In 2007, CJS was approached by Global Energy Services to resolve a problem they were having with the efficiencies in conveying their hydraulic submersible pump. Past methods of deployment of their pump proved unwieldy and very expensive. Since three tubulars were required both to drive the pump and receive production fluid to surface, CJS considered a coiled tubing umbilical to be the best solution for the problem. However, a typical round umbilical presented some issues relating to wrapping the inner tubulars to prepare for spooling. This process is both complex and costly; moreover, the resulting matrix is very large, difficult, and expensive to deploy. Due to these concerns, CJS considered making the umbilical rectangular in shape so that each of the inner tubulars would be kept on the same plane. Working with an extrusion company located in the US, CJS developed the original prototypes of FlatPak.
FlatPak was deployed for the first time in Spring 2008. In this gas lift scheme, the FlatPak umbilical was configured with a plastic production tube, a steel injection tube and a capillary string to be conveyed into a waxy light oil well in Montana. The system worked flawlessly, setting the stage to expand the uses of this product to other artificial lift systems.