a review of weatherford’s dual - artificial lift · 3 standard side pocket mandrel design flow...
TRANSCRIPT
1
A Review of Weatherford’s dual
barrier high reliability gas lift
equipment
Presenting:
• Steve Long – Product Line Manager
• Brian Sternaman – Engineering Manager
37th Gas-Lift Workshop Houston, TX February 3– 7, 2014
Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
A Review of Weatherford’s Dual Barrier Equipment
• DVX mandrel design and differentiators
• External check valve designs
• Flow control devices validation update
• New designs and developments update
• Typical concerns and explanations of DVX
mandrel
Flow Performance - Physical testing and CFD
comparison
Pressure trapped in channels of DVX mandrel
Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
3
Standard Side Pocket Mandrel Design Flow Path
Valve in
pocket Valve out
of pocket Feb. 3 - 7, 2014
2014 Gas-Lift Workshop
When valve
is pulled
from
pocket,
fluid flows
into casing
4
DVX Gas Lift Mandrel Design Flow Path
Valve in
Valve out
of pocket Feb. 3 - 7, 2014
2014 Gas-Lift Workshop
When valve
is pulled from
pocket, fluid
ins contained
in tubing
5
Weatherford DVX Gas Lift Mandrels can be validated to API 19G1 V1
• INCLUDES:
– DOCUMENTATION
– DESIGN REVIEW
– PRESSURE TESTING AT RATED
TEMPERATURE
– INTERNAL PRESSURE CYCLES
– FEA (FINITE ELEMENT ANALYSIS)
– STRAIN GAUGE TESTING
– INSTALL/PULL FLOW CONTROL DEVICE
– SLICKLINE OPERATION TESTING WITH
KICKOVER TOOL
– INTERNAL DRIFT
– EXTERNAL DRIFT
Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
Metal to Metal / Soft Seal Combination Check
• Utilizes proprietary PTFE based
Thermoplastic along with Metal to
Metal Primary Seal
• Can be utilized in both gas lift valve
and DVX side pocket applications
• BARRIER QUALIFIED
– Passed Statoil testing per
document TR2385
– Pressure Rating-10,000 PSI
– Temperature Rating 150C/302F
• Material K-500 Monel body with 718
Inconel check dart
Feb. 3 - 7, 2014
2014 Gas-Lift Workshop
Metal to Metal Checks
• Directs flow away from
sealing surfaces
• Metal to Metal Seal
• BARRIER QUALIFIED
– Passed Statoil Testing
per document TR2385
– Pressure Rating-
10,000 PSI
– Temperature Rating
150C/302F
• Material – 718 Inconel Closed Open
Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
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Weatherford Barrier Qualified Gas Lift Valves - API 19G2 V1 Validations • INJECTION PRESSURE OPERATED
VALVES
• ORIFICE VALVES
• SHEAR ORIFICE VALVES
• DUMMY VALVES
– The above 1.5” versions have
been tested and validated to API
19G2 level V1
Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
New designs and concepts for dual barrier (high reliability) equipment
• DVX mandrels with 15,000 psi working pressure
designed and built for orders
• DVX mandrels with 20,000 psi designed with FEA
completed
• Developing high pressure gas lift valves for extreme
conditions
• Experimenting with scale resistant coatings and
designs
Feb. 3 - 7, 2014
2014 Gas-Lift Workshop
Weatherford DVX Gas Lift Mandrel
Typical Questions
Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
11
Is there a significant pressure drop in the flow path of the DVX Mandrel?
P2
P3
• Flow tests were performed at Southwest
Research
• 1.5” pocket mandrel configuration test fixture
was used
• Points of measurement
– P1: pressure at source
– P2: pressure outside of external checks
– P3: Pressure inside of pocket undercut
Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
12
DVX Gas Lift Mandrel Physical Testing
CFD ANALYSIS PREDICTED 90 PSI PRESSURE DROP
Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
13
What if gas is trapped in DVX pocket channels and pressure is elevated?
• Although extremely unlikely to happen, trapped
pressure in the DVX mandrel design was analyzed.
• With checks assembled externally to the DVX
mandrel pocket, the checks prevent flow from
tubing to the casing annulus
• With a dummy valve installed in the mandrel pocket,
there can be trapped gas in the chamber between
the dummy valve and external DVX checks
• If gas pressure in this chamber increases due to a
significant temperature increase, it will be trapped
and cause a pressure increase in the chamber
– The DVX checks keep the pressure from
evacuating out into the casing annulus
• What if this trapped pressure exceeds the mandrel
internal pressure rating?
Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
14
DVX Mandrel Analyzed
• Finite Element Analysis (FEA) was performed
to analyze the strength of the trapped pressure
chamber in the pocket with various loading
conditions
• Analyzed 4.5 SBRO-2GRDVX 13CR mandrel
with 7.06” OD, 3.833” ID drift, with single
groove
• Internal working pressure rating = 5,510 psi
• Groove for:
– 0.660” line
– 0.535” line
– 2 x 0.410” lines
Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
15
Trapped Pressure FEA Analysis
FEA Loading Conditions
• 2 External loading cases were considered
– 5,000 psi external pressure simulated casing
annulus pressure around the mandrel
– 0 psi external pressure expected to be worst
case condition
• Internal pressure was applied to the trapped
pressure chamber only with each of the 2 external
pressure load cases, ramping up internal chamber
pressure continuously from 0 to 35,000 psi
• Elastic/plastic analysis with material properties of
13CR 80ksi min yield was used to determine at
what load conditions permanent deformation of
the pocket would occur
– 86,062 psi true yield strength
Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
16
Boundary Conditions DVX Pocket FEA Model
Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
External Pressure on the OD
Fixed support
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Boundary Conditions DVX Pocket Internal Chamber
Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
Internal Pressure inside the pocket and
DVX chamber – Wireframe view
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FEA Results – VME Stresses
Results with 5,000
psi External
Pressure
VME stress at
23,750 psi internal
(Trapped) pressure
Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
VME stresses exceed yield limit.
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FEA Results – Plastic Strain
Results with 5,000
psi External
Pressure
Max principal
plastic strain at
23,750 psi internal
(Trapped) pressure
Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
Max principal plastic strain
at ~1% onset of yielding –
permanent deformation. .
20
Results and conclusion of trapped pressure scenario
Results Summary
• With 86,062 psi actual material yield strength, yield pressure was
as follows
Conclusion
• For this design, the trapped pressure required to permanently
deform the DVX mandrel pocket, with either external pressure
loading case, is much higher than the mandrel’s 5,510 psi internal
working pressure rating
• The critical wall thickness determined from these results are now
used as a standard minimum wall thickness for all DVX mandrel
pocket designs
Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
21
Copyright
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Feb. 3 - 7, 2014 2014 Gas-Lift Workshop
22
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Feb. 3 - 7, 2014 2014 Gas-Lift Workshop