Gas-Lift Test Facility for High- Pressure and High-Temperature Gas Flow Testing
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1 40 th Gas-Lift Workshop Houston, Texas, USA Oct , 2017 Gas-Lift Test Facility for High- Pressure and High-Temperature Gas Flow Testing Angel Wileman, Senior Research Engineer Southwest Research Institute (SwRI ) 2017 Gas-Lift Workshop 1
2 Need for Gas Lift Valve Design Validation Up to $500,000 per day for intervention Oseberg Field Centre in the North Sea. (Photos: Ole Jørgen Bratland) 2017 Gas-Lift Workshop 2
3 Validation Testing Requirements Static pressure testing for packing stacks Static pressure testing for backflow integrity Erosion testing simulating liquid unloading Mandrel qualification testing Dynamic flow testing Independent test facility did not exist 2017 Gas-Lift Workshop 3
4 Dynamic Flow Testing Requirements Purpose: Operate the gas lift valve through an accelerated lifecycle and verify backflow integrity through the back-check valve assembly. Step Test: Incremental increase in flow rate up to the design flow rate Cycle Test: 100 open/close cycles of the back-check valve Long Duration Flow Test: 24 hours of flow at the design flow rate Backflow Integrity Test: Check the sealing integrity of the back-check valve, in-situ Similar to Statoil TR2385 Flow Testing requirements 2017 Gas-Lift Workshop 4
5 Facility Timeline Facility Conception Design Complete Testing Commissioning Complete 2017 Gas-Lift Workshop 5
6 Design Challenges for HPHT Testing 2017 Gas-Lift Workshop 6
7 GLTF Design Process Gas Recirculating loop Methane and nitrogen source already on site Chiller Compressors (10 prime mover, 1 facility charging) Heat Exchanger 2017 Gas-Lift Workshop 7
8 GLTF Main Facility Slab and Cover Fire Suppression System Pump Room Primary Entrance/Exit Electrical Building Liquid Nitrogen Source Nitrogen Gas Source Chiller 2017 Gas-Lift Workshop 8
9 GLTF Test Facility Site (Test Fixture) Manifolds Charge Panel Test Fixture Methane Volume
10 Control Software 2017 Gas-Lift Workshop 10
11 GLTF Prime Movers Hydropac brand Reciprocating compressor Single stage double acting Allows for >200ºF gas inlet temperature Hydraulically driven with 100 hp pump Requires 20 tons of cooling capacity per compressor 2017 Gas-Lift Workshop 11
12 Heat Rejection Air Cooled Heat Exchanger Minimum Loop Operating Temperature ~ 150ºF Picture of ACHE 2017 Gas-Lift Workshop 12
13 Pulsation Control 3 x 10 ft 3 volumes Out of sync compressors Upstream flow control valve 2017 Gas-Lift Workshop 13
14 Test Fixture Holds a gas lift valve and a barrier check valve Easy test article installation Instrumented for check valve chatter detection Accelerometers Dynamic pressure measurement Outlet Inlet 2017 Gas-Lift Workshop 14
15 Gas Mixing Real time, continuous measurement of gas concentration Tuned to detect methane and nitrogen 2017 Gas-Lift Workshop 15
16 Safety Remote operation Restricted access Software operating features Software safety shutdowns Hardwired safety shutdowns Permanent methane gas detectors IR flame detectors Safety restraints 2017 Gas-Lift Workshop 16
17 Restricted Access Safety glasses required at all times Access controlled entrances Yellow, red warning lights Basic Operational Rules No one allowed in facility during dynamic condition (pressurization, compressor(s) operating (flowing), depressurization) SwRI personnel allowed in facility if pressurized and in a static condition. Pre operation walk through to confirm no personnel and closed, locked gates. Facility status posted in gas test control room. Facility enable switches disabled when not in use and when personnel in GLTF. Main loop depressurized for tour Facility shop air pressurized Nitrogen supply pressurized 2017 Gas-Lift Workshop 17
18 Methane Detection 2 permanent methane detectors installed under canopy 1 focuses on the flow loop 1 focuses on the compressor area Methane alarm shuts down compressors and warns GLTF operator Portable gas detectors worn when required 2017 Gas-Lift Workshop 18
19 Flame Detection 3 IR sensors installed under canopy 2 IR sensors focus area on compressors 1 IR sensor focus area on main loop Flame alarm shuts down compressors and warns GLTF operator Confirmed with IR simulator gun
20 Safety - Piping Restraints 2017 Gas-Lift Workshop 20
21 Control Software 2017 Gas-Lift Workshop 21
22 Data Aquisition Over 20 instruments recorded Digital signal instruments (HART) for primary instruments provides increased accuracy Background Data recorded at 0.25 hz whenever DAQ is connected Status of most equipment is also recorded Logged Data recorded at 1Hz during critical testing Dynamic Data recorded at 10 khz and captured in 60 second intervals during testing 2017 Gas-Lift Workshop 22
23 Data Examples Flow Data - Cycles 2017 Gas-Lift Workshop 23
24 Data Examples Dynamic Data 2017 Gas-Lift Workshop 24
25 Summary Design and commissioning was performed methodically. Safety was given the utmost priority Gas-Lift Workshop 25
26 Summary The flow loop was designed for TR2385 type flow testing, but can be used for API 19G2 testing as well Gas-Lift Workshop 26
27 Summary The Backflow Integrity Test is performed with the valve in-situ, without removal from the test fixture Gas-Lift Workshop 27
28 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 Gas-Lift Workshop 28
29 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-inafter 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, noninfringement of copyright or patent rights of others, merchantability, or fitness or suitability for any purpose Gas-Lift Workshop 29
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