Replaceable Gas Lift Valve System for Continuous Well Production
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Solution Overview
Problem
Existing gas lift mandrels in oil wells are permanently installed and prone to corrosion, leading to costly well shutdowns when they fail, as there is no effective way to repair or replace them without shutting in the well.
Innovation Solution
A replaceable gas lift valve system that can be inserted into the production tubing at any desired level, allowing for quick extraction and replacement of the entire unit, including a mandrel and valve, using standard slick line techniques, enabling continuous oil production without well shutdowns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a permanently installed gas lift mandrel is used, then gas injection can be established, but the mandrel will corrode and fail over time requiring costly well shutdowns and complete reworking
Solution Approach 1:
The gas lift system is divided into separate components: a permanent mandrel with pre-installed valve pockets and a separate replaceable valve assembly. This segmentation allows the valve to be replaced independently without removing or repairing the mandrel, resolving the contradiction by making the system maintainable while keeping the permanent installation intact.
Solution Approach 2:
The valve assembly is designed as a disposable/replaceable component that can be retrieved, refurbished or replaced when corroded. This allows the permanent mandrel to be preserved while the consumable valve is cycled out and recovered, eliminating the need for complete well reworking when corrosion occurs.
2Reliability
If a permanently installed gas lift mandrel is used, then gas injection infrastructure is established, but when the mandrel fails there is no way to repair it requiring well shutdown
Solution Approach 1:
By separating the permanent mandrel infrastructure from the replaceable valve assembly, the system allows the valve to be serviced independently. This resolves the contradiction by making the critical flow-control component repairable while preserving the permanent gas injection infrastructure.
Solution Approach 2:
The system transitions from a static permanent mandrel to a dynamic configuration where the valve assembly can be removed and replaced. This dynamic capability allows maintenance without well shutdown, resolving the contradiction between permanent installation and repairability.
3Ease of operation
If gas lift valve is installed in fixed locations during initial well completion, then gas injection is established, but the valve cannot be replaced without shutting in the well
Solution Approach 1:
The valve is segmented as a separate replaceable assembly that attaches to the permanent mandrel. This allows the valve to be changed without affecting the permanent installation, resolving the contradiction by enabling easy replacement while maintaining simple initial installation of the mandrel infrastructure.
Solution Approach 2:
The valve assembly is designed to be retrieved and replaced like a consumable component. This resolves the contradiction by allowing the valve to be cycled out and replaced without shutting in the well, while the permanent mandrel remains in place from initial installation.
4Ease of repair
If the entire mandrel and valve unit is made replaceable, then quick repair is enabled, but the device complexity increases
Solution Approach 1:
The system is segmented into a simple permanent mandrel and a separate valve assembly. This segmentation allows the valve to be replaced as a complete unit for quick repair, while the mandrel remains a simple permanent infrastructure piece, resolving the contradiction by distributing complexity appropriately.
Solution Approach 2:
The replaceable valve assembly is designed as a universal component that can be used across multiple wells with standard mandrels. This universality reduces the complexity of individual units while enabling quick replacement, resolving the contradiction by making the replaceable unit standardized and interchangeable.
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
Enables continuous gas injection and oil production even after mandrel failure, as the replaceable unit allows for quick repair and reuse, extending the life of aging wells without the need for complete reworking.
Implementation Method 1
Gas lift systems have been used in oil wells to help increase production
Implementation Method 2
gas to be pumped down the space between the casing and the production tubing
Implementation Method 3
allows the appropriate amount of gas or other fluid to enter the gas-producing zone to provide lift for the oil
Data Source
AI summary
A replaceable gas lift valve system. In this system, the device is inserted into the production tubing (or gas producing zone) at a desired level. This allows gas to be pumped down the space between the casing and production tubing (or flowed from the zone). Although the tool is placed in the production tubing, space is provided to allow almost normal production through the tool. Once in place, the device has a metering valve that allows the appropriate amount of gas of other fluid to enter the production tubing to provide lift for the oil. If the device fails, it can be quickly extracted and a replacement device quickly installed. Once installed, the replacement device allows resumed production. The recovered device can be dismantled, repaired and staged for another quick replacement where needed.