Replacement of Gas-Lift Valves in Marlim Sul

Size: px

Start display at page:

Download "Replacement of Gas-Lift Valves in Marlim Sul"

Brittany Osborne
6 years ago
Views:

Petroleum Engineer Fabio Paula Brum Petroleum Engineer José Ricardo

1 37 th Gas-Lift Workshop Houston, Texas, USA February 3 7, 2014 Replacement of Gas-Lift Valves in Marlim Sul Anna Luiza de Moraes y Blanco de Mattos Petroleum Engineer Fabio Paula Brum Petroleum Engineer José Ricardo Furlanetto de Azambuja Petroleum Engineer Feb. 3-7, Gas-Lift Workshop 1

2 GOAL To prioritize rig interventions for the replacement of Gas-Lift Valves in Marlim Sul 2014 Gas-Lift Workshop 2

3 SUMMARY Goal Context: Marlim Sul Motivation: well 1-RJS-460 Gas-Lift Maintenance in Marlim Sul Correction, prevention and prediction Field data History of Gas-Lift Failure Installed Gas-Lift Valves Intervention plan Final comments 2014 Gas-Lift Workshop 3

4 CONTEXT: MARLIM SUL 2014 Gas-Lift Workshop 4

5 CONTEXT: MARLIM SUL 2014 Gas-Lift Workshop 5

6 CONTEXT: MARLIM SUL Area: 600 km² (230 mi²) Reservoir depth: 2,500-4,500 m (8,200-14,800 ft) Water depth: m (2,600 8,200 ft) Oil: API GOR: sm³/sm³ 4 production units asset discovery P-40 FPSO-MLS P-51 P Gas-Lift Workshop 6

7 CONTEXT: MARLIM SUL Gas-Lift is extremely important to us! All our production wells are equipped with Gas-Lift Valves Gas-Lift is the only artificial lift method employed in Marlim Sul Compressors discharge pressure: 195 kgf/cm² (~190 bar) Typical gas-lift rate per well: up to Nm³/d (typically, 1.96 kg/s) Instalation depth of Gas-Lift Valves: 1,700-3,900 m (5,600 12,800 ft) 2014 Gas-Lift Workshop 7

8 MOTIVATION: WELL 1-RJS Gas-Lift Workshop 8

9 MOTIVATION: WELL 1-RJS-460 Completed in 2001 Connected to P-40 Producing since 2002 Gas-Lift injection since 2005 PDG signal unavailable Schlumberger Gas-Lift Valves: Orifice RDO m (5,580 ft) Dummy Valve m (7,220 ft) Oil production: 830 m³/d (~5,220 bpd) in Jan, Gas-Lift Workshop 9

10 MOTIVATION: WELL 1-RJS-460 LOSS OF GAS-LIFT INJECTIVITY Consequences of Gas-Lift Valve Failure: Unstable Gas-Lift injection Unstable multiphase flow: severe slugging! Increasing difficulties to re-establish production Scale inhibition program: reliability is key! Well testing limitation 2014 Gas-Lift Workshop 10

11 MOTIVATION: WELL 1-RJS-460 Extra difficulty: prioritizing workover intervention, competing against other operations 01/28/ /29/ /19/2013 First signs of Gas-Lift injectivity loss appeared Well was closed for Gas-Lift Valve replacement Well re-opened with a new Gas-Lift Valve Total oil loss (390 days): 56,000 m³ (~ 350,000 bbl) Gas-Lift related oil loss: 40,000 m³ (~250,000 bbl) Intervention oil loss: 13,750 m³ (~87,000 bbl) 2014 Gas-Lift Workshop 11

12 MOTIVATION: WELL 1-RJS-460 Intervention scope and results Replacement of Orifice Valve by a new Venturi Valve (high-reliability) Deepening of injection point Technical inspection: damage confirmed 2014 Gas-Lift Workshop 12

13 MOTIVATION: WELL 1-RJS-460 Intervention solved this well s problem, but we must prepare for similar cases in the future! Current status: corrective maintenance Goal: preventive and/or predictive maintenance, reducing intervention time if possible We needed criteria! We needed more data! 2014 Gas-Lift Workshop 13

CORRECTION, PREVENTION AND PREDICTION Oil rate (m³/d) Is it viable to intervene and replace the Gas-Lift Valve BEFORE oil loss escalates, or BEFORE it even fails?

14 CORRECTION, PREVENTION AND PREDICTION Oil rate (m³/d) Is it viable to intervene and replace the Gas-Lift Valve BEFORE oil loss escalates, or BEFORE it even fails? Diagnosis tools: simulation Petrobras assumption: offshore wells should operate for a period of 6 to 10 years before workover Gas-Lift Performance - 1-RJS Gas-Lift injection rate (Nm³/h) 2014 Gas-Lift Workshop 14

15 CORRECTION, PREVENTION AND PREDICTION Is it viable to COMBINE Gas-Lift Valve replacement to some other pre-scheduled operation, so that total oil loss is reduced? Marlim Sul history: Gas-Lift Valve replacement alone: days of rig intervention Adding Gas-Lift Valve replacement to scope: days 2014 Gas-Lift Workshop 15

16 FIELD DATA Detailed history of Gas-Lift Failure in Marlim Sul Detailed data of installed Gas-Lift Valves in Marlim Sul Intervention schedules for Marlim Sul wells 2014 Gas-Lift Workshop 16

17 HISTORY OF GAS-LIFT FAILURE In Marlim Sul: 10 replacements of Gas-Lift Valves since 2001 Gas-Lift Valve Replacements 30% 50% 20% Not related to Gas-Lift failure Not related to Gas-Lift Valve failure Related to Gas-Lift Valve failure 2014 Gas-Lift Workshop 17

18 HISTORY OF GAS-LIFT FAILURE WELL GAS-LIFT VALVE INSTALATION TIME BEFORE FAILURE WELL PRODUCTION TIME BEFORE FAILURE GAS INJECTION TIME BEFORE FAILURE 1 NOVA15 8 years 7 years 0 2 RDO 6 years 6 years 1 year 3 RDO 11 years 10 years 7 years 4 RDO 11 years 8 years 5 years 5 RDO 11 years 10 years 7 years 2014 Gas-Lift Workshop 18

19 HISTORY OF GAS-LIFT FAILURE Three Gas-Lift Valves failed in 2012: Orifice Valves (RDO 5/16 ) Installed for 11 years Injecting gas for over 5 years Rule: all Orifice Gas-Lift Valves with instalation time superior to 10 years shall be replaced preventively Gas-Lift Workshop 19

20 INSTALLED GAS-LIFT VALVES P-40 FPSO-MLS P-51 P-56 TOTAL Number of production wells Production start Number of Gas-Lift Valves Dummy Valves Orifice Valves (instalation: ) Venturi Valves, non-qualified by Petrobras as high-reliability valves (instalation: ) Venturi Valves, qualified by Petrobras as high-reliability valves (instalation: ) TOTAL Gas-Lift Workshop 20

21 INTERVENTION PLAN Search for any operations demanding long production stops and/or rig interventions 2014 Gas-Lift Workshop 21

22 INTERVENTION PLAN * Candidate for abandonment 2014 Gas-Lift Workshop 22

23 FINAL COMMENTS Rule confirmation: Three preventive replacements after 1-RJS-460 Two Orifice Valves: damaged One Venturi Valve: intact All supported the 10-year rule for Orifice Valves Next steps: Future interventions: two replacements planned for 2014 Extremely small sample: study in progress Rule for Venturi Valves 2014 Gas-Lift Workshop 23

24 Disclaimer 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, noninfringement of copyright or patent rights of others, merchantability, or fitness or suitability for any purpose Gas-Lift Workshop 24

Gas Lift Valves Barrier Testing

Gas Lift Valves Barrier Testing Sven Aarrestad, IRIS Jørn Andre Carlsen, Statoil Statoil & IRIS* In 1982 Statoil introduced a qualification testing program for Down Hole Safety Valves This was the start