Feb. 6, ASME/API Gas-Lift Workshop1 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

Feb. 6, ASME/API Gas-Lift Workshop2 Routine Validation Testing of Every Gas-Lift Valve Outline Brief historyBrief history Business justification for routine testingBusiness justification for routine testing How the tester worksHow the tester works Intended operational useIntended operational use Field experienceField experience Outstanding issuesOutstanding issues

Feb. 6, ASME/API Gas-Lift Workshop3 Routine Valve Testing A Brief History History Only the Ptro test is performed routinelyOnly the Ptro test is performed routinely In 1995, API RP 11V2 provided standards for testing and modeling gas-lift valvesIn 1995, API RP 11V2 provided standards for testing and modeling gas-lift valves In 1996, the Valve Performance Clearinghouse, an industry JIP, was formed to implement 11V2In 1996, the Valve Performance Clearinghouse, an industry 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 Tester (GLV-AVT) is to test every gas-lift valvePurpose of Gas-Lift Valve, Automatic Validation Tester (GLV-AVT) is to test every gas-lift valve –Before it is run –After it is pulled

Feb. 6, ASME/API Gas-Lift Workshop4 Routine Valve Testing Business Justification Rationale for testing each valve Not all valves of a specific type are manufactured to the original specificationsNot all valves of a specific type are manufactured to 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 that valves will perform as intended

Feb. 6, ASME/API Gas-Lift Workshop5 Routine Valve Testing Business Justification Justification for pre-installation testing Screen out valves that will not perform as intendedScreen out valves that will not perform as intended –Due to manufacturing faults or limits –Due to handling problems –Due to setting problems Know actual valve characteristicsKnow actual valve characteristics –May be different than "typical" valve tested by VPC –Use actual characteristics in gas-lift programs Evaluate various valves types/sourcesEvaluate various valves types/sources –If a given valve type/model is routinely unsatisfactory –If a used valve should not be re-run

Feb. 6, ASME/API Gas-Lift Workshop6 Routine Valve Testing Business Justification Justification for post-installation testing Evaluate valve conditionEvaluate valve condition –Can it be re-dressed and re-run, or –Should it be discarded LearnLearn –How well did the valve survive in the well's environment –Is a different valve type needed in this environment –Is a different valve metallurgy needed

Feb. 6, ASME/API Gas-Lift Workshop7 Routine Valve Testing How the Tester Works Quick, 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 N 2 bottle)Apply nitrogen pressure (from N 2 bottle) Conduct these tests, under computer controlConduct these tests, under computer control –Opening pressure –Closing pressure –Port leak rate –Load rate of bellows and/or spring –Maximum effective stem travel –Back check valve leak rate –Port/bellows ("R") ratio –Bellows failure and/or dome leak

Feb. 6, ASME/API Gas-Lift Workshop8 AVT Front Panel

Feb. 6, ASME/API Gas-Lift Workshop9 AVT Computer Control

Feb. 6, ASME/API Gas-Lift Workshop10 Preparing to Test a Valve

Feb. 6, ASME/API Gas-Lift Workshop11 Close Fixture, Connect Hose

Feb. 6, ASME/API Gas-Lift Workshop12 Routine Valve Testing How the Tester Works 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 criteria –A 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. –Plot based on VPC (or standard) characteristics Exports a fileExports a file –Test results and actual valve characteristics can be exported to any gas-lift program –For example, Shell inputs results into WinGLUE

Feb. 6, ASME/API Gas-Lift Workshop13 AVT Test Results Screen

Feb. 6, ASME/API Gas-Lift Workshop14 Routine Valve Testing Intended Operational Process Routine 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 it –If valve "fails" one or more tests, return it –Have one or more spares on hand Store every test result in a gas-lift program and a databaseStore every test result in a gas-lift program and a database –Use in program for routine analysis –Use in database to learn, evaluate Test every valve when it is pulledTest every valve when it is pulled –Store results in database –Compare "after" performance with "before"

Feb. 6, ASME/API Gas-Lift Workshop15 Routine Valve Testing Initial Field Experience Use of the AVT has….  Increased accuracy of pressure and port leak measurements.  Extended the practice of testing gaslift valves to individuals who may not be familiar with typical shop practices.  Insures a consistently applied testing standard. The technician cannot “help” the valve pass a test.

Feb. 6, ASME/API Gas-Lift Workshop16 Routine Valve Testing Initial Field Experience Use of the AVT has…  Found that good valves re-test consistently.  Provided the technician, engineer, and wireline operator with a “certificate” indicating the valve has passed all tests.  Provided a link from the gaslift shop to the engineers desk.

Feb. 6, ASME/API Gas-Lift Workshop17 Routine Valve Testing Initial Field Experience Camco BKR-5 valves were tested for Brunei Shell Petroleum in Seria, Brunei  The tested R ratio was MUCH larger than the manufacturer’s published R ratio.  Valves with 3/16” TC ports tested with R ratios of.154. The printed R ratio is.118.  This means the valve will have approximately 30% more casing sensitivity than expected.

Feb. 6, ASME/API Gas-Lift Workshop18 Chamfered TC Port

Feb. 6, ASME/API Gas-Lift Workshop19 Routine Valve Testing Initial Field Experience Camco BKR-5 valves were tested for Brunei Shell Petroleum in Seria, Brunei  Back checks do not seal leak tight.  The AVT found several valves with bad O- rings on the seat.  The AVT found 1 valve with a leaking tail plug.  The AVT found several valves with leaking O-rings at the valve body joints.

Feb. 6, ASME/API Gas-Lift Workshop20 Routine Valve Testing Initial Field Experience Camco BKR-5 valves were tested for Brunei Shell Petroleum in Seria, Brunei  The loadrate was generally less than 1300 psig/inch. This is expected for valves set at pressures less than 1000 psig.  The effective stem travel was generally less than inch. This is less than expected but enough for a 3/16” ported valve with an 8 or 10 choke.

Feb. 6, ASME/API Gas-Lift Workshop21 Routine Valve Testing Outstanding Issues There 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 device It may be possible to use the tester to help conduct some VPC testsIt may be possible to use the tester to help conduct some VPC tests –Needs to be evaluated

Feb. 6, ASME/API Gas-Lift Workshop22 Routine Valve Testing Conclusions This is one more step forward for gas-lift There is now a cost-effective way to test every gas-lift valveThere is now a cost-effective way to test every gas-lift valve –Before it is run –After it has been pulled This should greatly improve quality assurance and reduce "infant mortality" that comes from running valves that are not properly suited:This should greatly improve quality assurance and reduce "infant mortality" that comes from running valves that are not properly suited: –Manufacturing faults –Handling problems –Setting problems