a review of weatherford’s dual - artificial lift · 3 standard side pocket mandrel design flow...

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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


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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

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DVX Gas Lift Mandrel Design Flow Path

Valve in

pocket

Valve out

of pocket Feb. 3 - 7, 2014


When valve

is pulled from

pocket, fluid

ins contained

in tubing

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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


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


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


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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


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


Weatherford DVX Gas Lift Mandrel

Typical Questions


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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


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DVX Gas Lift Mandrel Physical Testing

CFD ANALYSIS PREDICTED 90 PSI PRESSURE DROP


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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?


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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


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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


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Boundary Conditions DVX Pocket FEA Model


External Pressure on the OD

Fixed support

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Boundary Conditions DVX Pocket Internal Chamber


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


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


Max principal plastic strain

at ~1% onset of yielding –

permanent deformation. .

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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


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Copyright

Rights to this presentation are owned by the company(ies) and/or author(s) listed on the title page. By submitting this presentation to the Gas-Lift Workshop, they grant to the Workshop, the Artificial Lift Research and Development Council (ALRDC), and the American Society of Mechanical Engineers (ASME), rights to:

– Display the presentation at the Workshop.

– Place it on the www.alrdc.com web site, with access to the site to be as directed by the Workshop Steering Committee.

– Place it on a CD for distribution and/or sale as directed by the Workshop Steering Committee.

Other uses of this presentation are prohibited without the expressed written permission of the company(ies) and/or author(s) who own it and the Workshop Steering Committee.


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Disclaimer

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The Artificial Lift Research and Development Council and its officers and trustees, and the Gas-Lift Workshop Steering Committee members, and their supporting organizations and companies (here-in-after referred to as the Sponsoring Organizations), and the author(s) of this Technical Presentation or Continuing Education Training Course and their company(ies), provide this presentation and/or training material at the Gas-Lift Workshop "as is" without any warranty of any kind, express or implied, as to the accuracy of the information or the products or services referred to by any presenter (in so far as such warranties may be excluded under any relevant law) and these members and their companies will not be liable for unlawful actions and any losses or damage that may result from use of any presentation as a consequence of any inaccuracies in, or any omission from, the information which therein may be contained.

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a review of weatherford’s dual - artificial lift · 3 standard side pocket mandrel design flow...

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