IPO Unloading Valve Technology Developments and The Associated Benefits Alan Brodie, Feb 2011

IPO unloading valve technology developments Introduction IPO Unloading valve operation reminder What the industry wanted in tomorrows unloading valves What’s different about PTC unloading valves The benefits these differences are delivering

IPO Unloading valve operation reminder Required during gas lift well commissioning – Where lift gas pressure can’t facilitate deep lift During unloading they should have: – Predictable operating characteristics ( opening and closing pressures) – High as possible throughput After unloading they should: – Stay reliably closed for the life of the well – Not be a weak link in the primary well barrier envelope – Not allow shallow lift gas entry or multi-pointing Unless well conditions change or are unpredictable: – And lift gas via the operating valve becomes unachievable – Then the unloading valve should be capable of: Reliably acting as an operating valve

IPO Unloading valve operation reminder Ball and seat valve set in side pocket mandrel Also incorporates a check valve ( not shown here): – To provide tubing > casing integrity Held closed by an N2 charged dome Annulus (P1) and Tubing (P2) pressure trying to open it P1 acts on large bellows area P2 acts on the valve port: – When pressures are high enough valve opens – Injection pressure dominates....but tubing pressure still has an impact

The industry wish list for tomorrows unloading valves Improved Integrity: – Well barrier performance in line with packers and plugs Improved Reliability: – Life of well longevity – Fail safe architecture Reduced well commissioning costs Higher throughput for faster unloading Ability to pressure test tubing and annulus with live valves in the well Improved Performance: – High pressure rating to enable deeper installations – Reduced valve throttling and chattering – Flexibility to use as an operating valve if well conditions change Without compromising integrity or reliability

What’s different about PTC unloading valves Well Integrity Incorporates well barrier accredited check valve module: – Optimised flow paths and long valve travel – Minimal erosion – Patented orifice check dart linkage Chattering virtually eliminated:

What’s different about PTC unloading valves Well Integrity

Incorporates well barrier accredited check valve module: – Optimised flow paths and long valve travel – Minimal erosion – Patented orifice check dart linkage Chattering virtually eliminated: – Spring location (around dart) & size Robust and requires 25 psi dp to open Achieved V1( <20 cc /10 mins based on ISO 14310), even: – As part of an unloading valve – After flowing erosive fluid through the valve A well barrier is for life not just to pass a FAT

What’s different about PTC unloading valves Reliability In addition to well barrier accredited check valves The PTC IPO valves use a revolutionary bellows design All dome seals and inflation valves are metal / metal: – Reduces likelihood of dome pressure leakage: Bellows rated to psi – Usually operating well within range No dp across bellows – Tested up to cycles without failure: Very low load rate ( flexible even at psi ) – Long stem travel / large valve opening – Little throttling / erosion / chattering Valve held closed by spring – Not by bellows pressure as is more common – Active fail safe closure mechanism in the event of dome pressure leak bellows failure – No multi-pointing

What’s different about PTC unloading valves Reduced well commissioning costs Faster unloading rates – Long stem travel in both unloading and check valve modules: – Designed using computational fluid dynamics Faster completion pressure testing – Shearable unloading valves – Avoids the need to run dummy valves for tubing and annulus testing – Patented shear mechanism external to valve Works even with multiple valves in the well

What’s different about PTC unloading valves Improved performance Bellows area larger than in most unloading valves: – Low R factor......less tubing pressure sensitive More predictable performance Bellows load rate ( stiffness) lower than in most unloading valves: – Even at psi – Valve fully opens quickly with long stem travel Less throttling / chattering: – Ideal where conditions are uncertain or may change Unloader module becomes “practically invisible” Unloader can be used as a shallow operating valve – Without compromising well integrity or reliability 10 k psi pressure rating: – Valves can be used in deep or high pressure applications Deeper lift depth results in higher production

Conclusions A new generation of IPO valves are now available: – Their design is revolutionary and in many ways unique They are now delivering a step change in: – Well integrity Unique well barrier capability even after erosion testing – Reliability Unique high pressure low load rate bellows – Commissioning costs reduction Unique shearable unloaders – Performance Unique flexibility to use as an operating valve

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