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Technical Presentations
Session: I Session Chairs:
Gas-Lift Valves and Barrier Testing Sten Viggo Lundbo, Statoil
Niek Dijkstra, Schlumberger
Presentation Title: I – 1 Company(ies):
Testing (Gas-Lift Valves) in a Safe International Research Institute of
Manner Stavanger (IRIS)
Author(s): Contact Information:
Jørn Carlsen Sven.Aarrestad@iris.no
Abstract:
International Research Institute of Stavanger (IRIS) has tested down hole equipment since 1983
- As described during the session “Gas Lift Valves Barrier Testing”, Houston 2010 (speakers Jørn Carlsen,
Statoil and Sven Aarrestad, IRIS)
During a test related to ISO 14310 in 2009, the anchors on a bridge plug released unforeseen.
This resulted in a projectile of 180 kg penetrating the text fixture end cap with a velocity of 65 m/s, representing a
kinetic energy of 380 kJ.
Based upon this experience, a new test pit was designed using a specific company within the Norwegian Defence – a
company with experience in “both directions:
- Penetrating the barrier to the “enemy”
- Protect against projectiles from the “enemy”.
This test pit with crash-box system in both ends, a length of 20 meters and a square of 2 x 3 meters, has capacity to
withstand a projectile of:
- Weight: 300 kg
- Velocity: 193 m/s
- Static load: 300 tons,
representing a kinetic energy of 5600 kJ
We will describe in detail the development of the new test facility from the test accident in 2009 and up to the opening
of the new facility in 2012.
Notes:
2013 Gas-Lift Workshop Page 2
Points of interest
Validation levels.
Test data calibration versus CFD, FEA.
Dimensional requirements and limitations.
Field experience.
Notes:
2013 Gas-Lift Workshop Page 4
In addition, recent emphasis on a requirement that the reverse check valve act as a barrier from the tubing to the
casing with significantly lower leak rate criteria than the international standards has garnered much attention by
designers, manufacturers and end-users of gas lift valves. New standards have been written and implemented by
several operators, specifically the gas lift valve portion of Statoil’s TR2385, to address this barrier requirement.
The international test standards as well as the operator specific standards have taken a significant step forward in
testing gas lift valve reliability and performance but thus far have not completely addressed the dynamic performance
and reliability of the barrier check sub-system.
A recent effort by the Schlumberger Gas-Lift New Product Development team has addressed some areas of concern
beyond the traditional leak rate sealing tests performed on barrier valves in order to characterize and improve the
reliability and performance of the reverse flow check system. Some of this effort in general design and testing
philosophy will be discussed.
Notes:
2013 Gas-Lift Workshop Page 5
Many Operator or Service Provider employees have not witnessed these standard tests and are unaware what types
of facilities and systems are required to perform the testing. This presentation shows a selection of facilities and test
fixtures used to qualify new and existing gas lift valves to the API 19G2 standard.
Notes:
2013 Gas-Lift Workshop Page 6
1. Gas-lift unloading
2. Gas-lift casing heading
3. Gas-lift tubing heading
4. Dual gas-lift gas robbing
The main goal of the presentation is to visualize the importance of dynamic simulation for gas-lift operation and the
added value to gas-lift design. The presentation will also emphasize the importance of the collaboration between
hardware manufacturers and software providers.
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Notes:
Even though all the wells intervened were flowing seemingly normal, various issues were found. These ranged from
multiple point injection, to subcritical injection, tubing heading, and sub-optimized injected gas. The main causes of
these issues included leaking valves and improper sizing of orifice ports. These issues were addressed by replacing
leaking or damaged unloading valves, changing standard orifice valves to venturi orifice valves with proper port size,
as well as adjusting the gas rates to an optimized value.
Overall, the campaign on these seven wells yielded a total production increase of 14% and a net oil increase of 15%.
These values were monitored and remained stable over a three month period. A network model was also created for
the analyzed wells, determining the optimum and maximum gas injection values and how they would affect the
overall production.
Notes:
The tool has been applied with great success. An operator required the ability to replace GLV’s in their completion for
increased oil production. Conventional methods had reached their limits: slickline was unable to overcome the higher
deviations while coiled tubing, with imprecise depth control, took multiple run-in-hole attempts to pull and replace the
valve. Based on previous, positive experiences with electric line, mechanical solutions, the customer chose the KOT
to be run in tandem with a tractor and a hydraulic stroking to pull the existing GLV and replace it in a single run. The
tractor conveyed the toolstring to the correct depth where the stroking tool and the upper KOT provided the pulling
force for removal. Then, the stroking tool and lower KOT successfully installed the new GLV into the mandrel.
Operators are now enabled to optimize their gas-lift design without limitations imposed by the previous, conventional
means. This allows them to place GLV’s in the high angle sections if that is the best possible location for increased oil
recovery from their reservoirs.
This presentation will describe the challenges with the planning and execution of this particular operation and the
implications for future gas-lift design.
Notes:
The hunt for further oil and gas recovery from old wells is booming, and the industry look to new and improved
technology for adding several years of operational time. New methods like light well intervention procedures sets high
stress on old wellheads and infrastructure, and a general increase in development of marginal fields have raised
issues over safety aspects yet again.
In the arctic region, politicians struggle to set a standard for allowing oil and gas recovery due to possible
environmental impact from a major disaster. After the very unfortunate Deepwater Horizon accident, a lot of
suggested technology improvements involves better pressure management.
Aside from developing improved procedures around cementing operations, leakage detection and oil spill recovery,
additional success factors will be the ability to monitor pressure and temperature fluctuations in B annulus, as well as
finding models and produce technology to manage such pressure builds successfully.
Notes:
Artificial lift is an essential part of Apache North Sea’s operations, however, the selection process between ESP and
gas-lift is often not clear cut and has evolved over time to meet the changing requirements of the assets; this is
particularly relevant in the Forties Field. Factors affecting the artificial lift selection include gas availability, topsides
plant constraints, sand production, well productivity, and ESP run-life. Long term planning and detailed production
forecasts are also a key requirement of the artificial lift selection strategy.
An understanding of gas-lift systems is an essential part of effectively delivering the artificial lift strategy, however, it
has been seen that this can sometimes be lacking in both onshore and offshore staff. At times this has had an
impact on operations; consequently training and coaching have been necessary to ensure that systems are properly
designed and operated in such a way to maximize production. Good record keeping and data storage are important
parts of understanding any assets gas lift wells and should not be overlooked.
In 2008 Apache began to run permanent downhole pressure and temperature gauges in selected gas-lift wells; this
approach will also be applied to the Beryl wells on the current drilling plan. The data from the downhole gauges is
continuously streamed onshore via a fiber-optic link and this has proved invaluable to the onshore engineers
especially when troubleshooting problem wells. In addition to this, a distributed temperature system (DTS) has been
installed in one Forties well which, coincidently, suffered major operating issues when the deep-set production packer
became unseated. Evaluation of the DTS data concluded that changing out the gas-lift orifice would help to optimize
the well which avoided an expensive workover.
Notes:
Production is via the annular spaces and bores of the IGLS components and coiled tubing / pipe.
IGLS can be installed using traditional Intervention techniques therefore making this a cost effective option to any
work over program.
Components of the IGLS can be used for other applications e.g. water injection systems, in order to dissolve salt
deposits that reduce production rates, and can also be combined with some of our Renaissance System
components.
These systems offer a revival for troubled wells by expanding the productive life.
Notes:
An innovative Retrofit Deep Gas Lift (RDGL) system was designed, in a cooperative project involving Operator and
Service Company, to provide a means of allowing lift gas to access the lowest perforation. This incorporates
punching holes in the tubing directly above the packer and straddling them, using thru-tubing methods, with a two
piece straddle/crossover assembly and a tailpipe extending to the desired depth. This ISO 14310 V0 qualified
system directs lift gas from the tubing/casing annulus via a special crossover assembly to the desired depth with the
resultant production returning via the tailpipe annulus through the crossover to the tubing above. This system was
initially installed in a well with 5-1/2” tubing to provide lift gas to a point some 800 ft below the production packer and
resulted in the resumption of production from a well that had been shut in for 2.5 years.
Notes:
2013 Gas-Lift Workshop Page 15
The latest gas-lift valve technologies can still be regarded as a work in progress; as these new barrier qualified gas-
lift valves gain exposure in wells around the world, we get a better picture of the long term reliability of these types of
valves. One such field where we have a long track record with these newer types of gas-lift valves is the Statoil
Norne field.
The Statoil Norne field is located in the Northern Norwegian sector of the North Sea; its wells are subsea completed
in a water depth of 380m, with single-point gas-lift injection systems for production enhancement. During 2005/2006
five wells were completed on Norne, with a gas-lift system based on newly designed barrier-type 1-3/4” OD gas-lift
valves. Ever since, these valves have been subjected to very high gas injection rates of up to 11 mmscf/d, with
regular well integrity testing to confirm barrier integrity.
Up to date there has been no recorded failure of any of these newer type 1-3/4” gas-lift valves on Norne, which gives
an indication of their long term functionality. Recently one valve was pulled which gives us a glimpse of the condition
these valves are in after being in the ground for extended periods. This case history will give further information of the
gas-lift operations on Norne, and overview of the long term reliability of these newer barrier qualified gas-lift valves in
one of the fields with one of the longest track records involved.
Notes:
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These models work fine as long as the surface is smooth and there is no active compression system limits. Wells
which have discontinuous gas-lift performance curves perform a not smooth optimization surface. Then, the surface
optimization based on traditional gradient methods (like BFGS and Quadratic Programming) does not work. A
commercial software was tried to optimize through operational boundary conditions but no reasonable solutions were
obtained. Compression capacity should be a model input and total gas-lift rate a model variable in addition to wells
gas-lift rates.
This work describes two field-implemented methods based on Operational Research techniques, Dynamic
Programming and Mixed Integer Programming, to overcome these modeling difficulties.
The gas-lift optimization by Dynamic Programming model allows prescribing a set of wells which must be closed in
case of compression system capacity constraint at a minimum well gas-lift rate.
Optimization by Mixed Integer Programming performs a more complex model. It is possible to add operational
constraints such as capacity reduction in produced water disposal system. It defines which wells can remain opened,
their respective gas-lift rates and well head pressures. This model applies piecewise linearization to deal with non
smooth surfaces.
These models accomplish the optimization task at one offshore platform in Campos Basin, giving a fast response to
operational daily changes.
Notes:
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Assume static temperature gradients for nitrogen valve pressure setting and then expect them to operate for the first
time at higher flowing temperature gradients?
“Age” valves at 5,000psig and then subject them to higher hydrostatic test pressures in service?
Locate orifice valves as deep as possible when, for most of the well’s life, it will not be possible to reach that depth?
Specify large orifice port sizes and then choke the gas injection rate, making the tubing pressure susceptible to
instability?
Not pay attention to the learning from tear down inspections?
Expect integrity from check valves so clearly subject to scale deposition?
Use very basic gas metering equipment and guess at valve temperature and casing pressure?
Use idealized gas-lift performance curves for well, network and reservoir modeling when only a limited range of rates
are truly achievable?
Many of our assumptions may be nonsense! This presentation will also examine some recent work that illustrates in
a practical way the true upper and lower limits of gas injection rate for a specific installed design and how they
change over the life of a well.
Laing has over 35 years of petroleum engineering experience, including 18 years with major international operator
Amoco. For the last 5 years they have delivered both gas-lift consulting and artificial lift training. They also helped to
develop an MSc degree in Petroleum Production Engineering for the Robert Gordon University.
Notes:
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New technology in wireless systems, flow measurement, downhole sensors for pressure, temperature, and fluid
density, and equipment associated with testing wells will be discussed.
Notes:
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