2001 asme/api gas-lift workshop

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Feb. 6, 2001 2001 ASME/API Gas-Lift Wo rkshop 1 2001 ASME/API Gas-Lift 2001 ASME/API Gas-Lift Workshop Workshop Routine Validation Testing Routine Validation Testing of Every Gas-Lift Valve of Every Gas-Lift Valve Informal Presentation Informal Presentation by by Naiza Abdullah, Brunei Shell Petroleum Naiza Abdullah, Brunei Shell Petroleum Ken Decker, Decker Technology Ken Decker, Decker Technology Cleon Dunham, Oilfield Automation Consulting Cleon Dunham, Oilfield Automation Consulting

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2001 ASME/API Gas-Lift Workshop. Routine Validation Testing of Every Gas-Lift Valve Informal Presentation by Naiza Abdullah, Brunei Shell Petroleum Ken Decker, Decker Technology Cleon Dunham, Oilfield Automation Consulting. Routine Validation Testing of Every Gas-Lift Valve. Outline - PowerPoint PPT Presentation

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Page 1: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 1

2001 ASME/API Gas-Lift Workshop2001 ASME/API Gas-Lift Workshop

Routine Validation TestingRoutine Validation Testingof Every Gas-Lift Valveof Every Gas-Lift Valve

Informal PresentationInformal Presentation

byby

Naiza Abdullah, Brunei Shell Petroleum Naiza Abdullah, Brunei Shell Petroleum Ken Decker, Decker TechnologyKen Decker, Decker Technology

Cleon Dunham, Oilfield Automation ConsultingCleon Dunham, Oilfield Automation Consulting

Page 2: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 2

Routine Validation TestingRoutine Validation Testingof Every Gas-Lift Valveof Every Gas-Lift Valve

OutlineOutline• Brief historyBrief history• Business justification for routine testingBusiness justification for routine testing• How the tester worksHow the tester works• Intended operational use Intended operational use • Field experienceField experience• Outstanding issuesOutstanding issues

Page 3: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 3

Routine Valve TestingRoutine Valve TestingA Brief HistoryA Brief History

HistoryHistory• Only the Ptro test is performed routinelyOnly the Ptro test is performed routinely• In 1995, API RP 11V2 provided standards for In 1995, API RP 11V2 provided standards for

testing and modeling gas-lift valvestesting and modeling gas-lift valves• In 1996, the Valve Performance Clearinghouse, an In 1996, the Valve Performance Clearinghouse, an

industry JIP, was formed to implement 11V2industry JIP, was formed to implement 11V2• Typically, the VPC tests one valve of each typeTypically, the VPC tests one valve of each type• Purpose of Gas-Lift Valve, Automatic Validation Purpose of Gas-Lift Valve, Automatic Validation

Tester (Tester (GLV-AVTGLV-AVT) is to test every gas-lift valve) is to test every gas-lift valve– Before it is runBefore it is run– After it is pulledAfter it is pulled

Page 4: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 4

Routine Valve TestingRoutine Valve TestingBusiness JustificationBusiness Justification

Rationale for testing each valveRationale for testing each valve• Not all valves of a specific type are manufactured Not all valves of a specific type are manufactured

to the original specificationsto the original specifications• Some companies are not API certifiedSome companies are not API certified• Some valves may be damaged in handlingSome valves may be damaged in handling• Many operating companies re-run used valvesMany operating companies re-run used valves• Operating conditions in wells varyOperating conditions in wells vary

Operators need a high degree of assurance Operators need a high degree of assurance that valves will perform as intended that valves will perform as intended

Page 5: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 5

Routine Valve TestingRoutine Valve TestingBusiness JustificationBusiness Justification

Justification for pre-installation testingJustification for pre-installation testing• Screen out valves that will not perform as Screen out valves that will not perform as

intendedintended– Due to manufacturing faults or limitsDue to manufacturing faults or limits– Due to handling problemsDue to handling problems– Due to setting problems Due to setting problems

• Know actual valve characteristics Know actual valve characteristics – May be different than "typical" valve tested by VPCMay be different than "typical" valve tested by VPC– Use actual characteristics in gas-lift programsUse actual characteristics in gas-lift programs

• Evaluate various valves types/sourcesEvaluate various valves types/sources– If a given valve type/model is routinely unsatisfactoryIf a given valve type/model is routinely unsatisfactory– If a used valve should not be re-runIf a used valve should not be re-run

Page 6: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 6

Routine Valve TestingRoutine Valve TestingBusiness JustificationBusiness Justification

Justification for post-installation testingJustification for post-installation testing• Evaluate valve conditionEvaluate valve condition

– Can it be re-dressed and re-run, or Can it be re-dressed and re-run, or – Should it be discardedShould it be discarded

• LearnLearn– How well did the valve survive in the well's environmentHow well did the valve survive in the well's environment– Is a different valve type needed in this environmentIs a different valve type needed in this environment– Is a different valve metallurgy neededIs a different valve metallurgy needed

Page 7: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 7

Routine Valve TestingRoutine Valve TestingHow the Tester WorksHow the Tester Works

Quick, simple test of each gas-lift valveQuick, simple test of each gas-lift valve• Insert valve in test fixture – 1" and 1.5" availableInsert valve in test fixture – 1" and 1.5" available• Apply nitrogen pressure (from NApply nitrogen pressure (from N22 bottle) bottle)• Conduct these tests, under computer controlConduct these tests, under computer control

– Opening pressureOpening pressure– Closing pressureClosing pressure– Port leak ratePort leak rate– Load rate of bellows and/or springLoad rate of bellows and/or spring– Maximum effective stem travelMaximum effective stem travel– Back check valve leak rateBack check valve leak rate– Port/bellows ("R") ratioPort/bellows ("R") ratio– Bellows failure and/or dome leakBellows failure and/or dome leak

Page 8: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 8

AVT Front PanelAVT Front Panel

Page 9: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 9

AVT Computer ControlAVT Computer Control

Page 10: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 10

Preparing to Test a ValvePreparing to Test a Valve

Page 11: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 11

Close Fixture, Connect HoseClose Fixture, Connect Hose

Page 12: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 12

Routine Valve TestingRoutine Valve TestingHow the Tester WorksHow the Tester Works

Quick, simple test of each gas-lift valve (con't)Quick, simple test of each gas-lift valve (con't)• Entire test of one valve takes about 3 minutesEntire test of one valve takes about 3 minutes• Produces a reportProduces a report

– Actual test results vs. operator-entered test criteriaActual test results vs. operator-entered test criteria

– A Pass or Fail is declared for each testA Pass or Fail is declared for each test

• Produces a gas-lift valve performance plotProduces a gas-lift valve performance plot– Actual performance plot of the tested valve vs. Actual performance plot of the tested valve vs.

– Plot based on VPC (or standard) characteristics Plot based on VPC (or standard) characteristics

• Exports a file Exports a file – Test results and actual valve characteristics can be exported Test results and actual valve characteristics can be exported

to any gas-lift programto any gas-lift program

– For example, Shell inputs results into WinGLUEFor example, Shell inputs results into WinGLUE

Page 13: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 13

AVT Test Results ScreenAVT Test Results Screen

Page 14: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 14

Routine Valve TestingRoutine Valve TestingIntended Operational ProcessIntended Operational Process

Routine testing of every gas-lift valveRoutine testing of every gas-lift valve• Test every valve before it is runTest every valve before it is run

– If valve "passes" all tests, run itIf valve "passes" all tests, run it– If valve "fails" one or more tests, return itIf valve "fails" one or more tests, return it– Have one or more spares on hand Have one or more spares on hand

• Store every test result in a gas-lift program and a Store every test result in a gas-lift program and a databasedatabase– Use in program for routine analysisUse in program for routine analysis– Use in database to learn, evaluateUse in database to learn, evaluate

• Test every valve when it is pulledTest every valve when it is pulled– Store results in databaseStore results in database– Compare "after" performance with "before"Compare "after" performance with "before"

Page 15: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 15

Routine Valve TestingRoutine Valve TestingInitial Field ExperienceInitial Field Experience

Use of the AVT has….Use of the AVT has…. Increased accuracy of pressure and port Increased accuracy of pressure and port

leak measurements.leak measurements. Extended the practice of testing gaslift Extended the practice of testing gaslift

valves to individuals who may not be familiar valves to individuals who may not be familiar with typical shop practices.with typical shop practices.

Insures a consistently applied testing Insures a consistently applied testing standard. The technician cannot “help” the standard. The technician cannot “help” the valve pass a test.valve pass a test.

Page 16: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 16

Routine Valve TestingRoutine Valve TestingInitial Field ExperienceInitial Field Experience

Use of the AVT has…Use of the AVT has… Found that good valves re-test Found that good valves re-test

consistently.consistently. Provided the technician, engineer, and Provided the technician, engineer, and

wireline operator with a “certificate” wireline operator with a “certificate” indicating the valve has passed all tests.indicating the valve has passed all tests.

Provided a link from the gaslift shop to the Provided a link from the gaslift shop to the engineers desk.engineers desk.

Page 17: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 17

Routine Valve TestingRoutine Valve TestingInitial Field ExperienceInitial Field Experience

Camco BKR-5 valves were tested for Brunei Camco BKR-5 valves were tested for Brunei Shell Petroleum in Seria, BruneiShell Petroleum in Seria, Brunei

The tested R ratio was MUCH larger than The tested R ratio was MUCH larger than the manufacturer’s published R ratio.the manufacturer’s published R ratio.

Valves with 3/16” TC ports tested with R Valves with 3/16” TC ports tested with R ratios of .154. The printed R ratio is .118.ratios of .154. The printed R ratio is .118.

This means the valve will have This means the valve will have approximately 30% more casing approximately 30% more casing sensitivity than expected.sensitivity than expected.

Page 18: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 18

Chamfered TC PortChamfered TC Port

Page 19: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 19

Routine Valve TestingRoutine Valve TestingInitial Field ExperienceInitial Field Experience

Camco BKR-5 valves were tested for Brunei Camco BKR-5 valves were tested for Brunei Shell Petroleum in Seria, BruneiShell Petroleum in Seria, Brunei

Back checks do not seal leak tight.Back checks do not seal leak tight. The AVT found several valves with bad O-The AVT found several valves with bad O-

rings on the seat.rings on the seat. The AVT found 1 valve with a leaking tail The AVT found 1 valve with a leaking tail

plug.plug. The AVT found several valves with leaking The AVT found several valves with leaking

O-rings at the valve body joints.O-rings at the valve body joints.

Page 20: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 20

Routine Valve TestingRoutine Valve TestingInitial Field ExperienceInitial Field Experience

Camco BKR-5 valves were tested for Brunei Camco BKR-5 valves were tested for Brunei Shell Petroleum in Seria, BruneiShell Petroleum in Seria, Brunei

The loadrate was generally less than 1300 The loadrate was generally less than 1300 psig/inch. This is expected for valves set psig/inch. This is expected for valves set at pressures less than 1000 psig.at pressures less than 1000 psig.

The effective stem travel was generally The effective stem travel was generally less than 0.100 inch. This is less than less than 0.100 inch. This is less than expected but enough for a 3/16” ported expected but enough for a 3/16” ported valve with an 8 or 10 choke.valve with an 8 or 10 choke.

Page 21: 2001 ASME/API Gas-Lift Workshop

Feb. 6, 2001 2001 ASME/API Gas-Lift Workshop 21

Routine Valve TestingRoutine Valve TestingOutstanding IssuesOutstanding Issues

There is more work to be doneThere is more work to be done• Initial valve tester is a prototypeInitial valve tester is a prototype

– Needs to be re-packaged into a fully field-worthy deviceNeeds to be re-packaged into a fully field-worthy device

• It may be possible to use the tester to help It may be possible to use the tester to help conduct some VPC testsconduct some VPC tests– Needs to be evaluatedNeeds to be evaluated

Page 22: 2001 ASME/API Gas-Lift Workshop

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Routine Valve TestingRoutine Valve TestingConclusionsConclusions

This is one more step forward for gas-liftThis is one more step forward for gas-lift• There is now a cost-effective way to test every There is now a cost-effective way to test every

gas-lift valvegas-lift valve– Before it is runBefore it is run– After it has been pulledAfter it has been pulled

• This should greatly improve quality assurance This should greatly improve quality assurance and reduce "infant mortality" that comes from and reduce "infant mortality" that comes from running valves that are not properly suited:running valves that are not properly suited:– Manufacturing faultsManufacturing faults– Handling problemsHandling problems– Setting problemsSetting problems