Gas Lift Valve Contingency Insert for Tubing Bypass Flow
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Solution Overview
Problem
Existing gas lift valves in wellbores require costly and time-consuming removal of production tubing for maintenance due to their malfunction, which disrupts fluid flow and is inefficient.
Innovation Solution
A contingency flow system is installed within the production tubing, featuring a pressure-controlled valve and contingency insert that allows fluid flow through the sidewall when the primary surface-controlled valve is non-operational, enabling lift gas to bypass the malfunctioning valve and maintain fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a surface controlled valve is used to control lift gas flow, then the valve can be controlled from the surface, but the valve requires removal of production tubing for maintenance which is costly and time consuming
Solution Approach 1:
The system is divided into two independent pathways: a primary pathway through the surface controlled valve and a secondary contingency pathway through the insert with pressure controlled valve. This segmentation allows the contingency pathway to function independently when the primary valve fails, eliminating the need to remove production tubing for maintenance by providing an alternative operational route.
Solution Approach 2:
The contingency insert acts as an intermediary component installed within the production tubing that provides an alternative flow path. When the surface controlled valve malfunctions, the insert with its pressure controlled valve mediates the flow through the sidewall, enabling continued operation without direct access to the primary valve.
2Ease of repair
If the production tubing is removed for valve maintenance, then the valve can be accessed and repaired, but fluid flow is disrupted and downtime increases
Solution Approach 1:
The contingency insert is pre-installed within the production tubing during initial setup, creating a ready-to-use alternative pathway. When the primary valve fails, the contingency system is already in place and can be activated immediately without requiring removal of production tubing, thus maintaining fluid flow continuity while enabling valve maintenance.
Solution Approach 2:
The contingency pathway serves as a protective measure that prevents complete operational failure when the primary valve malfunctions. By having the insert with pressure controlled valve pre-positioned in the tubing, the system cushions against the harmful effect of valve failure, allowing continued fluid flow without disruption during maintenance operations.
3Reliability
If a contingency system is installed within production tubing, then continuous flow is maintained during valve malfunction, but the device complexity increases
Solution Approach 1:
The complex surface controlled valve is extracted from the critical flow path by providing a separate, simpler contingency pathway through the insert. This extraction allows the primary valve to be replaced with a simpler pressure controlled valve in the contingency path, reducing overall system complexity while maintaining reliability through the alternative pathway.
Solution Approach 2:
The contingency insert is designed as a simpler, more straightforward component compared to the primary surface controlled valve. While the insert may have limited service life, its simplicity and ease of installation make it a cost-effective backup that ensures flow continuity without requiring the complex maintenance procedures associated with the primary valve system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The contingency system ensures continuous fluid flow by bypassing the malfunctioning valve, reducing downtime and maintenance costs by allowing lift gas to flow through alternative pathways without removing the production tubing.
Implementation Method 1
The pressure control valve is an injection pressure operated valve, which optionally allows a flow of lift gas into the annulus or into the production tubing, and opens and closes in response to a destination pressure
Implementation Method 2
providing a contingency flow of the fluid through the sidewall of the production tubing
Implementation Method 3
By injecting sufficient lift gas into the production tubing, static head pressure of fluid inside the production tubing is reduced to below the pressure in the formation, so that the formation pressure is sufficient to push the fluids inside the production tubing to surface
Data Source
AI summary
A contingency for non-operation of a valve in a side pocket mandrel of production tubing includes creating a selective barrier to fluid communication across sidewalls of the production tubing. The barrier is formed by an insert that is installed in the side pocket mandrel, which includes a valve that responds to pressures inside and outside the production tubing to selectively allow fluid flow across the production tubing sidewalls. Types of the valve include a surface controlled gas lift valve, an inflow control valve, and an inflow control device.