SPE-171374-MS

Optimizing Gas Lift Operations Using Disintegrable Gas Lift Valve Plugs
Bobby J. Salinas and Zhiyue Xu, SPE; Bennett M. Richard, Baker Hughes

Copyright 2014, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Artificial Lift Conference & Exhibition-North America held in Houston, Texas, USA, 6 8 October 2014.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
Artificial lift encompasses approximately 96% of the US oil well market. Of the wells that use artificial
lift, 10% use gas lift for production. As gas is injected into the well, the viscosity of the fluid and pressure
is reduced, promoting flow to the surface. In typical gas lift valve systems, dummy valves are installed
in side-pocket mandrels to isolate the annulus from the tubing where pressurization is required to test the
tubing, test the annulus, set a hydraulic packer, or activate an isolation device. Then intervention would
be required to remove the dummy valves and install a live gas lift system. This can be a time-consuming
process and can pose risks to existing infrastructure while hindering production time.
This paper presents a newly developed nano-engineered disintegrable composite (DNEC) and its use
in gas lift valves. The DNEC gives gas lift valves the flexibility to be installed as dummy valves, but
switching to a live valve without intervention. The switch from a dummy valve to a live valve occurs
through an in-situ disintegration of the DNEC plug. This eliminates multiple intervention trips and enables
immediate production of these wells under optimized gas lift conditions.
The nano-engineered composite plug is lighter than aluminum, but as strong as some mild steel. The
DNEC plug has pressure rating of 5,000 psi and will disintegrate in brine during the cleanup process,
within 12 to 50 hours, making it an ideal tool for offshore gas lift valve applications. To date, more than
1,000 gas lift valves equipped with DNEC plugs have been successfully installed. The nanostructured
composite material, the valve design, the lab test data and a successful case history will be presented.

Introduction
Gas lift in the United States market encompasses 10% of the artificial lift systems used in oil producing
wells that have insufficient reservoir pressure. Compressed gas is injected from the surface into the well
to reestablish pressure, thus, making it produce. The injected gas is flowed through the casing tubing
annulus and enters the well through gas lift valves (GLV). The gas decreases the viscosity of the fluids
being produced; therefore, allowing the fluids to flow freely to the surface. Gas lift can be used in wells
producing 30,000 bbl/d and depths of 15,000 ft, and can potentially add approximately 250,000 bbl of oil
over the life of the well. Therefore, improvements in well productivity and economics make gas lift a
preferred choice for artificial lift [1].
For offshore wells, such as in the Gulf of Thailand and other regions throughout the world, gas lift is
the preferred choice of artificial lift. Wells that exhibit short life expectancies can be produced with

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improved productivity and economics. The simplicity, flexibility, and reliability of the GLV make it a
desirable form of artificial lift.
Conventionally, dummy valves are loaded in
side-pocket mandrels to isolate the annulus from the
tubing where pressurization is required to test the
tubing, the annulus, set a hydraulic packer, or activate an isolation device. Wireline intervention
would be required to remove the dummy valve and
install the live GLV to initiate gas lift. This can be
a time-consuming, costly, and cumbersome process
that can damage existing infrastructure and delay
production. Additionally, scheduling of wireline
crews can be delayed; therefore, causing delays in
production and leaving the well uncompleted. Initial
installation of a live GLV rather than dummy valves
during completion has proven to be an efficient
method to reduce operation time and cost. However,
the disadvantage of having a live GLV installed
initially is that it cannot hold pressure as well as if
a dummy valve were installed. Fig. 1 illustrates a
Figure 1Schematic of a gas lift valve system.
live gas lift system with GLV installed in the sidepocket mandrel. Injection gas is pushed down the
annulus through the GLV to reduced fluid viscosity, allowing hydrocarbons to be produced.
This paper discusses a nano-engineered disintegrable composite material that functions as a dummy
and live valve. This new smart valve can be installed during well completion and switched to live through
an in-situ micro-galvanic disintegration mechanism. A DNEC plug is installed below the flow check dart
and, in the presence of brine, the plug disintegrates in 12 to 50 hours. Fig. 2 shows the gas live vale
assembly with a DNEC plug installed. After the plug has completely disintegrated, the GLV becomes live.

Gas Lift Valve Plug Design

Typically, in a gas lift system either a dummy or live valve is installed at the initial completion phase. The
dummy valves then must be removed, via wireline, to allow for gas injection. The switch over from
dummy to live comes with some disadvantages: Increased cost for wireline crew, HS&E issues, and delays
in production. On the other hand, live valves cannot hold very much pressure during testing of the tubing
string and annulus, or to set a hydraulic packer. During a cementing job, the live valve can become
plugged or damaged, resulting in costly completion failures.
The implementation of a GLV that can switch from dummy (temporary) to live must serve the
following functions:
a) Capable of being used as high-strength temporary valves at various temperatures,
b) Must be integrated into current side-pocket mandrel designs,
c) Usable to blank off side-pocket mandrels for pressurization on the backside,
d) Resistant to drilling muds, but disintegrate in brines.
When installed, the plug must prevent fluid and cement flow from the annulus into the tubing sting,
similar to temporary wireline retrievable valves. Fig. 3 illustrates the DNEC gas lift assembly with a
disintegrable plug installed at the nose. The plug is designed to withstand high pressures during
pressurization phases of completion and disintegrate on contact with brines.

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The smart GLV incorporates a nano-structured

disintegrable material that, when in contact with an
electrolytic solution, typically brines and acids, a
galvanic reaction occurs at a controlled disintegration rate. The plug then disintegrates, transforming
the GLV from temporary to live. This provides a
solution for the above-mentioned issues and can be
installed in side-pocket mandrels (SPM) at the initial stage of completion. The DNEC smart gas lift
plug allows the gas lift assembly to act as a temporary valve enabling completion of the pressurization
and cementing phase. Upon exposure to brines or
acids, the plug disintegrates in-situ and switches the
GLV to live.

Design of Disintegrable Composite

The design of the nano-engineered disintegrable
composite (DNEC) encompasses two key properties: high strength and time-controlled disintegra- Figure 2(a) DNEC GLV assembly, (b) Close-up view of DNEC GLV
tion [2]. Both are incorporated into the design of the plug.
composited materials. The composite is manufactured by coating a reactive metal powder with metallics and/or ceramics. Mechanically, the material needs
to be durable enough to with stand installation and operation; however, it needs to disintegrate during a
specified time. Both properties can be engineered at the micro- or nano-scale level to provide varying
mechanical and disintegration properties. In the presence of brines and acids, the DNEC undergoes a
galvanic reaction that provides the mechanism for disintegration. Properties are engineered within the
grain structure of the nanomatrix; therefore, providing the nano-galvanic cell needed to trigger disintegration. Disintegration can be tailored based on application needs by varying the nano-galvanic triggering
mechanisms present in the grain boundary. Temperature and fluid chemistry contribute to the acceleration
of galvanic disintegration. The grain boundary also provides the high strength and toughness properties
needed to achieve the application requirements. Fig. 4 shows a (a) scanning electron micrograph of the
DNEC microstructure, (b) in-situ galvanic disintegration occurring on the grain boundary, and (c) the
uniform dimensional disintegration of a cylindrical sample. The disintegration along the grain boundary
allows uniform dimensional changes while maintaining mechanical properties.

Laboratory Testing of Disintegrable Composite Plug

In-situ testing of several nanomatrix chemistries was completed using 3% KCl at 200 F and, depending
on material composition, disintegration time was varied. The samples were fully submerged in warm brine
and monitored for dimensional change and weight. Typical laboratory test coupons are cylindrical in
shape and have a dimension of 0.5-in. OD x 1.0-in. length, with a smooth surface finish and metallic in
color. Once exposed to brine, the surface becomes rough and slightly pitted, but retains its cylindrical
shape (see Fig. 4 (c)). As seen in Fig. 5, the cross-section view of the corrosion surface shows that galvanic
disintegration only occurs on the outer surface of the material. The micro-galvanic cells serve two
functions [3]:
1. Facilitate the reaction,
2. Prevent penetration beyond the exposed surface.

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Figure 3Schematic of the DNEC smart gas lift valve assembly, with disintegrable plug.

Figure 4 (a) Scanning Electron Micrograph of DNEC, (b) in-situ video still grab of disintegration occurring along the grain boundary of DNEC,
and (c) cylindrical samples after disintegration.

Figure 5Scanning Electron Microscope image of a cross-section view of the corrosion surface of DNEC material.

Rates of disintegration of DNEC material vary with wellbore fluids; however, it is resistant to oil-based
drilling muds and only slightly reactive with fresh water. Its reactivity to electrolytic solutions, such as

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Figure 6 Rate of disintegration of DNEC GLV design in sea water at 275 F and 500 psi.

brines, makes it ideal for customization. Disintegration rates range from 0.1 to 450 mg/cm2/hr in 3% KCl
at 200 F and much higher in acid solutions.
Mechanical properties show good ductility, with elongation at failure from 8 to 12% and ultimate
compressive strength (UCS) of up to 64,000 psi. In comparison, the base material, without nano-coating,
exhibits UCS of 20,000 psi and a disintegration rate of less than 10 mg/cm2/hr.
Functionality tests were completed in-situ for a GLV plug to show its usability in the GLV assembly,
as shown in Fig. 3. A test fixture was assembled to replicate the GLV assembly head with plug and
completely submerged in sea water at 275 F and 500 psi. Mass loss was measured at various time
intervals and the test was stopped at 31.6 hours. Fig. 6 demonstrates the disintegration of a GLV plug over
time with uniform disintegration. Testing was stopped when sealing integrity was lost. The overall weight
loss was 1.8 g/hr, thus, verifying that the DNEC plug can meet the 12 to 50-hour requirement to convert
from temporary to live, as set forth in the statement of requirements (SOR).

Case Study of Gas Lift Valve Plug

Artificial lift in the Platong Field, in the Gulf of Thailand, is crucial because without it wells will cease
production in 2 to 6 months. Gas lift has increased production from 10 to 50% total field production during
June 2008 through June 2011; therefore, distinguishing gas lift as a contributor to prolonging well life.
Cost reduction is major challenge in gas lift wells due to the multiple wireline trips needed to switch from
temporary to live valves. In 2008, rig time was reduced by 1 day per well by implementing a mono-trip
gas lift completion [4].
Side-pocket mandrels were installed in the production tubing to prepare the well for gas lift. Typically,
temporary valves are initially installed in SPM; however, the DNEC plugs were installed in live/orifice
valves. The plugs disintegrated during the cleanup process, switching the DNEC temporary valve back

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into a live/orifice valve. This eliminated multiple wireline trips and intervention after completion. Cost
and HS&E risks were reduced by eliminating equipment and personnel needed to complete the well.
Use of the new nanostructured disintegrable engineered composite GLV plug was successful. The use
of this new system reduces:
a. Wireline trips,
b. Intervention after completion,
c. Cost,
d. HS&E risks.
The DNEC system provides a time-controlled disintegration of the plug, therefore, playing a crucial
role in the success of this completion. The creation of this technology saved months of scheduling wireline
units and the operator achieved a faster return on investment (ROI). The operator has requested that this
new system be used for all projects in the Gulf of Thailand.

Conclusions
Traditional gas lift systems use temporary or live orifice valves initially installed in the SPM. The
disadvantages of using these valves are:

Increased cost for wireline crews.

Intervention after completion,
HS&E risks,
Ability to hold pressure.

With the implementation of the disintegrable nano-engineered composite, temporary valves can be
transformed into live/orifice valves. The use of the time-controlled disintegration enables wells to be
completed before dissolution occurs during cleanup. Mechanical properties make this material strong
enough for pressurization testing of tubing and annulus.
DNEC material technology has proven to eliminate costly wireline trips and intervention and HS&E
risks. The resulting immediate oil recovery provides the operator with a quicker ROI.

Acknowledgement
The author wishes to thank Baker Hughes for permission to publish this work.

References
1. Z. Xu, B.M. Richard, and J.H. Kritzler, Smart Gas Lift Valves Eliminate Multiple Slickline Trips
in Gas Lift Operations, OTC 24798, OTC Asia Kuala Lumpur, 25-28 March 2014.
2. B.J. Salinas, Z. Xu, and G. Agrawal, Controlled Electrolytic Metallics An Interventionless
Nanostructured Platform, SPE 153428, SPE International Oilfield Nanotechnology Conference
and Exhibition, Noordwijk, The Netherlands, 12 14 June 2012.
3. Z. Zhang, Z. Xu, and J. Welch, Electrochemical Removal of Composite Tools in Oilfield
Applications, NACE Western Area Conference, Honolulu, Hawaii, 20 22 November 2013.
4. C. Boonmeelapprasert, etc., Gas Lift Journey to Maximize the Asset Value in Platong Field, Gulf
of Thailand, IPTC 14807, SPE International Petroleum Technology Conference, 7-9 February
2012, Bangkok, Thailand.