petrovalve brochure (NEW).cdr

PETROVALVE
VALVE SYSTEM
www.flotekind.com
Give us a call today and let us go to work for you
Gillette, WY Office
1540 Business Circle
Gillette, WY 82718
ph: 307-686-8420
fax: 307-686-8443
Farmington, NM Office
537 East Animas
Farmington, NM 87401
ph: 505-564-3309
fax: 505-564-4451
Houston, TX Office
6706 Calle Lozano
Houston, TX 77041
ph: 713-466-9881
fax: 713-896-4511
www.flotekind.com
June 10, 2005
History
The Petrovalve was co-invented in 1987 by Doug Jensen, then a Senior Field Maintenance
Superintendent with Northwestern Utilities Ltd. (“NUL”), and Ken McConnell, owner of
McConnell Oilfield Supply Ltd.
During his 15 years with NUL, Mr. Jensen realized his biggest challenge in bottom hole
pumps was with balls and seats and the ability to pump more fluid in order to produce more gas. He
designed the Petrovalve and approached Ken McConnell, who had 30 years experience in the supply
sector of the industry (primarily in repairing and upgrading bottom hole pumps).
After establishing the Petrovalve as a viable alternative to the ball and seat, demand grew for
the Petrovalve in a variety of materials and sizes. Mr. Jenson and Mr. McConnell realized they
would not be able to market the Petrovalve to its fullest potential, so they were introduced to Flotek.
Flotek acquired the Petrovalve technology and increased Petrovalve’s presence in Canada.
Flotek also spearheaded Petrovalve’s entry into the international market and introduced additional
materials and sizes required to compete in the market.
Design
Improvements Over Ball and Seat
The Petrovalve is the first major design change to the valve system in bottom hole pumps in
over 50 years. The last change that survived and worked was the introduction of the removable
insert to the cage body.
The Petrovalve has three major design improvements of the ball and seat. These
improvements are responsible for all the advantages that have been identified up to this point by the
end user.
The first advantage of the Petrovalve design is the addition of the guided upper and lower
stems to the valve, allowing the controlled movement of the Petrovalve while cycling at 9,00018,000 times a day. The result is less damage to the valve system.
The second major advantage of the Petrovalve is the increase in flow area through the valve
and cage body. This flow area increase is apparent in all sizes. Depending upon the size of valves
being used, it ranges from 27% up to 112%.
The third advantage in the Petrovalve design is the offsetting hardness between the plunger
and seat. With the plunger being slightly harder that the seat, continual lapping process helps enable
the Petrovalve to experience longevity in comparison to the ball and seat.
Benefits of Design
Improved Flow Dynamics
With the controlled movement of the Petrovalve, the violent self-destruction motion that is
observed in the ball and seat is eliminated.
There are certain benefits for flow dynamics that can be discussed. When the ball is moving
around in the cage body in an erratic pattern, the flow of fluid is disrupted causing the fluid to change
course constantly while it is passing either valve. This results in poor pump fillage and enables gas
to break out of the fluid causing yet another problem. With the Petrovalve’s guided movement, the
fluid enters and leaves the valve without its course being altered, thus reducing gas break out.
Improved Seating
The Petrovalve has a number of ways in which it improves the seating of the valve. The flat
back on the top of the valve causes the valve to be hydrostatically assisted in its closure. The
Petrovalve will close more quickly because of this and, because it is guided, does not bounce around
to find the seat.
With the ball and seat, inefficient seating occurs due to the fluid passing back by the ball
when it is trying to seat. The fluid tends to deflect around the ball as the hydrostatic column pushes
down, which causes the ball to move about. (Note: on a unit stroking at 6 spm, that means 10
seconds per cycle. If you have 5 seconds per direction of cycle and you are losing 1 second for the
ball to find its seat, you have lost 20% of the efficiency of the pump.)
The self-lapping of the Petrovalve, due to the offset hardness between valve and seat as well
as the rotation during use, is a factor in the improved seating.
Compressive Loading
The Petrovalve has proven itself to decrease compressive loading due to the increase in flow
area. We have documented information from our customers proving this point. With the increase in
flow area, there is less restriction on the fluid going through the traveling valve giving better plunger
fall and in many cases better net down hole stroke.
You may have a customer who is pumping 12 gravity oil who experiences problems with
compressive loading due in part to depth and viscosity of fluid or a customer who is pumping 40
gravity oil but doing it at 13 spm. There are many reasons for compressive loading but we are able to
reduce it whatever the cause may be.
When this decrease in compressive loading occurs, there is a wide range of benefits
including less rod and tubing wear, reduction in rod parts, reduction on wear and tear on pumping
units including gear boxes, and better production.
Pump Fillage
Increased flow area is the main reason for better fillage. Regardless if the fluid being
pumped is heavy oil, light oil, or gassy fluid, we are able to provide better pump fillage in most cases.
The Petrovalve has less pressure drop across the valve area which helps eliminate gas breakout, thus
eliminating a potential gas locking or severe gas interference condition.
In heavier oil applications, the Petrovalve allows for better pump fillage due to increased
flow area. Often the reservoir pressure in these fields is low which hinders both annulus fillage as
well as the ability to help with pump fillage.
HorizontalApplication
The Petrovalve is the only valve system that works equally as well in horizontal, deviated, or
vertical pumping. With the guided system and the hydrostatic assist for closure, there is no
efficiency drop as with the ball and seat.
The ball quite often has to pick itself up with the help of the fluid passing by in order to get up
onto the seat. Also, the inside of the insert can be built up to allow it to seat more quickly, but this
causes loss of flow area.
A large number of producers leave their pumps in the vertical portion or down as low as
possible in the deviated portion to increase pump efficiency. This solves one problem but leaves a
large hydrostatic weight on the formation that may hinder the inflow into the annulus.
Pump Efficiency
Pump efficiency is increased by a number of different reasons, some of which have been
addressed above. With the reduction in compressive loading, we are able to show a better net
downhole stroke, increasing efficiency. Better pump fillage, again, increases efficiency. With a
reduction in gas breakout from the fluid, efficiency increases. In most cases, the benefits resulting
from the installation of the Petrovalve will increase the efficiency of the pump.
Slow Pumping Speed
“Speed kills” and never has it been more apparent than in pumping wells. Because of
Petrovalve’s design benefits, either from fillage, reduction in compressive loading, reduction of gas
interference, or just plain better efficiency due to closure of the valve, we have been able to slow
down the strokes per minute and maintain existing production levels.
In certain applications we have slowed the pumping speed down by up to 30%. This saves
that particular customer over 2 million strokes per year. The power savings alone were 27%.
Valve Longevity
Petrovalve has shown increases in pump life of 2-6 times what the producer was
experiencing if the sole source of failure was the valves. This is due to the removal of the violent
action of the ball as it tumbles around beating on its sealing area and beginning the destruction of that
sealing area. With the controlled movement and the self-lapping that occurs during normal
operation, the Petrovalve will definitely outlast a ball and seat.
Extended Pump Jack Life
In high volume areas where pumping speeds are high, there is quite a bit of damage done to
the pumping unit from the bearings on through to the gearbox. The ability to slow down the spm and
maintain existing production levels, or to decrease the snapping action that occurs when the rods are
still falling and the pumping unit is rising, saves on maintenance for the entire pumping unit.
Gas Breaker
The Petrovalve Gas Breaker is a mechanical method to eliminate gas locking or major gas
interference without affecting the seating area of the valve. It incorporates all of the design features
of the Petrovalve, but includes a longer pin on the bottom of the traveling valve that comes into
contact with a trip sub above the standing valve allowing the traveling valve to open and relieve the
gas lock.
Relapping of Valves
When the Petrovalve is pulled from the well, if it does not have an absolute vacuum test, we
are able to relap the valve with a diamond lapping compound. It is much the same as relapping the
valves on a car and can be done by hand. Of course, if the Petrovalve has been in extended service or
extreme pumping conditions this may not be applicable, but generally they can be relapped. This
beats the alternative of either replacing the seat, or both the valve and seat.
Less Cost Per Barrel
All of the benefits discussed above mean less cost per barrel to the producer. Whether we can
save one rod change (lost production, rig time, rebuilt pump), or slow down the spm (power savings
in some areas, reduction in wear and tear on equipment), decrease the compressive loading (parted
rods, rig time, wear and tear) or increase efficiency (more production, less cost), the producer is able
to lower lifting costs and improve the bottom line.
Certain customers will ask what this valve will do for them. What it will do is help make
operations more effective, reduce operating budgets, and show management that they are looking
for new ways to better their overall operation.
There are quite a few companies who have initiated programs that allow the employee who
comes up with a cost saving procedure, or product to share a portion of the funds that were saved.
Hopefully more of this will spread through the oil patch.
Not a Prototype
The Petrovalve has been installed in well over 20,000 wells to date. It is being used
throughout Canada, Southern United States, South America, Australia, Europe, Russia, and
Indonesia. Many of the original valves that were run 7 years ago are still in use today. The
Petrovalve is not a prototype but rather a well engineered product that has been tested both downhole
and in theAlberta Research Council, which is a world class research facility.
Material
The Petrovalve has evolved through a series of ongoing improvements in regard to
metallurgy. These ongoing improvements are the result of both field tests and working closely with
theAlberta Research Council.
Shafts
The upper and lower shafts are now manufactured out of 17-4PH condition H1150 stainless
and then it is titanium nitride coated to bring the surface hardness up to 75-82 RHC. This coating
process penetrates into the shaft .0005” to .001”. All shafts are 2 or 3 piece construction with
shoulders above and below hemisphere. Shafts are dowel pinned and peened to prevent inadvertent
unscrewing during operation.
Spheres
Titanium carbide is now our standard sphere material. All spheres are 100% titanium carbide
as opposed to conventional balls that are only coated. We offer titanium carbide in all sizes. The
hardness of titanium is 90 RwA. It handles abrasion very well, and corrosion fairly well.
Seats
The majority of the carbide we sell at this point is tungsten. The seats have a hardness of 87.5
RwA and the valves have a hardness of 88.5 RwA. Tungsten reacts the worst in certain types of
corrosion. It is usually not recommended for over 3% H2S. This is due to a leeching process that
draws the cobalt binder out of the valve causing extreme pitting.
Guides
The upper and lower guides are manufactured from 17-4PH condition H1150 stainless steel.
Each guide has a tungsten carbide sleeve insert brazed in place to help prevent wear of the shafts.
These guides are interchangeable and can be used in either position.
Cages
We manufacture closed cages for traveling valve applications and open cages for standing
valve applications. All mating threads are API and will mate to any API sucker rod manufacturer’s
rod pump. The materials are 316 stainless steel or 4140 alloy steel with black oxide coating.
Petrovalve Gas Breaker
The Petrovalve Gas Breaker is an excellent product for eliminating gas locking or severe gas
interference. At this point there are very few effective ways to deal with this problem.
An operator can tap the pump hard enough to jar the ball off the seat, but doing so generally
results in considerable damage to the top end of the pump. We have seen instances where the valve
rod bushing either split or was pushed down inside the valve rod guide due to a heavy tap.
The Petrovalve Gas Breaker is a mechanical system, which eliminates gas lock. When run properly,
it has increased production by as much as 300%. We recommend an installation procedure for the
Gas Breaker. The procedure may take a few extra minutes, but it ensures the effectiveness of the Gas
Breaker.
PETROVALVE PLUS
THE ROD PUMP VALVE SYSTEM
THAT GETS THE MOST
FROM YOUR WELL
The Petrovalve Plus rod pump valve and the
Petrovalve Gas Breaker feature patented
technology in sucker rod pump valves. The
vast majority of producing wells employ
bottom hole sucker rod pumps which operate
using at least two valves known respectively
as traveling and standing valves. Ball and
seat failure is the most common cause of
sucker rod pump down time resulting in
recurring costs that consume a significant
portion of field maintenance and workover
budgets. Our research and engineering has
developed the next generation of Petrovalve
Plus and Petrovalve Gas Breaker with larger
flow areas and improved flow dynamics for all
types of artificial lift wells.
The Petrovalve is composed of a hemisphere,
penetrated by a stem which projects vertically
above and below. This component is called
the valve plunger. The stem guide above and
below the Petrovalve plunger is manufactured
with a single cross member containing an
aperture for the stem.
This creates a
precision guide stroke. Upper and lower
guides are identical and are reversible, as is
the seat. The guided valve plunger eliminates
the inherent problem of violent uncontrolled
contact of the ball’s multisurface sealing area
with the valve chamber, thus eliminating
irreversible damage to itself and the chamber.
The Petrovalve promotes longer valve life,
increased efficiencies and incorporates larger
flow areas than comparably sized API insert
ball-and-seat valves. Increases in area range
from 27% to 112% in sizes 1.25 through 5.75.
This increase may allow for increases in
production where reservoir conditions permit.
Petrovalves are applicable on ALL artificial lift
wells, including but not limited to high gas/oil
ratios, H2O/oil, heavy crude, and sandy wells.
In addition, operators are now able to operate
pumps efficiently in deviated and horizontal
areas of the well bore. Some high volume wells
may show increased production with our guided
valves at the same strokes per minute or the
same production while allowing the operator to
slow the pump down considerably. Reducing
the number of strokes per minute translates into
reduced lifting costs for fuel/electricity and
reduced wear on the complete lifting system.
This simple change in operating speed can
eliminate millions of strokes per year while
maintaining the same production level.
The Petrovalve Plus was initially designed for
wells utilizing rod pumps. However, the larger
areas and increased run times have shown the
advantages of installing Petrovalves in the
standing position for other types of artificial lift.
These include gas lift, chamber lift, plunger lift,
hydraulic and ESP installations, and steam
flood.
In addition to these applications,
Petrovalves are also used as discharge and
injection valves, as a discharge valve to protect
ESP or hyrdraulic systems in the event of
controlled or unexpected shut downs and as
injection/back pressure valves for waterflood or
waste injection wells.
Heavy Oil Recovery
“Heavy oil areas” are often characterized by some of
the most difficult pumping conditions in the industry,
primarily because pumping 8 to 15 API oil is like
pumping tar loaded with sand. The Petrovalve Plus
design offers better flow dynamics and increased
flow capacity, proven with test results from heavy oil
fields in Venezuela.
A ball moving wildly in front of the fluid trying to enter
the pump barrel greatly reduces the smooth flow
required to fill up the barrel. Petrovalve Plus, by
allowing the fluid to pass smoothly and equally on all
sides, permits greater speed and accessibility for
the fluid.
Deviated and Horizontal Wells
Most ball-and-seat rod pump systems are landed at
or near the vertical position in the well bore because
of the reduced efficiency and high failure rate of
pumps as the angle from vertical increases.
Petrovalve Plus valves are unaffected by the angle
of installation. The Petrovalve was designed to
allow high-efficiency pumping in any position.
Conventional ball-and-seat
action in standard
materials results in
excessive wear on both the
ball and seat.
The improved Petrovalve
Plus has greater flow area
than existing conventional
housings.
Big Bore Pumps
The design problems associated with ball-and-seat
valves are nowhere more obvious than in big-bore
pumps. A 5 3/4” big bore pump contains a stainless
steel ball that weighs 17 pounds. Because of the
weight of the ball material selection for large valves
has been limited to stainless steel to keep weight in
check. However, the Petrovalve Plus allows for the
use of harder, corrosion resistant materials which
reduces the mass effect on the seat.
1000
2000
Conventional completion
in vertical position.
3000
4000
5000
Horizontal completion
with Petrovalve Plus..
6000
This triangle costs producers money by
restricting the reservoir’s capability to produce
fluid. The weight of produced fluid having to rise
2 feet to the 3 foot level will result in lost
production.
TOP
TRIP SUB OR BOX END BARREL CONNECTOR
GUIDE
CAGE
PLUNGER
SEAT
FL
OW
PETROVALVE STANDING
OR TRAVELING
VALVE ASSEMBLY
GUIDE
SEAT PLUG
BOTTOM
.
1.25” to 2.75” Petrovalve
Plus Installation Procedures
Additional Notes
1. Install guide fully against the top
1.
profile in the cage (guides are
reversible).
2.
2. Tighten barrel connector onto cage.
3. Install Petrovalve Plus plunger with
flat side of hemisphere facing top
3.
guide.
4. Install seat against the profile in the
bottom of cage (seats are reversible).
5. Install bottom guide against seat.
6. Tighten strainer bushing or seat plug
onto cage.
Assemble Petrovalve Plus
units at the bench.
Pump valve spacing per API
“Recommended Practice
11AR”.
Petrovalve Plus recommends
API “Torque Make Up
Specifications”
Materials – Sphere/Seat
440C
TC
NC
Ti
S.L.
Ceramic
Stainless Steel
Tungsten Carbide
Nickel Carbide
Titanium
Silicon Nitrate
Ceramic
FLOW AREA COMPARISON
PETROVALVE PLUS vs. INSERT (API) VALVE
VALVE SIZE
(IN)
PETROVALVE
(IN2)
INSERT VALVE (API)
(IN2)
AREA INCREASE
(%)
1.25
0.236
0.166
42
1.50
0.425
0.292
45
1.75
0.598
0.353
69
2.00
0.726
0.569
27
2.25
0.826
0.568
45
2.75
1.432
0.935
53
3.25
2.221
1.068
107
3.75
2.896
1.394
107
4.75
4.863
—
—
5.75
7.703
—
—
NOTE: These calculations are strictly cross-sectional flow
areas and do not relate to flow dynamics.
GAS BREAKER
THE MECHANICAL TRAVELING
VALVE THAT ENDS GAS
LOCK PROBLEMS
Petrovalve Gas Breaker
High Temperature Production
The Petrovalve Gas Breaker eliminates
gas/steam-lock problems common in many
thermal and non-thermal well pumping
operations.
The Petrovalve Gas Breaker is designed
for use as the traveling valve in thermal
and non-thermal well pumping
situations. The Petrovalve Gas Breaker
is also very useful in natural gas wells
producing fluids, as it facilitates the
pumping of gasified fluids on a
continuous basis.
The Petrovalve Gas Breaker was
developed to combat this problem. As an
extension of the Petrovalve Plus, the Gas
Breaker (used in the traveling valve
position) mechanically opens at the end of
each pump cycle if the pump is gas locked.
This allows the gas to migrate out of the
pump into the tubing, leaving the pump
barrel filled with fluid. New oil can then
enter the pump on the up stroke. The
automatic opening is accomplished when
the extended bottom stem on the traveling
valve contacts the trip sub (modified barrel
connector).
Deviated and Horizontal Wells
Field installations confirm that the efficiency
of pumps incorporating the conventional
valve system drop as the angle of the pump
from vertical position increases. Efficiency
levels at angles greater than 35o are
extremely low. Under such conditions, the
hydrostatic weight of the fluid in the well
bore between the horizontal and the vertical
positions restricts the pay zone’s ability to
produce fluid.
The Petrovalve system is designed to allow
high efficiency pumping in any position.
Our guided valves work as effectively
horizontally as they do vertically by keeping
the seating surfaces aligned at all times.
Use of the Petrovalve Gas Breaker reduces
valve failures and service costs.
Deep Well Applications
Deep well applications present no
problem for the Petrovalve Gas Breaker.
The valve is designed to accommodate
rod stretch through the extended bottom
shaft. This makes the system easy to
install and simple to operate.
GUIDE
TOP
CAGE
CAGE
DAMPER SPRING
(IF REQD.)
PLUNGER
SEAT
FL
OW
GUIDE
GAS BREAKER TRAVELING
VALVE ASSEMBLY
SEAT PLUG
1.25” to 2.75’’ Gas Breaker
(Long or Short) Installation
Procedures
1. Install guide fully against the top
profile in the cage (guides are
reversible).
2. Install Gas Breaker plunger with
flat side of hemisphere and
damper spring (if reqd.) facing
top guide.
3. Install seat against the profile in
the bottom of cage (seats are
reversible).
4. Install bottom guide against seat.
5. Tighten seat plug onto cage.
BOTTOM
Additional Notes
Materials – Sphere/Seat
1. Assemble Gas Breaker units at
the bench.
2. Pump valve spacing per API
“Recommended Practice 11AR”.
3. Gas Breaker recommends API
“Torque Make Up Specifications”.
440C
TC
NC
Ti
S.L.
Ceramic
Stainless Steel
Tungsten Carbide
Nickel Carbide
Titanium
Silicon Nitrate
Ceramic
Installation Procedure for
the Petrovalve Standing
Valve and Gas Breaker
Traveling Valve
PLUNGER
STEP 1:
A) Assemble Petrovalve standing
valve per Petrovalve standing
valve assembly.
GAS BREAKER
TRAVELING
VALVE
B) Install assembled Petrovalve
standing valve complete with trip
sub onto barrel.
STEP 2:
A) Assemble Gas Breaker traveling
valve as shown in Gas Breaker
traveling valve assembly.
B) Attach Gas Breaker traveling
valve onto plunger and insert
fully into pump until traveling
valve meets trip sub. (Leave at
least 3” to 4” of rod above valve
rod guide.)
BARREL
TRIP SUB
STEP 3:
A) With Gas Breaker traveling valve
against trip sub, cut valve rod
1/2” above the highest point of
valve rod guide.
PETROVALVE
STANDING
VALVE
B) Thread 5/8” of valve rod and
attach supplied rod bushing.
The Gas Breaker traveling valve
automatically opens at the end of
each cycle if the pump is gas locked,
allowing trapped gas to escape from
the pump. Maintaining a liquid filled
pump is essential to achieve efficient
operations. The Gas Breaker
performs best when installed with a
Petrovalve in the standing valve
position.
Stainless steel housings
available upon request
for standard sizes.
Petrovalve Gas Breaker
Suggested Field
Operating Procedures
VALVE ROD
BUSHING
VALVE ROD
GUIDE
1. Space out the pump and maintain
6 to 8 inches off tap. Start up and
monitor operation during the initial
24 hours or until recovery of kill
and load fluids.
2. To ensure the Petrovalve Gas
Breaker becomes operational,
adjust the rod string spacing until
a very slight tap is felt on the polish
rod at surface.
HOLD DOWN
ASSEMBLY
BARREL
3. Pick up rod string 1/2 inch and
resume pumping. At this point
there should not be a tap felt at
surface on the polish rod.
4. Monitor pumping to ensure that no
pump tap is occurring.
PLUNGER
NOTE: If a slight tap can still be felt at
surface on the polish rod, raise rod
string an additional 1/2 inch.
We recommend a Petrovalve
representative be on hand for initial
customer pump assembly and
installation.
Petrovalve will work
closely with customers’ pump shop
and rig crews.
BARREL CONNECTOR
TRIP SUB
STANDING VALVE
STRAINER BUSHING
STANDING
PETROVALVE
STANDING PETROVALVE
CAN FIT ANY LIFT SYSTEM
COMPLETION CONSIDERATIONS
PLUNGER LIFT
TYPICAL PLUNGER L.
PIG LIFT
SUCKER ROD PUMPING
INSERT PUMP
TUBING PUMP
DUAL PUMP
GAS LIFT
SINGLE ZONE
CHAMBER LIFT
PCP
PCP INJECTION
PCP PRODUCTION
ELECTROSUBMERSIBLE
REGULAR ESP’s
HYDRAULIC PUMPING
JET PUMP
PISTON PUMP
SURFACE APPLICATION
BACK PRESS VALVE
RELIEF VALVE
CHOKE – REGULATOR
“N” LOCK MANDREL
AND STANDING PETROVALVE ASSEMBLY
UPPER LOCKING MANDREL
NO GO WITH EQUALIZING SUB
PETROVALVE PLUS (SV)
TUBING PUMP THM
DRAINAGE
TOOL
COLLECTOR
STANDING
PETROVALVE
PCP DOWNHOLE WATER INJECTION TOOL
GAS TO SURFACE
GAS / WATER
PRODUCING
ZONE
PROGRESSING
CAVITY PUMP
DOWNHOLE
INJECTION TOOL
WATER FLOW
INTAKE
DISCHARGE
BACK PRESSURE PETROVALVE
TUBING
ON / OFF
PACKER
INJECTION /
DISPOSAL ZONE
HYDRAULIC PUMPING EQUIPMENT
TRIPLEX PUMP
FOUR-WAY VALVE
PRODUCTION CASING
PACKER & NOSE
BOTTOMHOLE ASSEMBLY
PISTON OR JET PUMP
STANDING PETROVALVE
PACKER
GAS LIFT
FLOW CONTROL
VALVE
FLOW CONTROL
VALVE
SIDE POCKET MANDRELS
AND GAS LIFT VALVES
SIDE MANDREL
FOR CHAMBER LIFT
DUAL OR BYPASS PACKER
SIDE POCKET MANDREL
W/ DIFFERENTIAL VALVE
LIFT GAS
PERFORATED POP JOINT
PACKER
LOWER PACKER
STANDING PETROVALVE
STANDING PETROVALVE
SINGLE ZONE GAS LIFT
CHAMBER LIFT INSTALLATION
PLUNGER LIFT SYSTEMS
FOR INTERMITTENT GAS LIFT
PLUG VALVE
LUBRICATOR
CATCHER
SALES
MASTER VALVE
PLUNGER CONTROLLER
AND MOTOR VALVE
LIQUID LOAD
SUBSURFACE PLUNGER
BUMPER SPRING
RETRIEVABLE TUBING STOP
STANDING PETROVALVE
PIG LIFT
TO
TO SEPARATOR
SEPARATOR
SUPPLY GAS
LINE
PRESSURE
SENSOR
PRODUCTION STRING 1
PRODUCTION STRING 2
COUPLING
STANDING PETROVALVE
TOP
TOP ADAPTER
GUIDE
CAGE
PLUNGER
SEAT
GUIDE
FL
OW
STANDING VALVE ASSEMBLY
HANDLING INSTRUCTIONS FOR
TUBING INSTALLATION
BOTTOM
BOTTOM ADAPTER
3.25” Petrovalve Plus
Installation Procedures
1. Install guide fully against the top
profile in the cage (guides are
reversible).
2. Tighten top adapter onto cage.
3. Install Petrovalve Plus plunger
with flat side of hemisphere facing
top guide.
4. Install seat against the profile in
the bottom of cage (seats are
reversible).
5. Install bottom guide against seat.
6. Tighten strainer bushing or bottom
adapter onto cage.
Additional Notes
Materials – Sphere/Seat
1. Assemble Petrovalve Plus units at
the bench.
2. Pump valve spacing per API
“Recommended Practice 11AR”.
3. Petrovalve Plus recommends API
“Torque Make Up Specifications”.
3.25” Valve Thread required
torque is 250# with 36” length of
handle.
4. Assure the installation is in the
direction of flow. Arrow is on the
housing (cage) of the tool.
440C
TC
NC
Ti
S.L.
Ceramic
Stainless Steel
Tungsten Carbide
Nickel Carbide
Titanium
Silicon Nitrate
Ceramic
PETROVALVE CAGES
OPEN CAGES
STANDING SCREW
TOP TRAVELING
STANDING TEE
CLOSED CAGES
TRAVELING & STANDING
PETROVALVE
GASBREAKER (LONG)
GASBREAKER (SHORT)
PETROVALVE STANDARD CAGE MATERIALS INCLUDE:
- 8620 ALLOY FOR STANDARD SERVICE
- 420, 410 & 316 STAINLESS STEEL FOR CORROSIVE ENVIRONMENTS
ALL OTHER CAGE MATERIAL AVAILABLE UPON REQUEST
Well Data Sheet
Well Number:
Date:
Company:
Location:
Field:
Phone:
Fax:
Email:
Field Foreman:
Department:
Number of Wells in Area:
Name of Production Zone:
Casing Size:
Tubing Size:
Completion:
( )Natural ( )Acidized ( )Frac'd
( )Surfactant ( )Other
Prod. Method: ( )Rod Pump ( )Gas Lift ( )Other
Production Rate:
( )Oil ( )Water ( )Gas
Secondary Tertiary Method:
Temperature:
Formation Type:
Paraffin, Wax:
Asphalt Sludge:
Corrosion Type:
Oil Characteristics
Content of Sand:
Content of H2S:
Content of CO2:
Scale
CaCo3:_______ CaSO4:_______ MgCO3:_______ BaSO4:_______
Gas Oil Ratio (GOR):
Gas Liquid Ratio (GLR):
Water Cut (%):
Water Salinity (ppm):
CI (ppm):
API Fluid Gravity:
Production Before Petrovalve Installation:
Fluid Level:
Others:
Operating Condition Before Petrovalve Installation
Pump Type:
Description API:
Pump Depth:
Perforations Depth:
Well Temperature:
Traveling Valve Size:
Standing Valve Size:
Pump Anchor Type:
Material Used for Standing Valve:
Material Used for Traveling Valve:
Material Used for the Plunger and for the Barrel:
Plunger Length:
Plunger Diameter Size:
Barrel Length:
Barrel Diameter Size:
Strokes per Minute Pumping (spm):
Pump Stroke Length:
Spacing:
Beam Pumping Unit Type:
Model:
Reason for the Change:
Supply Dynamometer Chart Before and After Petrovalve Installation:
Number of Pump Pulling Per Year Per Well:
Other Observations:
Manufacturing:
FeSO4:______ _
JUNE 2004
The “Better Business” Publication Serving the Exploration / Drilling / Production Industry
Operators Look For Production Boost
By Brian Schaible
Special Correspondent
Drilling operations tend to get all the
attention, but at the end of the day, every
operator knows it is production that pays
the bills. So even as operators ramp their
drilling programs, they are keeping a
sharp eye on the performance of their
producing wells and working to optimize
daily outputs. Fortunately, new artificial
lift technologies are helping operators
produce their oil and gas wells better,
smarter and more profitably.
Operators want equipment that is simple, easy to maintain, yet appropriate for
the task of maximizing production efficiencies. They want sensors and data
transmission that will tell them the equipment is doing its job, or point the way to
adjustments that will improve efficiency, and therefore improve the bottom
line.
Equipment providers note a trend toward versatility as well. Supply companies
are modifying traditional oilfield applications to boost production in nontraditional
environments, such as heavy oil extraction
and dewatering of coalbed methane formations.
With electricity and other operating
costs on the rise, operators are demanding more capability at lower cost. Service companies have been quick to respond, offering trimmed-down versions
of equipment such as dynamometers capable of meeting specific needs while
avoiding extra, unused features. This tailoring of equipment to the job at hand is
particularly beneficial to marginal well
operators, where uncontrolled costs may
threaten the viability of the well. Simple
things such as cableless installation of a
controller not only save money, but enhance job site safety. A reduced-function
pump-off controller can bring economical on/off control to stripper wells that
has heretofore only been justified for rod
pump wells. Simple conversion equipment can turn idle pumping unit engines
into inexpensive, small volume compressors ideal for stripper wells.
Finally, artificial lift applications are
benefiting from equipment that can improve the economics of a well by doing
tasks in less time.Appropriate threading,
Petrovalve Plus from Petrovalve replaces the ball of a
sucker rod pump system with
a hemisphere design. The new
system increases flow area
through the valve and cage
body, and adds guides to ensure proper seating.
coloring, and labels on polished rods reduces inventory requirements and eliminates down time caused by delivering
the wrong rod to the field. New plunger
design allows operators to trip their well
without shutting it in, yielding three or
four more trips a day. A simple change
in ball design allows more fluid to flow
around the ball, giving the operator more
production from the same number of
strokes.
Better Ball And Seat
Ball and seat failure is the most common cause of down time for sucker rod
pumping systems. The ball and seat design also can limit fluid flow and create
pumping inefficiency when the ball is
knocked off the seat. Petrovalve’s Petrovalve Plus replaces the ball with a hemisphere design that increases flow area
through the valve and cage body, and adds
guides to ensure proper seating, according to Garry Tucker, NorthAmerican sales
manager.
“Our hemisphere, or half-sphere, is
guided on a stem that is held in place by
two guides, so it has to go straight up and
down to the same spot with each stroke,”
he indicates. “A regular ball can bounce
around on the seat within the cage. Further, the hemisphere allows more liquid
to flow around than a conventional ball.
The operator can get more production
out of the same number of strokes, or he
can maintain the production rate while
slowing the pump, which reduces lifting
costs.”
Although the valve originally was designed for rod pumped wells, Tucker says
it has been used to good advantage in
other types of artificial lift, including gas
lift, chamber lift, plunger lift, hydraulic
and ESP installations, and steam flood.
The design has been particularly effective in horizontal and deviated wells, he
Reprinted in part for Petrovalve with permission from The American Oil & Gas Reporter
Special Report: Artificial Lift Technology
notes.
“With a horizontal well, when a ball
comes off the seat, it tends to fall and hit
the side of the cage,” he explains. “Since
our system is guided, when the plunger
rod moves down, it pushes the hemisphere directly onto the seat through the
guides. The angle of the well bore doesn’t affect performance.”
In heavy oil situations where reservoir pressure is typically low, the increased flow area created by the valve
improves pump and annulus fillage.
Tucker says operators can combine
the valve with the Petrovalve Gas Breaker to improve results in wells that have
a problem with gas lock.
“This product is basically a traveling
valve connected to the plunger and rods,”
he observes. “As it comes down, it tags
the extended stem on the standing valve,
which pushes the hemisphere off-seat.
That basically ‘burps’ the valve, allowing
the gas to flow and eliminating gas locking. This system has been very effective
with older wells that have this problem.”
Tucker cites an example of a well in
Grady County, Ok., which suffered trash
and gas interference problems. The best
24-hour production off a 1¼ inch pump
was 12 barrels of oil and 100 Mcf of gas.
The well was averaging only six weeks
of pump runs before repairs were needed. The operator installed the Petrovalve
and Gas Breaker, and production increased to 18 barrels and 250 Mcf a day.
The pump run increased to nine months.