OTC 4253

New Safety Valve for Subsea Installations

by Mike Deaton Otis Engineering Corp.; Klaas W. Brands, Shelllnternationale Petroleum Maatschappij
B. V.; and Graham Potter, Shell U. K. Exploration and Production

COPYRIGHT 1982 OFFSHORE TECHNOLOGY CONFERENCE

This paper was presented at the 14th Annual OTC in Houston, Texas, May 3-6, 1982. The material is subject
to correction by the author. Permission to copy is restricted to an abstract of not more than 300 words.

ABSTRACT
In the same year Shell Expro,
operating in the UK sector of the
North Sea, had developed an interest
in SC-TRSSV's for their underwater
development scheme for the Cormorant
field.
As a result of this both SIPM
and Shell Expro ordered (different)
balance line SC-TRSSV's from Otis for
in-house testing.

A new safety valve was requi red by

North
Sea
Operators
fortheir
prospective sub-sea completions.
~he
valve
would
have
to
combIne
compatibility with low ~ressur~ s~b~sea
wellhead controls with hIgh relIabIlIty.
A
design
team
was
organized
consisting
of
engineers
from
an
operator
and
a
manufacturer.
The
pr-oject began in 1975.
Four years of
testing have provided data on the
operation of this safety valve.
The
first two valves were installed in a
North Sea Sub Sea Completion
in the
--Fall of 1980.

Tests carried out at

the
E&P
laboratory
in
Holland
demonstrated
that fail safe closing of either valve
under the test conditions, i.e. 3000
ft installation depth and 5,000 psi
internal
pressure
could
not
be
achieved.
In addition, the leakage
rate after 1000 opening and closing
cycles was approximately five times
that permitted by the API-14A.
These
disappointing test resul~s and the
pressing need for a relIable sa~ety
valve for both the Insert Tree proJect
and
the
Central
Cormorant
subsea
development
scheme,
led
to
the
decision to initiate a joint program
for the development of a SC-TRSSV
which
would
comply
with
the
requirements for a dual 3-1/2 inch
underwater TFL-completion.

This paper discusses the design

parameters and features of the safety
system as well as the. perfor!Uance of
the system in tests and In servIce.
INTRODUCTION
In
1975
Shell
Internationale
Petroleum Maatschappij B. V. (SIPM) in
the Hague, Holland was looking for a
reliable deep set surface controlled,
tubing retrievable, subsurface safety
valve (SC-TRSSV) for installation in a
dual 3-1/2 inch TFL-completion for a
new subsea production wellhead referred
to as the Insert Tree project.
The
attention was focused on Otis who
presented at that time their below
mudline wellhead (BMW) study which had
evolved around the Otis Tubing Hanger
Safety
System
and
incorporated
SC-TRSSV's.

Throughout
the
design
phase
regular meetings. were h.eld be~ween
Shell and Otis wIth contInuous Input
of
ideas
from
both
sides.
This
finally
led
to
a
valve
which
incorporated
both
the
operators
experience
and
the
manufacturers
engineering skills.
The valve has
unique features
such as a
second
balance chamber to facilitate fail
safe closing under all circumstances,
a
lock-out/isolation
sleeve,
295

in a clean hydraulic fluid and the

space available for the valve (even in
a dual string completion) means more
reliability
can
be
built
into
components.

a sliding sleeve which accommodates a

TFL back-up valve and a carefully
selected sealing arrangement for all
static and dynamic seals.
During the extensive testing phase
both in Holland and at the Bacton TFL
test site,
some minor modifications
proved to be necessary.
Finally, after
evaluating all test results, the valve
was accepted for offshore service.

2.0

This requirement is
two other factors:-

Two of the requirements for the

safety system for
the
Insert Tree
changed with the effect that a single
line valve had to be installed.
Based
on the
experience gained with
the
balance line SC-TRSSV, a single line
SC-TRSSV
and
a
TFL
insert
valve,
applying the same technology as used
for the balanced valve, were designed
and manufactured.
Two
single
line
valves
were
installed in March 1981 in the Insert
Tree completion offshore Brunei.
The
early
coordination
of
the
operators
requi.remen.ts
with
the
manufacturer
engI neenng
capabi 1 it ies
and
the
extensive
testing
of
the
prototype valves were the basis for the
successful completion of this project.

dictated

by

2.1

The valve is to be "depth

independent". A balanced
valve will not operate
satisfactorily at any depth,
but is more easily set at
greater depths without
changing other operating
parameters.

2.2

The valve must be able to be

controlled via the sub-sea
control system which controls
all other sub-sea functions.
The working pressure range of
the sub-sea hydraulic system
is 2000-3000 psi.
The long control line lengths
(30,000 ft platform to
manifold, 15,000 ft manifold
to satellite wells) precluded,
for economic reasons, the use
of a dedicated high pressure

DESIGN REQUIREMENTS

hose to operate the downhole

safety system. The electro-

In 1977, the design team met to

safety
establish
criteria
for
a
system.
In
June
of
1977
these
meetings produced the followini list of
requirements:
1.0

The valve should be of the

balanced type

hydraulic control system

ensures fast action of the
hydraulic valves.
3.0

Primary safety valve to be a

surface controlled full bore
tubIng retrIevable safety valve

In the event of a malfunction of

the tubIng retrievable safety
valve the valve must be able to
be locked open (by TFL)
The closure device (ball) should
be able to be locked in the fully
open position and also seal-off
control balance line access to the
val ve
(thus
isolating
any
hydraulic leaks in the operating
section of the tubing retrievable
safety
valve).
Experience
has
shown that downhole safety valves
fail as much from hydraulic seal
failures as baIlor flapper leaks,
consequently
any
redundancy
feature should isolate both.

This eliminates the requirements

to remove the safety valve to carry
out TFL or wireline work downhole,
offer s less_ rest tic t i on to flow but
requires a workover of the well to
replace the val ve.
Because of the
permanent
nature
of
a
tubing
retrievable safety valve a long
operating life is required (the
total
Central
Cormorant
sub-sea
system is designed for a life of 25
years).
A longer service life can
be
designed
into
a
tubing
retrievable safety valve as the
majority of the seals will operate

296

Secondary safety valve to be a

TFL installed safety valve

9.0

Sinfle seal (or seal pack)

fal ure must not cause loss of
fall-safe and must be able to be
dlagnosed

4.0

After
the
tubing
retrievable
safety valve is locked open it
must be possible to install a TFL
retrievable safety valve.
This
should preferably be in a separate
nipple (sleeve type) so as to:-

a
This
requirement
stems
from
of
possible
failure
mode
safety
conventional
balanced
valves:-

9.1
Avoid over complicating
tubing valve assembly

A tubing leak into the control

line could tend to keep the ball
open if the leakage rate is greater
than the bleed-off rate through the
control line.
5.0

9.2
Enable balance line to be
flushed (in case of gas ingress)
10.0

Body seals to be metal to metal

The downhole completion design is
such that all connections above the
telescopic joints have metal to
metal
seals
to
eliminate
the
possibility of an elastomer failure
allowing
the
annulus
to
become
pressurized.
This
concept
is
required of the downhole safety
system also.

6.0

10.1 Operated by the same control

system

(~

500

ft

7.0

11.0

8.0

10.3

Working pressure
of

being

pumped

The system should be suitable

for productlon or water
lnJectlon serVlce
The
Central
Cormorant
sub-sea
system
is
to
be
used
for
simul taneously inj ected de-aerated
seawater and producing crude with
small
percentages
of
H2S
and
C02.
To give maximum flexibility
the safety system should be used
in ei ther a water injection well
or a production well.

Kick-off depth

Working pressure to be 5000 psi

To be compatible with the
the sub-sea system max.
pressure is 5000 psi.

Working setting depth

10.5 Single seal leak should not

cause loss of safety

in

6.2
Hydrate
and wax
formation
depth.
The safety system depth
should be below these depths
6.3

10.2

10.4
Capable
through

This depth setting is determined by

the following factors:Water depth
CQrmorant area)

TFL safety valve to have similar

characteristlcs as the tublng
valve
The TFL valve should be similar in
the
following
respects
to
the
tubing valve:-

Working setting depth should be a

mlnimum of 3000 ft (below sea
level)

6.1

the

rest of
working

The tubing retrievable safety

valve should be capable of being
pumped through

SAFETY SYSTEM DESIGN

The requirements established by
the
design
team
represented
new
thinking in design.
The system would
have to combine TFL compatibility with
defined 'fail safe' criteria.

Even is a control line fails it

should be possible to pump through
the valve from above so that in an
emergency the well can be killed.

297

Initial testing had shown that an

through
!Ireliability
of
approach
provide
could
not
simplicity
compliance with the fail-safe criteria
which had been established.

by
from
tubing pressure
protected
balance line chambers. To prevent the
any
single
length
of
excessive
was
sleeve
the
second
assembly,
designed as a separate component.
It
would be run above the TRSV and
connected by external lines.

1.0 The most obvious area of concern

In previous
was the piston chamber.
balanced safety valve designs, a leak
from the well bore into the ;&st;;
chamber could cause the valve
was
weakness
This
self-opening.
negated by the addition of a balance
the
piston
above
chamber
pressure
This addition prevented
~~gmb;~il(l).
open condition by insuring
that any critical packing leak would
first admit tubing pressure into the
balance chamber and assist closure of
This I!balance protection
the valve.
to cover all,
feature was extended
control pressure chambers including the
shifting sleeve, the TFL Safety Valve
Nipple and the TFL Safety Valve.

3.0 Tests of earlier models of this

valve had shown that at 5000 psi
simulated
and
a
internal pressure
was
ft performance
depth of 3000
of
prime
cause
marginal.
The
at
higher
reduction
performance
packing
was
increased
pressures
friction. Tests were run concurrently
The valve was
with prototype design.
designed to receive both standard W
seal
unidirectional
and
a
packing
between opposing sets of W packing.
Two closing springs
increase performance.

were

used

to

4.0 The body connections of the TRSV

were designed to have metal-to-metal
Each connection of
seal protection.
body parts received both an elastomer
seal and a soft metal gasket. A small
pipe thread port was added between the
two seals to allow separate testing of
the two seals at final assembly.

Most Tubing Retrievable Safety

2.0
Valves in existence at the time of this
project incorporated a sliding sleeve
in the upper section of the valve.
This sleeve provided a landing nipple
for a retrievable safety valve and a
lock open device for the TRSV. To meet
the fail safe criteria for this system
the sleeve needed to perform three
functions. In addition to the function
of safety valve nipple the sleeve had
to provide for flushing of the balance
line in case of gas dilution of the
A sleeve designed to
balance fluid.
allow for flushing operations would
have to be shifted open and closed for
such operations. A sleeve designed to
if accidently
lock the TRSV open,
released to allow the TRSV to close on
would present a
a TFL tool string,
situation causing permanent closure.
To provide for all considerations a two
sleeve system was designed. One sleeve
would lock the TRSV permanently in the
Control pressure would
open position.
be routed to this sleeve directly from
In the normal position
the surface.
the sleeve would route the control
control
the
TRSV
pressure
on
to
When shifted, this sleeve
chamber.
would lock the TRSV open, route the
control pressure to the second sleeve,
and block control pressure from the
second
contr,ol chamber.
The
TRSV
sleeve would shift to accept a TFL
safety valve and to allow flushing of
Al1 sleeves
the balance line (2).
line ports
would have the control

5.0 The high reliability which was

required of the TRSV promoted several
tests of state-of-the-art materials
and coatings.
Packing materials were
Several
tested on a coninuing basis.
coatings were tested and two were used
on the final versions of the valves.
These coatings reduced friction and
galling.
the
threat
of
minimized
Galling had been a recuring problem
with corrosion resistant alloys.
Since the production of the
6.0
original TRSV S , several more have
been ordered for sub-sea completions.
Also, a single-line version has been
installed in Brunei. This version has
most of the features of the original
valve but requires pressure greater
than internal tubing pressure to open
the valve. The porting of the single
line valve is considerably simpler
than than that of the original valve.
7.0 Future development of the TRSV
will be centered around the packing.
are
being
designs
friction
Lower
tested. The valve can be equipped as

90Q

-Response testing with various

hydraulic fluids

a double line valve with low operating

pressure, as a double line valve with
and
closure
assisted
well
pressure
higher operating pressure and as a
single line valve with a depth rating
dependent on the operating pressures
which can be tolerated.

-Surface testing
-Installation and operation in
test well
-Integration tests with UMC
Control System

MANUFACTURING PROCEDURES
1.0
Although prototype assemblies
would normally be manufactured in an
engineering job shop, the decision was
initial
manufacture
the
made
to
assemblies as if they were a regular
production run. The theory behind this
provide
full
check-out
of
was
to
manufacturing processes, and insuring
few
future production runs would see
provide
problems.
To
manufacturing
engineering support for its operation a
special procedure was initiated. This
engineering
procedure
required
pr;!ent
at
each
technician
to
be
inspection or assembly operation. This
assistance
and
engineering
provided
which
would
have
troubleshooting
previously been available only in a
model shop atmosphere.

2.0

SUMMARY

highlighted
some
2.1
Testing
design weaknesses which were
and
subsequently
re-designed
checked out.
2.2 The valve would not operate
with
the
original
smoothly
was
fluid
and
this
hydraulic
subsequently changed.
seal
friction
2.3
High
contributes to long closing times
at worst case conditions.
2.4 The valve has been cycled in
excess of 2000 times now and apart
has
above
instances
from
the
operated perfectly. In early 1980
approval was given for this design
of valve to be installed in the
first Central Cormorant Sub-sea
Well
(completed
June
~;;;;lite

2.0 Although the valves were destined

for the North Sea, they were to be
manufactured in conformance with API
prevent
would
standards.
This
differences in later models and provide
additional quality control.

3.0

RESPONSE TESTING WITH VARIOUS

HYDRAULIC FLUIDS

PROTOTYPE TESTING
3.1

Tests

BACTON
1.0

In order to arrive at the most

suitable hydraulic fluid for the
system
various
control
sub-sea
The tests
fluids were checked.
were conducted on the bench with
the
horizontal
the
valve
in
ambient
position.
The
the
fluid
temperatures
a-n
d
were
monitored.
temperatures
Hydraulic fluids tested were:-

INTRODUCTION

Three prototype tubing retrievable

safety valves destined for use in
Central Cormorant subsea wells were
One was
manufactured in Dallas.
delivered to the Bacton test site
testing
1978
and
September
in
The
immediately.
commenced
objectives of the prototype tests
were to undergo 2 or 3 life cycle
tests (500 cycles = life) on the
test program and to be installed at
operating depth in the test well.

-Water Soluable
-Hydraulic Fluid A
-Hydraulic Fluid B

Testing of the safety valve

into four distinct sections:-

fell
times were
Ball
valve closure
measured with internal pressure of
and
5000
lQOO, 2000, 3000, 4000,
psi.

900

(inspected)
lengths
of
Varying
horizontal dual control lines were
used and each length was used with
its own particular balance line
varying
simulate
(to
pressure
setting depths), i.e.:-

Slam tests (closing under

flowing conditions).
Pump through tests (with O psi
control pressure)
TFL tool passage.

165 ft with 300 psi

Lock-out feature.
700 ft with 300 psi
4.2

Failure and Subsequent

Disassembly of Safety Valve

1950 ft with 800 psi

3.2

Results

The following closure times were

line length
observed with a control
of 1950 ft and a balance line head
(operating
psi
of
750-800
condition).
Fluid
Water Soluble
Water
Soluble
Hyd. A
Hyd. A
Hyd. B
Hyd. B
4.0

Internal
Pressure
5000
2000
5000
2000
5000
2000

psi
psi
psi
psi
psi
psi

Closure Time
The valve was stripped down and
the following points were noted:36 sec
16 sec
7 rein, 18 sec
6 rein,47 sec
10 rein,3 sec
8 rein,1 sec

SURFACE TESTING
4.1

While testing under compressive

loading conditions (total number
of cycles = 7S0) the valve stuck
in the open position with an
internal body pressure of 4000
freed by
psi.
The valve was
still
operated
but
exercising
erratically and noisily.

a)
Due to some slack machining
tolerances and a weak design of a
component the packing stack on the
moving piston was over compressed
thereby increasing seal friction.
b) A screw had backed out of the
piston connector and thus may have
jammed the valve.

Tests

A full program
of functional and
proving tests for the safety valve
1979.
in
October
commenced
program
test
the
Briefly,
encompassed the following:Pressure testing control line,
balance line. Body (water G
N2), under ball (water G N2)
Determining opening and closing
pressures and volumes with
varying internal pressures.
Determining response times under
various conditions.
Cycle testing under various
conditions.
with valve in
Response tests
tension, compression and under
deflection.

Hydraulic fluid B was found

to make the action of the valve
low
i.e.
very
erratic
very
lubricity.

c)

New components were supplied and

the test program was continued.
4.3

Results

The test program highlighted some

weak component designs which were
The
low
remedied.
easily
lubricity of Hydraulic Fluid B
indicated its unsuitability as a
control fluid for this valve and
Hydraulic Fluid A was used to
continue testing.
A further problem was observed
when pumping TFL tools through the
valves in the horizontal position.

The TFL toolstring fishing neck

into
the void!f
drop
could
the
when
the piston
above
valve was open. Although being
position
horizontal
the
in
accentuates this problem the
was
lengthened
neck
fishing
anyway.

pressure then venting the control

line and checking closure times
(by bleeding off above the valve)
determine
also
used
to
was
response times.
5.3

Valve closure times when pumping

from below were found to be around
3 reins 30 sees. The times did not
vary much with internal pressure
4000
=
(max internal pressure
psi). When 1000 psi balance line
pressure was applied all closure
times were below 1 minute.

All other testing indicated that

the valve operated as designed.
5.0

INSTALLATION IN TEST WELL

5.1

Installation
Prior to running the tubing
retrievable safety valve in the
was
well
it
test
5000
ft
and
modified
down
stripped
components fitted.

Static testing of the safety valve

was more difficult as, with the
valve installed in the test well,
it is not easy to determine when
the valve is closed.

The valve was made up in a

ball
below
the
sub-assembly
valve nipple sleeve with two 3
between
couplings
flow
ft
The well was completed
them.
in January 1979 and the safety
valve was set at a depth of
below
the
tubing
180S
ft
hanger.
The test well had a
production
casing
similar
scheme as an offshore well i.e.
10-5/8 casing down to 2000 ft
and 9-5/8 casing below that.

The response times were about 4

reins but some closure times of up
to 9 minutes were observed.
The closure times were acceptable
but reduction of internal seal
friction should be an aim for
future valves. (The safety valves
used on P-1 had closer control on
which
piston
tolerances
the
reduced seal friction. )
6.0

The larger casing in the upper

sectio.n.was desirable to enable
a 3-1/2 thread connection to
fit alongside the safety valve
rather than use a slim line
joint in 9-5/8 casing.
5.2

Results

INTEGRATION TESTS WITH UMC

CONTROL SYSTEM
6.1

Object

The object of the test was to

show that the tubing retrievable
function
would
valve
safety
correctly when connected to the
sub-sea control system.

Tests

pressure
tests
initial
After
following installation the response
times under varying conditions were
determined:-

6.2

Tests

The tests were conducted on

surface with the valve in the
horizontal position and with 2000
The
ft of dual control line.
control line was hooked into the
underwater manifold control system
via a tubing hanger an Xmas tree.
conducted with
The
tests were
and
pressures
internal
varying
different levels of balance line
pressure.

a) Pumping through the valve from

BPM
with
varying
below
at
1
with
varying
pressures
internal
balance line pressures the control
line was vented to zero and the
closure time measured.
b) As flow through the valve tends
to help valve closure, a method of
pressuring both tubing strings (of
the completion) to varying internal

w+

.J

6.3

1.2
A total of ;;;h opening and
closing
cycles

psi
5000
nitrogen
inside
the
valve,
followed
by
three
days
of
observation for Nitrogen leakage
past the seals into the balance
line.

Results

These tests showed that the valve

could be controlled satisfactorily
using the sub-sea control system.
Valve closure time with 300 psi
balance
and
pressure
3000
psi
internal pressure was 46 seconds.
Traces obtained of the opening and
indicate
closing
pressures
some
degree of friction in the valve at
the end of the closing cycle and
the beginning of the opening cycle.

1.3
Fifty opening and closing
cycles
with
2000 psi
nitrogen
valve,
inside the
followed by
three days
of
observation
for
Nitrogen leakage past the seals
into the balance line.
1.4 Leakage tests under the ball
and seat with water (5000 psi) and
nitrogen (2OOO psi) before and
after the cycle tests.

HOLLAND
The prototype valve was tested at
KSEPL.
The investigation at the
Holland test site concentrated on
the following four aspect-s:
I

Performance and functional

tests.

II

Aging properties and chemical

resistance of the elastomeric
seal materials under simulated
downhole conditions.

III

Leakage/diffusion rates of
methane from tubing to balance
line.

IV

Evaluation of the mechanical

design.

1.5
opening
and
closing
The
behavior of the valve with five
different
was
control
fluids
investigated.
These tests revealed that:
(a)
The
opening
and
closing
performance
of
the
valve
was
reliable under all conditions and
with all control fluids, except
iB?.
Hyd .
Later
investigation
revealed that the incompatibility
of this oil with the fluorocarbon
seals
led
to
increased
seal
friction.
The
operator
later
changed the control fluid.
This
poroduced excellent test results
under all conditions.

Test Results
Testing commenced in October 1978
and
was
completed
in
December
1980.. In this period the full test
program
out
was
carried
which
included six disassembly jobs for
inspection and, where necessary,
repairs
as
well
as
additional
comparison
testing
of
various
hydraulic oils.
1.0

(b)
The
opening
and
closing
pressures and times of the valve
are not significantly influenced
by the various control fluids in
the viscosity range from 1-30 est.
(c) Leakage test under the closed
ball and seal assembly after 1S00
opening and closing cycles both
with water and nitrogen resulted
in leakage rates which were only a
fraction (l-2%) of the accepted
rates as per API 14A, sections B5
and B7.

Performance and Functional Tests

test
The
program
included
following
performance
functional tests:

the
and

These
results
already
test
demonstrated
that
this
valve
provided reliable and fail safe
closing operation under simulated
deep downhole conditions.

1.1
and
Opening
closing
performance
under
simulated
downhole conditions, i.e. 5000 psi
tubing
pressure
and
1350
psi
(=3000ft)
hydraulic pressure on
balance and control line, with and
without up to 3000 ft of 1/4 inch
control line.

-A..

The valve was subjected to 500

opening/closing cycles between day
20 and 30 during which time the
Soot
was
initially
temperature
and later900C.

The
recommendat ions
for
improvements resulting from earlier
tests of SC-TRSSVS, which had been
incorporated in this valve, had
indeed resulted in a successful
function test.

2.3
2.o

Aging Properties and Chemical

Resistance of Elastomeric Seals

After each test the valve was

inspected
and
seals
were
replaced where applicable.

The elastomeric sealing elements of

a permanently
installed SC-TRSSV
are some of the most critical parts
of the valve.
Considerable time
and effort has been spent testing
all seals under actual downhole
conditions
in
order
to
obtain
sufficient
confidence

the
sealing
system
to
qual~;y
for
installation in a-subsea well.

In the valve three different

types of seals were used. The
tests revealed that both the
moulded seals installed in the
out
lock
sleeve
and
the
installed
in
the
T-seals,
valve
as
back-ups
to
the
primary piston seals and as
static seals; performed well
under all test conditions.

Both the fluorocarbon seals used in

the valves and the nitrile seals
used in the Insert Tree completion
were tested in their respective
crudes and with the actual control
fluids used in the field.
Two
hydraulic oils were tested on and
for
project.
the
Tree
Insert
Results of these tests led to the
recommendation
to
change
to
a
different
water
based
control
fluid.
The test program included
the following steps:
2.1

W-packings,
applied
in
The
sets of three, performed well
when
to
subjected
well
effluents; however, the first
seal of each set in contact
with
well
effluent
became
significantly deformed
under
the extreme test conditions.
The performance of the total
W-seal
stack
remained
acceptable throughout the test
period.
The deformation of
the first W-seal of each stack
was led to a modification of
the opposing packer keeper.
the
Thereafter
seal
deformation
stayed
within
acceptable limits.

Hot Oil Test

During this test the valve was.
subjected
to
crude
oil
920-970C,
(198-2030:j
and 5000 psi internal pressure
for 20 days.
Throughout the
test
the
line
control
was
pressurized to keep the valve
open and the balance line was
to
open
atmosphere
for
observation of leaks.

In total, 3 hot oil tests and

4 gas tests were carried out
with four different control
fluids.
In the final configuration for
the
assembly,
i.e.
seal
material, packing keeper, and
control fluid, all tests were
successful to the extent that
no leakage was observed during
any of the tests. These tests
highlighted once again that
application
for
each
compatibility
tests
of
the
seals with the well stream
completion fluid and control
fluid under actual downhole
conditions are essential for a
successful subsea completion.

After 10 days the valve was

~~~~:d (open/close) 500 times
test
conditions,
i.e.
psi
and
approximately
5000

92CIC.
2.2

Inspection

Gas Test
On this test the seals were
subjected to methane (CH4) at
2000 psi
(194F) interrupted
by 8 days at
500C
(1210F)
after the first 14 days.

Qn.a

CH4

inspections
These
inspected.
revealed three minor defects, viz...

The compatibility test of the seals

with high temperature methane were
combined with a test t:f es~:~~~;~
rate
diffusion
the
through the W-seals. In particular
the
into
leakage/diffusion
gas
balance line could potentially lead
to an unsafe condition.

due
to
deformation,
(a)
A
overloading, of the seal adapter
which is connected to the piston.

Prior to all methane tests the

emptied.
were
chambers
balance
During the tests the balance line
was connected to a sensitive volume
Calculations showed that
meter.
diffusion may be expected below 150
and
hour
per
CH4
std
CC
Of
quantities above this level can
only be attributed to leakage plus
diffusion.

A persistant leakage of the

(c)
external thread connections between
the bottom sub and spring housing.

the
confirmed
results
The
test
The results
theoretical approach.
revelaed that:

During the regular inspection, we

found that serious galling problems
had occured on some of the mating
This problem is
steel surfaces.
inherent with the applied materials
service and the tight
for H2S
that
implies
This
tolerances.
stringent assembly and disassembly
procedures are required.

Leakage/Diffusion rates of
Trom Tubing to Balance Line

3.0

When leakage occured,either due

properties
or
sealing
poor
to
damaged to seal bores, the leakage
and
unpredictable
rate

unaccepta~ly high (up to 35 std

cc/rein).
When sealing surfaces and seals
only
condition
good
in
are
diffusion occurs.
at
an
was
rate
diffusion
The
acceptably low level ranging from
10 to 60 std cc/day. Under actual
downhole conditions the diffusion
rate would be even lower as a
result of the hydrostatic fluid
pressure
the
reducing
column
differential acro;;te:he seal.
In
one years
the case that
operation a gas saturated balance
considered
be
fluid would
line
undesirable, the balance line fluid
the
using
replaced
by
be
can
balance line flushing capabilities
of the valve.
4.0

Evaluation
Deslzns

of

the

Mechanical

The valve has been subjected to a

multiple life-cycling program, the
total number of valve operations
During
being approximately 4000.
the valve was
the test
regularly d;~~~~~~bled and

the
of
extrusion
~~~stome;?c seal material of the
W-packings into the packing keeper
by-pass slots.

The defects under a) and b) -were

corrected by installing redesigned
the pro;:;
applying
parts.
By
torque on a torque machine,
external leakage stopped and no
further problems were encountered.

Conclusion
conclusion
is that
general
The
after the extensive tests as far as
reliability of operation (fail safe
closing) and seal performance are
concerned, this SC-TRSSV gives a
highly reliable performance.
DALLAS
the
Testing
by
centered in two areas:

1.0

manufacturer

1.

Seal development

2.

Duplication of API Tests

Seal testing had been performed

on a continuing basis since the
project.
the
of
inception
Elastomers had appeared to be
with
limitation
prime
the
respect to long-term downhole
Long-term
reliability.
reciprocating test of different
materials were conducted.

Shapes and tolerances were then

adjusted to minimize friction.
The three prototypes were built
these
incorporating
developments in a standard seal
package.
2.0

The Downhole Safety System is based on

a tubing retrievable valve with the
back-up of a ball valve nipple which
can accept a TFL run safety valve. The
system is of the balanced type (dual
line) to enable:

Duplicate API tests were run as

benchmark
for
TRSV
~erformance:

i)

2.1 Standard API functional tests

were performed and passed.

ii)

2.2 API 14A class 1 and

performance
tests
performed and passed.
2.3 API 14D tests
and passed.

were

class 2
were
performed

2.4 API 14D tests were performed by

the certified API test facility
in San Antonio, Texas.
the
could
not
be
While
TRSV
certified as a wellhead Surface Safety
Valve due to the length and flange
requirements of the API 14D Spec, this
test was performed as a durability
test. The test includes 500 operations
against a differential of 400 psi. The
valve was designed to operate against
zero differential.
After negotiating
the sand slurry test, the valve showed
zero
water
leakage
at
5000
psi.
However, the valve had a leakage rate
of 0.16 scfm Nitrogen at 2000 psi.
exceeds
the
zero
leakage
This
requirements of API 14D, however, it is
only 3% of the allowable API 14A leak
rate . Unlike a gate valve, no service
was performed on the valve during the
test.
COMPLETION DESIGN
The completion is designed for sub-sea
completions with servicing by Through
Produced
Rl~~dsLine (TFL) techniques.
enter
tubing
through
standing valves set in sleeves opposite
the zone(s). At any time the well can
be circulated to the formation.
Downhole EEP surveys can be carried-out
by
running
a
gauge
underneath
a
standing valve or by setting the gauge
in a lock and locator nipple and
producing the other string.

iii)

Use of the control

hydraulic supply.

system

below
wax
Installation
hydrate formation point
Installation
depth.

below

and

kick-off

The casing scheme is tailored to

suit the bulk of the safety system
in that 10-3/4 casing is run to
below the propsed setting depth
where it then swages down to 9-5/8.
Wherever possible, on accessories,
tubing to annulus seals are metal
to metal, but where it is necessary
to employ resilient seals (such as
in te;;.ss;ping joints) they are
the circulation kill
used
point.
Space-out of the completion is such
that maximum contraction of the
not
impose
tubing
string
does
excessive pull on the packer. This
contraction
place
when
takes
circulating with cold fluids and
necessitates the use of a number of
telescoping
swivel
joints.
The
the joints
production phase closes
and imparts a downward force on the
packer which is protected against
excessive downward force by its
hanger-type feature.
Tubing used is 3-1/2 - 9.3 - L80.
Materials employed throughout are
in
suitable
for
service
H2S
accordance with NACE Specification
Mr-01-75.
In addition the safety
system upwards is also suitable for
C02
service.
Al1
tubing
accessories are fully certified and
traceable. The safety system will
be proven at least to the standard
of API 14A.

OFFSHORE INSTALLATION
1.0

INSTALLATION

A tubing retrievable safety valve

run as part of the downhole safety
system on each tubing string of the
first sub-sea satellite producing well
The
in the Central Cormorant field.
well was designed P-1.

was

The two safety systems were made up

shore.
Each
as
sub-assemblies
on
sub-assembly comprised (from the bottom
up):-

brine and temporarily abandoned while

was
completed.
hook-up
platform
Production via the platform commenced
on 1st Jan 1981 and the well produced
until 26th April when the platform was
shut in for hook-up work. During this
time P-1 produced 630,000 barrels with
The well was
a downtime of 6.3%.
opened up in October 1981 and has
since reached a cumulative production
figure of 1,000,000 bbls. The sub sea
system, including the safety valves,
have been satisfactorily tested every
three months an during the time since
initial installation and have oprated
faultlessly.

-orientation swivel joint

3.0

SINGLE LINE VERSION

-tubing retrievable safety valve

-6 ft flow coupling
-ball valve nipple
-6 ft flow coupling

A single line version of the

valve using the same basic components
was installed in the Insert Tree
sub-sea completion in Brunei in March
1980 and has operated satisfactorily
since then.

-pup joint
CONCLUSION
The tubing sub-assemly was assembled,
pressure
lines
connected,
control
tested and function tested. The tests
were repeated offshore prior to running
in the hole.
Both strings of the completion were
run simultaneoulsy using dual running
The two downhole safety
equipment.
systems were positioned C.S. 100 ft
apart ; the orientation swivel joints
beneath each sub-assembly permitting
with
other
orientation
the correct
string
being
(The
other
string
cradled in the control line tflugsof
the tubing valve and valve nipple).
Relative rotational movement of the two
using
prevented
by
strings
was
one
attached
to
alignment
clamps,
the
other,
and
guiding
string
positioned every three joints. Control
line protectors were run on every joint
dual
clamp
the
tubing
to
of
line
to
the
control
encapsulated
tubing. After installation the tubing
retrievable valves were pressure and
function tested.
2.0

The running of completions and

early production performance of these
Perhaps
valves has met expectations.
contributor to this
the single largest
meeting
regular
was
the
success
schedule of the design team. Meetings
were scheduled on a regular basis
whether or not a need for a meeting
In these meetings many
was visible.
potential problems were discovered and
the prototypes were
solved even as
Communication
being
manufactured.
failures were reduced to a minimum.
and
operator
Most
importantly,
manufacturer negotiated regularly and
agreed on the performance required of
the product.

OPERATIONAL EXPERIENCE

The downhole completion was run in

June of 1980. The well was perforated
an production tested in July 1980. In
August of 1980, P-1 was circulated to

~1-m