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Equipment Development for Gas-Lift in Sub-Sea Operations
Roger Stinson
Product Manager - Gas Lift
Schlumberger Completions Systems
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Deepwater Gas-Lift Challenges
• Limited & costly intervention opportunities– requires highly reliable equipment– operational flexibility
• Higher gas injection pressures– 3000 psi to 5000 psi– evaluate current products
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Current Projects
• RIPC Gas Lift Valve – normally open gas lift valve
• 3000 PSI Gas Lift Valve – evaluate current products
– development
• Surface Controlled Downhole Flow Control– WRFC-H -Hydraulically Controlled
– WRFC-E - Electrically Controlled
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RIPC Gas Lift Valve Application
• Developed for applications which will use two levels of injection pressure.
• One point of injection for low operation injection pressure and one point of injection for high operation injection pressure
• Use of this valve requires a low injection pressure for lifting from a shallow depth
• A switch to a high pressure system to accommodate a deeper injection point will close the valve
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Open Closed
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Open Closed
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RIPC FlowRate vs Downstream pressure
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
1000 1100 1200 1300 1400 1500 1600 1700 1800
Downstream Pressure psig
Flo
w R
ate
mm
cfd
Projected Natural Gas Flow Rate Minimum Tubing Pressure
Maximum Tubing Pressure Gas Requirement
Nitrogen Flow (Measured)
Specification 1
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RIPC FlowRate vs Downstream pressure
0.0
1.0
2.0
3.0
4.0
800 900 1000 1100 1200 1300 1400 1500
Downstream Pressure psig
Flo
w R
ate
mm
cfd
Nitrogen Flow (measured) Projected Natural Gas Flow Rate Minimum Tubing Pressure
Maximum Tubing Pressure Gas Requirement
Specification 2
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3,000 PSI Gas Lift ValveDevelopment Project
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1-1/2” IPO Gas Lift Valve - 3,000 PSI TRO
• Currently have 3 existing 1-1/2” IPO Gas Lift Valve Designs
• Limited to 1,700 PSI Dome Pressure
• Test R-20, SR-20 & N-17R @ High Pressure To Determine Limitations
• Analyze Test Results
• Make Design Modifications For 3,000 PSI WP
• Manufacture Final Design Prototypes
• Test Final Design
• Flow Test Final Design
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Scope of ProjectTo develop a gas lift valve capable of greater setting pressures (up to 3000 psi desired) for higher pressure injection systems in sub-sea completions. Testing to include:
Phase I - Probe Testing - Cycle Testing
Phase II - Probe Testing - Cycle Testing - Gas Flow Testing
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Probe Testing
Probe Testing
measures the amount
of stem travel the
valve achieves per psi
of pressure.
Dome Pressures:
1000, 1500, 2000,
2500, 3000
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Cycle TestingCycle Testing measures the fatigue life of the bellows. Pressure is applied through the ports and across the bottom of the ball. One full cycle occurs upon opening and full closure.
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Cycle Testing - Results
• Valve set to 3000 psi Dome charge
– results for all valves were unacceptable
• N-17R Slightly better than R-20
• Valve set to 1500 psi Dome charge
– mixed results
• R-20 Considerably better than 3000 psi test
• N-17R No significant improvement over 3000 psi test
• Test ringed bellows and alternate material
– Ringed bellows results comparable to no-ringed bellows
– Alternate material improved cycling-higher load rate
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Current Status
• Development valve - alternate bellows material
• Test additional alternate bellows designs &configurations
– load rates
– cycle testing
• Future development decisions based on ongoing evaluation
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Wireline Retrievable Flow Control- Hydraulic & Electric
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WRFC - Wireline Retrievable Flow Control
• Variable Orifice Gas Lift Valve• Side Pocket Mandrel Mounted• Wireline Retrievable• Electric or Hydraulic Operation• Same Operating System for Electric
Permanent Down Hole Gauge
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Side pocket mounted hydraulically actuated Flow Controller that is remotely controlled from surface. Designed for flow rates up to 10,000 BBL/D, 30MMSCF/D.
Description
Features
Status 8 successful installations per August 2000
• Gas Lift and SCSSV based technology• Retrievable Valve for repair or replacement• Actuated through a single 1/4”
control line• Customizable 6 position actuator
Wireline Retrievable Flow Control Hydraulic (WRFC-H)
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Wireline Retrievable Flow Control Electric(WRFC-E)
• Electrically actuated• Retrievable Flow Control Valve
Description
Features
Status Field Test Q-1 2001
• Based on Gas Lift technology• Retrievable valve for repair or replacement• Actuated through a single 1/4” tubing encased electrical conductor line• Infinite position actuator• Annular and tubing pressures
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Retrievable Flow Control Valve
Actuator
Bottom cross-section view
Electronics Cartridge
Sapphire Gauges
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WRFC/EGLV Overview
WRFC Projector.exe
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WRFC Specifications
Electric Hydraulic
Max temp: 150 C 200 C
Pressure rating: 5/10K PSI 5/10K PSI
Flow area (see note): 0.75 in2 0.75 in2
Instrumentation Annular & tubing SeparatePressure & Temp
Control resolution: Infinite Increments
Note - Equivalent flow area
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Norsk Hydro, TOGP
Safety Valve
WRFC-H - used to control gas
Penetrations in Gas Cap
Sand control completion in oil zone
• 30/40 Subsea installations planned
• Control gas from gas cap to lift
• Longer producing life
• Eliminates compression facilities