New 1.5” Differential Gas Lift Valve - ALRDCalrdc.org/workshops/2016_2016GasLiftWorkshop... ·...
Transcript of New 1.5” Differential Gas Lift Valve - ALRDCalrdc.org/workshops/2016_2016GasLiftWorkshop... ·...
© 2006 Weatherford. All rights reserved.1
New 1.5” Differential Gas Lift Valve
Date: March 30, 2016
Steve Long
© 2006 Weatherford. All rights reserved.
Introduction – Background Information
• First differential valves used widely in 1930’s & 40’s
• 1944 King Injection Pressure Operated Valve (IPO)
• New differential valve designs - 1990’s & 2000’s
• 2012 Weatherford development for Shell HPHT
• 2014 Weatherford New 1.5” Differential Valve
• 2016 Weatherford RH-2 XHP IPO Valve (5000 psi)
2May 16 - 20, 2016
© 2006 Weatherford. All rights reserved.
Why Bother with Differential Valves?
• Can operate at varying injection gas pressures
3
• No Bellows
• Not temperature sensitive
• Good flow characteristics
• Simplicity in design and handling
3May 16 - 20, 2016
© 2006 Weatherford. All rights reserved.
New Weatherford 1.5” Differential Valve
• Complete redesign similar to a velocity type safety valve
• Positive results from flow testing
• Closes on predetermined differential pressure
• Reopens at lower differential pressure than original closing differential
• Considerations
– Specific unloading and kick-off procedures
– Surveillance and planning
44May 16 - 20, 2016
© 2006 Weatherford. All rights reserved.
New 1.5” Differential Valve Flow Path
55May 16 - 20, 2016
© 2006 Weatherford. All rights reserved.6
New 1.5” Differential Valve
Patent Pending
Inlet
Ports
Flow
Tube
ChokeSpringCheck
Valve
Flow
Through
Latch
Sealing
Head
6May 16 - 20, 2016
© 2006 Weatherford. All rights reserved.7
New 1.5” Differential Valve Mechanics – Open Position
Patent Pending
Differential
Closing Pressure=
Spring Force
ID Area of flow-tube – ID area of choke
Friction
Factor
Differential
Closing Pressure= Casing Pressure – Tubing Pressure
Where:
Flow Tube IDChoke IDSpring
Force
Casing
Pressure
7May 16 - 20, 2016
Tubing
Pressure
© 2006 Weatherford. All rights reserved.8
New 1.5” Differential Valve Mechanics – Closed Position
Patent Pending
Differential
Reopening Pressure
Spring Force
ID Area of flow-tube =
Where:
Differential
Reopening Pressure = Casing Pressure – *Tubing Pressure
Note: If check is spring loaded check valve and the sealing head with a positive seal is
used, then trapped pressure inside the flow-tube instead of tubing pressure applies
Flow Tube IDSpring
force
8May 16 - 20, 2016
Casing
Pressure
Tubing
Pressure
© 2006 Weatherford. All rights reserved.
Weatherford Gas Lift Valve Test Skid at R&D Lab
99May 16 - 20, 2016
© 2006 Weatherford. All rights reserved.10
New 1.5” Differential Valve – Test #57 Close
0
500
1000
1500
2000
2500
3000
3500
0
200
400
600
800
1000
1200
1400
1600
1800
0 10 20 30 40 50F
low
Ra
te (
Ms
cfd
)
Pre
ss
ure
(p
si)
Time (s)
Patent Pending
• .313” Choke
• ~1520 upstream/casing
• Closed at 680 psi
downstream
• 840 psi differential
closing pressure
• 2.9 MMSCF/Day at
close
10May 16 - 20, 2016
© 2006 Weatherford. All rights reserved.11
New 1.5” Differential Valve – Test #57 Reopen
0
100
200
300
400
500
600
700
800
900
1000
0 20 40 60
Pre
ssu
re (
psi)
Time (s)
Patent Pending
• .313” Choke
• 450 psi Reopen
11May 16 - 20, 2016
© 2006 Weatherford. All rights reserved.
Example Well Data
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Tubing Size 5.5”
Mid Perforations 10,000’
Static BHP 5000 psi
Completion Fluid Gradient .500 psi/ft
Productivity Index 5
Water Cut 50%
Water Specific Gravity 1.07
Formation GOR 200:1
Wellhead Back Pressure 200 psi
Injection Pressure 1500 to 2000 psi
Injection Gas Specific Gravity .70
Injection Gas Volume Requirement 3 to 5 MMSCF/Day
Production Rates** *10,000 BFPD with 1500 psi injection pressure
*12,000 BFPD with 2000 psi injection pressure
12May 16 - 20, 2016
© 2006 Weatherford. All rights reserved.
Example Well Differential Valve Design
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True
Vertical
Depth
(feet)
Valve Type Choke Size
(inches)
Differential
Close
(psi)
Differential
Reopen
(psi)
2800’ Differential 16/64” 1050 650
4800’ Differential 20/64” 750 450
6200’ Differential 22/64” 750 400
7600’ Differential 24/64” 750 400
9000’ Orifice 24/64” NA
*The above spacing is based on minimum of 1500 psi injection pressure
and maximum 2000 psi
13May 16 - 20, 2016
© 2006 Weatherford. All rights reserved.14
Stage 1 – New 1.5” Differential Gas Lift Valve Unloading
2800’
6200’
7600’
9000’
• Well is loaded with completion fluid.
• All differential valves are open
• The orifice valve remains open at all times
4800’
Open
Open
Open
Open
Always Open
14May 16 - 20, 2016
© 2006 Weatherford. All rights reserved.15
Stage 2 – New 1.5” Differential Gas Lift Valve Unloading
2800’
6200’
7600’
9000’
• Injection gas is started to unload well
• Differential valves open
4800’
1000 psi
Open
Open
Open
Open
Always Open
15May 16 - 20, 2016
© 2006 Weatherford. All rights reserved.16
Stage 3 – New 1.5” Differential Gas Lift Valve Unloading
2800’
6200’
7600’
9000’
• Injection gas enters top differential valve at 2800’
4800’
1500 psi
Open
Open
Open
Open
Always Open
16May 16 - 20, 2016
1050 ∆P close
© 2006 Weatherford. All rights reserved.17
Stage 4 – New 1.5” Differential Gas Lift Valve Unloading
2800’
6200’
7600’
9000’
• Fluid level in casing continues to drop as gas is injected in top
differential valve at 2800’
4800’
1500 psi
Open
Open
Open
Open
Always Open
17May 16 - 20, 2016
1050 ∆P close
© 2006 Weatherford. All rights reserved.18
Stage 5 – New 1.5” Differential Gas Lift Valve Unloading
2800’
6200’
7600’
9000’
• Injection gas enters 2nd differential valve at 4800’
• Top and 2nd differential valves will be injecting gas simultaneously
• Sufficient injection gas volume will have to be maintained
4800’
1500 psi
Open
Open
Open
Open
Always Open
18May 16 - 20, 2016
750 ∆P close
1050 ∆P close
© 2006 Weatherford. All rights reserved.19
Stage 6 – New 1.5” Differential Gas Lift Valve Unloading
2800’
6200’
7600’
9000’
• Differential valve at 2800’ closes
• Injection point is at 4800’ as unloading continues
4800’
1500 psi
Closed
Open
Open
Open
Always Open
19May 16 - 20, 2016
1050 ∆P close, 650 ∆P reopen
750 ∆P close
© 2006 Weatherford. All rights reserved.20
Stage 7 – New 1.5” Differential Gas Lift Valve Unloading
6200’
7600’
9000’
• Injection gas enters 3rd differential valve at 6200’
• 2nd and the 3rd differential valves will be injecting gas simultaneously
• Sufficient injection gas volume will have to be maintained
1500 psi
Closed
Open
Open
Open
Always Open
20May 16 - 20, 2016
2800’
4800’
1050 ∆P close, 650 ∆P reopen
750 ∆P close
750 ∆P close
© 2006 Weatherford. All rights reserved.21
Stage 8 – New 1.5” Differential Gas Lift Valve Unloading
6200’
7600’
9000’
• The differential valve at 4800’ closes
• The injection point stabilizes at 6200’
• Production rate of ~10,000 BFPD
1500 psi
5/23/2016
Closed
Closed
Open
Check Closed
Check Closed
6200’
2800’
4800’
1050 ∆P close, 650 ∆P reopen
750 ∆P close, 450 ∆P reopen
750 ∆P close
© 2006 Weatherford. All rights reserved.22
Stage 9 – Unloading Complete for 2000 psi Injection Pressure
2800’
6200’
7600’
9000’
• The differential valve at 7600’ closes
• Injection point stabilizes at 9000’
• Production rate is ~12,000 BFPD
4800’
2000 psi
5/23/2016
1050 ∆P close/650 ∆P reopen
750 ∆P close/450 ∆P reopen
750 ∆P close/400 ∆P reopen
750 ∆P close/400 ∆P reopen
Closed
Closed
Closed
Closed
Open
© 2006 Weatherford. All rights reserved.
Questions?
2323May 16 - 20, 2016
© 2006 Weatherford. All rights reserved.2424
© 2006 Weatherford. All rights reserved.2525