Barrier Philosophy for Wells on Gas lift and Ways of Reducing HSE Risks. Alan Brodie Feb 2011 For more info visit

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1 Barrier Philosophy for Wells on Gas lift and Ways of Reducing HSE Risks Alan Brodie Feb 2011 For more info visit

2 Introduction Gas Lifted Well Integrity Management Incremental HSE risks Case histories The impact of getting it wrong Solutions to incremental HSE risks Image used with the permission of J Bellarby

3 Oil and Gas Well Integrity Management Basic Requirement Risk of hydrocarbon release from a well is ALARP (As Low As Reasonably Practicable) Which means using: Best available equipment Current industry best practices To achieve this most OPCO s usually adopt: Double independent barrier pressure containment envelope In natural flow example shown: Primary barrier outlined in red Secondary barrier outlined in blue With Acceptance criteria defined for each element e.g: ISO procedures for testing tubing connections Leak criterion for gas: 9 cc/15 min Image used with the permission of J Bellarby

4 Key differences # 1 ( tubing integrity) With many gas lift valves Primary well containment barrier is compromised ISO Flow control devices for side-pocket mandrels These devices are designed and intended to prevent reverse flow through a flow control device. They are not designed nor intended to provide a tight shut-off pressure safety seal or to be a part of the safety system. Allowable leak rate 6883 ml/10 mins Compare this to acceptance criteria for packers ISO Downhole equipment -- Packers and plugs Allowable leak rate 20cc /10 mins ISO Image used with the permission of J Bellarby

5 Key differences # 2 ( High pressure gas inventory) High pressure gas in tubing / production casing annulus Question: What precautions are taken at well sites re gas bottles: Store safely away from areas with:» High risk of dropped objects» Potential sources of radiant heat Carefully manage logistic and numbers Potential volume of gas in annulus of each well: Equivalent of > 1000 industrial gas bottles Even where DHASV s used typically >100 Lift gas lines / valves from HP header to annulus: Pass thru area with Relatively high risk of dropped objects Many potential sources of radiant heat The first gas bottle explodes Other risks associated with leakage from inner to outer annulus Are production casing threads gas tight? Image used with the permission of J Bellarby

6 Getting it wrong (1) Piper Alpha Disaster N Sea 1988: Gas lift was widely used, Wasn t the root cause but it exacerbated the situation SCSSSV s generally closed But Gas lift check valves didn t Gas lift lines parted between isolation valve and wellhead Due to radiant heat from nearby fires Wells flowed naturally via annulus NB It appears the wells structural integrity was relatively unaffected despite the severity of the incident Image used with the permission of J Bellarby

7 Getting it wrong (2) Outer Annulus Pressure build up Onshore gas lifted well shut in Lift gas leaked from the inner to the outer annulus Outer annulus pressure built up to lift gas pressure ( psi) Well restarted and heated up by 76 F Trapped pressure increased to 7700psi Outer annulus casing ruptured Flying debris damaged the HP gas line Contents of inner annulus vented and ignited Question How easily could this happen on your wells? #1 Source of info:

8 Reducing the HSE risks (1) ( tubing integrity) Employ qualified well barrier gas lift valves Operating Valves Unloading Valves Tested to the same allowable leak rate as packers etc Erosion test the valves to ensure: They will remain well barrier valves for the life of well Not just to pass a factory acceptance test (FAT) Image used with the permission of J Bellarby

9 Reducing the HSE risk (High pressure gas inventory) Down-hole Annulus Safety Valves (DH ASVs) Introduced after Piper Alpha in some parts of world To reduce the volume of gas topsides is exposed to Still typically equivalent of >100 gas bottles!! Shallow set dual path packers Integral check valve or sliding sleeve Usually not designed to be gas tight Always requires a full workover to replace on failure DH ASV reliability issues Apparently many wells closed in due to failed DH ASVs Problems with packer technology in thermal cycling Integral check valve reliability challenges Reputedly often difficult to retrieve

10 Reducing the HSE risk (High pressure gas inventory) PTC s fresh approach to DH ASVs Dual Packer technology designed for thermal cycling deg C Client supplied SCSSSV attached above ISO V1 equivalent leak rate on gas side Solid body compact packer design Up to 10 control lines pass-through Single trip retrieval using Sondex cutter

11 Reducing the HSE risk (HP lift gas inventory) Eliminate the potential for annulus venting Using Surface Annulus Safety (SAS) valve Set in the wellhead VR profile Employs PTC Safelift GLV check valve design No erosion across metal / metal seal faces Performance exceeds that delivered by DH ASV Valves tested to API 6A PSL 3G PR2 Fire tested to API 6FB and API 6FD Achieving V0 with gas as test medium Valves replacable without workover Image used with the permission of J Bellarby

12 Reducing the HSE risk (HP lift gas inventory) Actuator module holds check valve open throughout life Protecting seal faces from chattering Modular design facilitates actuator detachement In case of annulus line damage Leaving check valve intact in wellhead Image used with the permission of J Bellarby

13 Reducing the HSE risk (HP lift gas inventory) > 250 SAS valves installed In use in GOM and N Sea Gas lifted wells with failed DH-ASV s previously had to be closed in Awaiting workover Now permitted to remain on stream If SAS valves are installed And if well barrier accredited gas lift valves are used Increasingly recognised by OPCOs as: required for achieving ALARP risk in gas lifted wells Some OPCOs even using them in combination with DH ASVs Their interpretation of ALARP

14 Gas Lifted well integrity Mgt Reducing the HSE risk (trapped annulus) Automated annulus pressure management Unique VR Plug / sensors can be installed on all annuli Continual annulus P&T measurement» Wireless (HART protocol) / wired link to control room Wireless module detaches safely under impact Leaving VR plug / sensor in wellhead Annuli can be bled down automatically via M-SAS valves Before closing again to ensure well integrity

15 Gas Lifted well integrity mgt Reducing the HSE risk Automated annulus pressure bleed down PTC gas lift valve derivatives One way (outer to inner) valves Pre set opening pressures (MAASP) Installed in special casing pups below wellhead New wells only Not just for gas lifted wells Ideal for subsea wells Typically casings are not cemented into previous shoe track To provide option for pressure to bleed off into formation Deploying annulus bleed valves would reduce this HSE risk

16 Conclusions HSE risks in well completions are managed to be ALARP Gas lift introduces significant additional HSE risks cf any other lift method: GLV s can be primary well containment envelope weak link Enormous inventory of high pressure gas introduced to hazardous area Potential for lift gas leakage into outer annuli New technologies developed to address these concerns: Well barrier gas lift valves and unloading valves Wellhead VR profile actuated Surface Annulus Safety (SAS) valves ISO V1 equivalent leak rate DH ASVs Wellhead VR profile pressure temperature sensors Trapped annulus pressure relief valves

17 Final thought Lets do a little role playing exercise : You re sat in the office next month and your phone rings Its your CEO on the line He tells you he has been invited to a meeting with the government To discuss a recent safety incident involving a gas lifted well He asks you Can I confidently say our designs ensured the risks were ALARP What s your answer...

18 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 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. Feb Gas-Lift Workshop 18

19 Disclaimer The following disclaimer shall be included as the last page of a Technical Presentation or Continuing Education Course. A similar disclaimer is included on the front page of the Gas-Lift Workshop Web Site. 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. The views, opinions, and conclusions expressed in these presentations and/or training materials are those of the author and not necessarily those of the Sponsoring Organizations. The author is solely responsible for the content of the materials. The Sponsoring Organizations cannot and do not warrant the accuracy of these documents beyond the source documents, although we do make every attempt to work from authoritative sources. The Sponsoring Organizations provide these presentations and/or training materials as a service. The Sponsoring Organizations make no representations or warranties, express or implied, with respect to the presentations and/or training materials, or any part thereof, including any warrantees of title, non-infringement of copyright or patent rights of others, merchantability, or fitness or suitability for any purpose. Feb Gas-Lift Workshop 19

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