceptance Criteria: Able to maintain the hold pressure with the Sprague pump.
`
`Steps:
`1. Set with 4,000 psi
`2. Pressure below element with 4,000 psi and hold for 15 minutes
`3. Add another 500 psi and hold for 15 minutes
`4. Continue applying pressure in 500 psi increments until failure
`
`Test 4: Determine pressure rating in larger ID hole with pressure from above
`
`Casing ID: 6.500”
`Elastomer: Nitrile
`
`Setting Temperature: 250°F
`Test Medium: Water
`
`Acceptance Criteria: Able to maintain the hold pressure with the Sprague pump.
`
`Steps:
`1. Set with 4,000 psi
`2. Pressure below element with 1,000 psi less than the failure pressure from test #3
`3. Reverse pressure to above at 4,000 psi and hold for 15 minutes
`
`RESTRICTED - OUTSIDE ATTORNEYS’ EYES ONLY - TECHNICAL
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`BH00363814
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`Ex. 2052
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`IPR2016-01506
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`

`

`
`
`
`
`PROJECT PLAN
`
`.105 NUMBER:
`
`429-140
`
`Hourly Rate: $11.95
`
`Project Slaps
`
`F§A§IEILI TY
`oO'ma;2%
`
`Hours
`Re d
`
`Prototype
`Ex - = nsos
`
`Completion
`Date
`
`Comments
`
`Roqd Documuntatlon
`Sui -
`Verlfled
`
`05%;*3.3253''“8-I'D3.3E6.'38
`
`anufac'run‘ng Feasibility
`anceplual Layout-Sketch
`Preliminary Calculations
`PR E
`FiNiTl N
`08 CONTROL CARD
`
`Form Design Team
`
`“a?h .2I.'II SI. EanQ.E(a
`
`redesign
`CONCEPTUAL DEVELOPMENT
`
`IIIE
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`_—_—-_
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`

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`PROJECT PLAN
`
`-
`
`Ex nus
`
`Date
`
`Sta --
`
`Verified
`
`
`
`Releasefor Production —__—-—
`
`mn—_—-—
`
`-___——
`
`
`
`
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`
`
`ENGINEERING JOB EST. ATI'AOHED:
`
`YES
`
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`
`
`
`PROJECT TOTAL - HOURS
`PROJECT TOTAL - PROTOTYPE
`TOTAL ENOR EXPENSE
`
`1.354
`000.000
`$1 H.573
`
`
`
`IF FOR SOME REASON, MANDATORY PHASES 0R STEPS DO NOT APPLY. APPROVAL MUST BE GIVEN
`BY AN ENGINEERING MANAGER T0 OMIT. PROOF OF APPROVAL MUST BE INSERTED INTO THE ENGINEERING
`JOB CONTROL FILE DOOUMENTINB THE REASON FOR DISCREPANCY
`
`mfg:
`
`DATE:
`
`
`
`DATE:
`
`I
`
`-
`
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`1
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`
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`
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`
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`
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`
`PROJ. PLAN PREPARED BY:
`
`PROJ. PLAN APPROVED BY:
`
`{Manager}
`PROJ. PLAN APPROVED BY:
`
`(Englmrlng DIncbor]
`
`Output “OHM:
`{District manage! or dolignoe)
`JOB CLOSURE APPROVED:
`
`[Engineering Dlnchot]
`
`[DOCUMENTATION OF MANDATORY STEPS MUST BE VERIFIED BY APPROVERS AT JOB CLOSURE)
`
`FORM: PROJ PLAN {02!02}
`Raf: Eng Unit 201
`
`Page 2
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`- TECHNICAL
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`BHOO363817
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`Ex. 2052
`IPR2016-01506
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`
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`Opportunin Prolile 582 OH Premier
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`Date Printed: 11“ @2004
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`RESTRICTED - OUTSIDE ATTORNEYS' EYES ONLY - TECHNICAL
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`15 of 34
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`Ex. 2052
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`RESTRICTED - OUTSIDE ATTORNEYS’ EYES ONLY - TECHNICAL
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`BH00363825
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`Ex. 2052
`IPR2016-01506
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`

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`RESTRICTED
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`OUTSIDE ATTORNEYS' EYES ONLY
`19 of 34
`19 of 34
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`- TECHNICAL
`
`BH00363826
`
`Ex. 2052
`IPR2016-01506
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`

`

`Fiadoil, Inc.
`
`1251 FM 529, HOUSTON. TEXAS 73'041 (713] SEMI-‘93. FAX 937-4524. EMAIL hbsughflradui‘lccm
`
`August 10. 2004
`
`Baker Oll tools
`PO. Box 3048
`Houston. Texas 77243-3048
`
`QUOTATION NO. 040802-01
`
`ATTENTION: John Folhergill, Manager - Cased Hole Market Developcmenl
`
`Subject: DEVELOPMENT PROGRAM - 2 7'18" ISOLATION PACKER 8:. PACKER ANCHOR
`
`ITEM QTY DESCRIPTION
`
`1
`
`2
`
`3
`
`4
`
`1
`
`1 ENGINEERING DESIGN - ANCHOR PACKER - 2 WI!"
`‘ Collect design infonnalion, including:
`2 71’8" API Upset tubing thread
`10.000 p.s.i. minimum burst pressure
`30.000 lbs. minimum tensile load
`50,000 lbs. minimum compressive load
`4140 28-36 Floc 0 material specification
`3.90“ min I.D.
`. 5.91" max. 0D.
`
`#9999»:
`
`‘ Prepare Acad manufacturing detail drawings
`* Prepare Acad assembly drawing
`' Prepare design calculation package
`
`1 PROTOTYPE MANUFACTURE - ANCHOR PACKER - 2 TI "
`* To be estimated based on actual drawings
`’ Prototype testing will be as follows:
`‘
`1. Mechanical functioning
`* 2.
`Internally pressure test to 10,000 p.s.i.
`* 3. Set in 6.50' |.D. pipe & pull to 30,000 lbs.
`
`"
`
`1 ENGINEERING DESIGN - FRAC PACKER - 2 TI
`* Collect design information, including:
`2 7B" API Upset tubing thread
`10,000 psi. minimum burst pressure
`80.000 lbs. minimum tensile load
`50,000 lbs. minimum compressive load
`4140 28-36 Floc C material specification
`3.90" min I.D.
`. 5.91" max. 0.0.
`
`sweeper
`
`repare Acad manufacturing detail drawings
`* Prepare Acad assembly drawing
`* Prepare design calculation package
`
`1 PROTOTYPE MANUFACTURE - FRAC PACKER - 2 71'8"
`* To be estimated based on actual drawings
`" Prototype testing will be as follows:
`"
`1. Mechanical functioning
`‘ 2.
`lntemally pressure test to 10.000 p.s.i.
`" 3. Set in 6.50“ l.D. pipe & pull to 00,000 lbs.
`
`1 ENGINEERING DESIGN - FRAC SLEEVE
`“ Collect design inlcrmaticn, including:
`1. 2 W3" API Upset tubing thread
`
`ITEM
`COSTS
`
`TOTAL
`COSTS
`
`$3,200.00
`
`$3,200.00
`
`$18,000.00
`
`$10,000.00
`
`$3,200.00
`
`$3,200.00
`
`$18,000.00
`
`$18,000.00
`
`$3,200.00
`
`$3,200.00
`
`RESTRICTED - OUTSIDE ATTORNEYS' EYES ONLY - TECHNICAL
`20 of 34
`20 of 34
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`BH00363827
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`Ex. 2052
`
`IPR2016-01506
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`

`

`PM"???
`
`10.000 p.s.i. minimum burst pressure
`80,000 lbs. minimum tensile load (100.000 preferred}
`50,000 lbs. minimum compressive load {75,000 preferred)
`4140 28-36 Ftoc C material specification
`3.90" min LD.
`7. 5.91 " max. OD.
`
`' Prepare Acad design layouts
`* Prepare Acad manufacturing detail drawings
`Prepare Acad assembly drawing
`Prepare design calculation package
`
`2
`
`1 PROTOTYPE MANUFACTURE - FRAC SLEEVE
`" To be estimated based on actual drawings
`' Prototype testing will be as follows:
`‘
`1. Mechanical functioning
`* 2.
`Internally pressure test to 12,500 psi, 2 times
`
`TOTAL FOR THIS QUOTATION
`
`Notes:
`
`1.
`2.
`3.
`4.
`5.
`
`Terms: Net 30 days
`Delivery: Item 1 & 3 in 3 weeks. item 2 & 4 due 6 weeks after approval of item 1
`Past due invoices will be subiect to a charge of 't 12% per month
`Quotation is valid for 90 days
`Warranted to be tree of manufacturing defects for one year
`
`We appreciate the opportunity at providing this quotation.
`
`$14.000.00
`
`$14,000.00
`
`$59,600.00
`
`Regards,
`
`Benton F. Baugh, Ph.D., P.E.
`President
`
`RESTRICTED - OUTSIDE ATTORNEYS' EYES ONLY - TECHNICAL
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`BH00363828
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`Ex. 2052
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`IPR2016-01506
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`

`

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`RESTRICTED - OUTSIDE ATTORNEYS’ EYES ONLY - TECHNICAL
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`BH00363829
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`Ex. 2052
`IPR2016-01506
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`

`

`Parts Lit-
`
`582-387 lso-Frac
`
`WI 4.5" 13.5 lb/ft Buttress Casin Thread, Box x Pin
`
`n
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`*HWWGE1BOBR
`n
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`Lower Back-U Retainer
`n
`
`|
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`RESTRICTED - OUTSIDE ATTORNEYS' EYES ONLY - TECHNICAL
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`23 of 34
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`BH00363830
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`Ex. 2052
`
`IPR2016-01506
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`

`

`
`SHONS
`
`135E111”TfllINSTALLINGSEALSNIBBACK-UPS
`
`u3.BakerOilTools
`
`GEIIEIIITEIIIIITIEIlicrofiinfionCIDSYSTEM
`
`§ §3 E
`
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`FIXTURE
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`
`““ASSEMBLYVIEW
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`
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`
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`SKD‘ISPRESSURETEST
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`RESTRICTED - OUTSIDE ATTORNEYS' EYES ONLY - TECHNICAL
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`BH00363831
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`Ex. 2052
`
`IPR2016-01506
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`nun-uummwwt"audiomam-4H"In-bud"HIM-am
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`9mm [mfik :75"
`
`(2%: Mtg Jacky. = fig
`EE 1 We = 7%"
`
`
`fisol
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`
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`— System Status (resting and Development)?
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`
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`
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`
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`
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`I Packer
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`
`isoFrac — Generation 3
`I Generation 3 Drivers
`- General Design Specifications
`I 10.000 P51 l35IJF
`I Generation 2 System Chassis
`I MulflpIe Cycle Free Sleeves
`I mum Open Hole Sizes
`- Technical Road Blocks — Settan sequence and force
`trensler of long element at higher ten-learning.
`
`/_.
`
`RESTRICTED - OUTSIDE ATTORNEYS' EYES ONLY - TECHNICAL
`25 of 34
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`BH00363832
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`Ex. 2052
`
`IPR2016-01506
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`

`

`Generation 3 Requirements
`- MALT Nee
`- Freestone Nee:
`I B urinfi‘fi'floia ID
`I10Ki'320F
`U Hamel -4io 5 Zones
`—VemoanoasierArea:
`I smmawmla ID
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`
`
`
`Market Drivers & Opportunities
`
`- Competition:
`— Packers Plus
`I Flown System
`- Opportunities
`- Mid Can
`I Generation 1 and Geranium 2
`- e m‘ 0pm Hob, 8.5mPSL am
`- MALT
`I Generation 3
`u 6 W (hat Hale, 1011mm. 8 375F
`
`.fi‘: m.“
`
`RESTRICTED - OUTSIDE ATTORNEYS' EYES ONLY - TECHNICAL
`26 of 34
`26 of 34
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`BH00363833
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`Ex. 2052
`
`IPR2016-01506
`
`

`

`Iso Frac Packer Testing Update
`
`Test #1: Simulate loads on lower packer
`
`Casing ID: 6.250”
`Elastomer: HNBR
`
`Setting Temperature: 250°F
`Test Medium: Water
`
`Acceptance Criteria: Able to maintain the hold pressure with the Sprague pump.
`
`Steps:
`Heat fixture to 250°F
`
`7499:5903?
`
`Set with 4,000 psi
`Pressure below element with 5,000 psi and hold for 30 minutes
`Cool down to 100°F with 5,000 psi below and hold for 30 minutes
`Reverse to top at 100°F and hold 5,00