Circulating Valve

Thru-Tubing Standard Tools

Joe DeGeare, in The Guide to Oilwell Fishing Operations (Second
Edition), 2015
Dual-actuated circulating valve
A dual-actuated circulating valve (Figure 22-5), developed mainly for
coiled tubing workover-motor applications, has a traditional sleeve
valve-opening mechanism with a rupture-disk port below the sleeve
valve. The rupture-disk port allows circulation through the coiled
tubing if the workover motor gets plugged with debris. If this occurs,
pressure applied to the coiled tubing will blow out the side-mounted
disk when rupture pressure has been reached.

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Figure 22-5. Dual-actuated circulating valve.
(courtesy of Baker Oil Tools)
Rupture disks are available in many different pressure ratings, and
one should be selected with rupture pressure just below the safe
surface limit for coiled tubing internal pressure set by the operator.
Once the rupture disk is blown out, a ball can be circulated through
the coiled tubing string to the sleeve valve above the rupture disk.
Applying coiled tubing pressure again will open this valve and large-
area flow ports.
The dual-actuated circulating valve serves three main purposes in
workover-motor applications. They are as follows:
●
It provides a flow path through the coiled tubing if the motor
becomes plugged during operation.
●
It provides a large-area flow path out of the coiled tubing during
hole cleanup after milling or underreaming. This prevents flowing
through the workover motor, which creates additional back
pressure and increases wear on the motor.
●
It diverts fluid flow through the coiled tubing to the annulus above
the workover motor when pulling out of the hole. This prevents
the motor from spinning when it comes out of the hole.
Read full chapter
Well Completion Tubing String
Wan Renpu, in Advanced Well Completion Engineering (Third
Edition), 2011
High-Pressure High-Rate Gas Well Completion Tubing String
In order to ensure safe production, the main structure of a high-
pressure high-rate gas well completion tubing string includes
subsurface safety valve, circulating valve, telescopic joint, and
permanent packer. Some gas wells had used 7-in. casing tieback, 4
1/2-in. tubing string (Figure 9-36) and 5 1/2-in. tubing string (Figure 9-
37). A 7-in. completion tubing string has been adopted to control gas
flow velocity to mitigate the abrasion and erosion of the casing by gas
(Figure 9-38).
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Figure 9-36. Well completion tubing string in some wells (7-in. casing and 4 1/2-in.
tubing).
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Figure 9-37. Five and one-half-inch completion tubing string. 1, 4 1/2-in. pressure-
transmitting pipe; 2, 20-in. conductor; 3, 5 1/2-in. subsurface safety valve and flow
nipple; 4, 13 3/8-in. intermediate casing; 5, 9 7/8-in. production casing; 6, 5 1/2-in.
tubing; 7, crossover joint (5 1/2-in. internal thread × 7-in. external thread); 8, 7-in. × 9
7/8-in packer + milling extension pipe; 9, ball sealer seat; 10, seal plug-in pipe + tieback
seal bore; 11, 7-in. × 9 7/8-in combination liner hanger-packer; 12, 9 7/8-in. × 7-in. liner
hanger; 13, 7-in. × 4 1/2 thread change joint; 14, 4 1/2-in. tubing screen; 15, 114-mm
perforating gun assembly; 16, 7-in. liner.
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Figure 9-38. Seven-inch completion tubing string. 1, 4 1/2-in. pressure transmitting pipe;
2, 20-in. conductor; 3, 7-in. subsurface safety valve and flow nipple; 4, 10 3/4-in. casing;
5, 13 3/8-in. intermediate casing; 6, 9 5/8-in. production casing; 7, 7-in. tubing; 8, 7-in. ×
9 7/8-in. packer + milling extension pipe; 9, ball sealer seat; 10, seal plug-in pipe +
tieback seal bore; 11, 7-in. × 9 7/8-in combination liner hanger-packer; 12, 9 7/8-in × 7-
in. liner hanger; 13, 7-in.× 5-in. thread change joint; 14, 5-in. tubing screen; 15, 114-mm
perforating gun assembly; 16, 7-in. liner.
Read full chapter
Production Engineering
In Standard Handbook of Petroleum and Natural Gas Engineering
(Third Edition), 2016
6.4.3.2.9 Cleaning the System
In a free-type installation, the system can be cleaned by, circulating
fluid after installing the tubing standing valve and before installing the
pump.
In a fixed type installation, however, this is not possible so
a circulating valve, starting filter assembly and check valve are
normally used. The circulating valve, when run, is placed in the
circulating position. This permits fluid to be circulated down the tubing
string, but it is prevented from going to the pump. When the circulating
time is finished, a ball is dropped down the tubing string and lands in
the circulating valve. Pressure causes a sleeve in the valve to shift
which shuts off the circulation ports and permits the power fluid to flow
through a starting filter and on to the hydraulic pump.
Read full chapter
Marine Petroleum (Gas) Engineering and Equipment
Huacan Fang, Menglan Duan, in Offshore Operation Facilities, 2014
3.22.8 Incision
It has been used widely at the offshore fields that the hydraulic cutting
tools installed at the coiled tubing cut off various downhole strings. For
example, the hydraulic tubing cutter installed at the bottom of the
downhole power drilling tools can cut off the production tubing. When
operating, the motor and cutting knife are driven by the circulated fluid
through the coiled tubing. The assemble is shown in Figure 3-157.
The coiled tubing is connected with a set of the tool strings which
includes the hydraulic release tool, a hydraulic centralizer, a double
acting circulating valve, a hydraulic motor and a hydraulic tubing cutter
and so on. The hydraulic motor consists of three pieces of the
hardening steel hydraulic cutting knives. When completing the cutting
operation, the hydraulic pressure make the knives return back and it
can be pulled out. The hydraulic tubing cutter can cut the tubing with
the diameter of about 48∼88.9 mm (1.9∼3 ½ in). The hydraulic tubing
cutter is driven by the piston of the hydraulic cylinder. When the piston
pushes outward, the hydraulic cutting knives stretch out and are
touched with the tubing. Conversely, the hydraulic cutting knives
return back. The double acting circulating valve controls the position of
the hydraulic centralizer by changing the flow of the circulating fluid.
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FIGURE 3-157. Combination of tools for coiled tubing cutting operation.
In addition to these purposes, coiled tubing technology can also be
used for logging operations in the completion process, perforation
jobs, sand control for tubing, etc.; at the same time, in the process of
drilling, it can also be used for the deepening of old wells,
sidetracking, new well drilling and drilling open holes in marginal
regions, etc. In addition, if the original production string cannot be
used in ordinary jet pump wells, we can also adopt the coiled tubing
jet pump technology. Thus, the popularization and application of coiled
tubing technology should continue to be important in China.
Read full chapter
Well-Site Operations
Paul J. Nardone, in Well Testing Project Management, 2009
Establishing an Underbalance
A final task prior to firing the TCP guns is the introduction of the
underbalance so that the reservoir fluids can flow to surface. Diesel is
a common underbalance fluid and is readily available on most facilities
in the quantities desired. Resources needed for this operation include
the rig cementing services unit and a supply of diesel from the motor
room. Because this operation involves interfaces between several of
the services on the facility and the well test crew, the procedure
should address the interface issues, which include;
•
The rig safety management system or permit to work system
•
Communication and overall responsibility for the transfer
operation
•
Other controls and measures to manage the operation including
•
Pressure testing of lines and valves critical to the operation
•
Methods for monitoring volumes pumped and volumes returned
•
Storage of fluid returns, including the use of the trip tank and pits
•
Pressures indicating underbalance and U-tube pressure
•
Contingency procedures in the event of valve closure, leak, or
seal failure
Before the operation commences, the well test engineer will perform a
calculation to determine the volume of diesel required to achieve the
desired underbalance pressure, leaving an adequate safety margin to
ensure diesel is not accidentally displaced through the circulating
valve and into the annulus.
To displace the fluid in the test string with underbalance fluid, a valve
providing tubing to annulus communication near the bottom of the test
string is opened. Depending on the valve design, this is usually
achieved with tubing pressure cycles. As a preliminary step, a volume
of water is pumped to the test string prior to the diesel to ensure the
correct valve lineup; returns taken from the annulus to the trip tank
provide the necessary indication. Once the correct valve configuration
has been confirmed with fluid returns to the trip tank, the diesel supply
is direct to the pump and displaced to the test string, pushing the
heavier kill weight fluid into the annulus. The returned fluid is
recovered back to the facility trip tank, and the volumes are monitored
to ensure the desired displacement is achieved. During the
displacement, the well test engineer will direct the cement unit
operator not to exceed preset limits for pump rate and pressure. This
ensures no other valves downhole are operated accidentally. The
downhole circulating valve is then closed in preparation for the test.
The procedure will include all the steps necessary to operate the valve
as per the contractor's procedures.
The above procedure assumed diesel as the underbalance fluid, but
other fluids including water, base oil, and nitrogen gas essentially
involve the same downhole valve manipulations.
Pretest Safety Meeting
Just prior to perforating TCP guns and opening the well to production,
a thorough pretest safety meeting must be held to ensure that all
safety controls are in place and personnel are aware of operations
and their responsibilities.
This safety meeting is attended by all parties connected with the well
test, including facility management, resource company
representatives, the driller and floor hands, service contractors, and
deck crew. Typically, the meeting takes place on the drill floor and
takes 20 to 30 minutes to ensure thoroughness. The meeting is
normally facilitated by the well test engineer using a checklist of well
test safety-related items to ensure all points are covered. The
checklist includes a sign-off upon completion.
The topics covered by the checklist include
 •
Permit to work for well test operations
•
Responsible personnel and communication focal points
•
Review of sequence of operations, expected flowing conditions,
and durations
•
Review of operation of emergency shutdown system, who is
authorized to operate it, and under what circumstances
•
Emergency response during a well test
•
Review of metocean conditions, wind direction, and sea state
•
Final check and confirmation of equipment readiness and valve
alignment
An example pretest safety checklist, provided in the appendices.
Read full chapter
Well Completion Mode Selection
Wan Renpu, in Advanced Well Completion Engineering (Third
Edition), 2011
Monobore Well Completion
The hole structure of a traditional oil and gas well includes two flow
channels: the tubing used for oil and gas production and the tubing–
casing annulus used for circulation and well killing [see Figure 2-
42(a)]. The hole structure of a monobore well has only a flow channel,
that is, tubing [see Figure 2-42(b)]. This hole structure can save the
drilling and completion equipment and tools, such as casing, packer,
and circulating valve, and the operating procedures of running these
equipment and tools. In addition, the perforated completion operation
of monobore well completion does not take up rig time, thus reducing
drilling and completion costs greatly. However, the problems of well
killing, lifting, induced flow, and plugging will occur when the
monobore hole structure is used; as a result, the monobore well
completion application is restricted to some extent. The monobore well
completion technique is mainly applicable to oil wells flowing in whole
production life, especially to gas wells. For gas fields with low
reserves, low permeability, a low individual-well production rate, and
no sand production, the investment can be reduced greatly by using
this completion technique, thus achieving better economic benefit.

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Figure 2.42. Hole structures of a traditional oil and gas well (a) and monoborne oil and
gas well (b).
Good Results Obtained in Gulf of Thailand
The geological features of the Gulf of Thailand include continental
deposit, cataclastic structure, more faults, low oil and gas reserves,
and lower individual-well production rate. By adhering to the low-cost
strategy and uninterrupted technical innovation, Unocal has
implemented a series of measures with the monobore well completion
technique as the kernel and has acquired great success in oil and gas
exploration and development.
More than 80 wellhead platforms have been built, and more than 1600
wells have been drilled by Unocal in the Gulf of Thailand (Figure 2-
43). In 1983–2002, the hole structure of the wells drilled in the Gulf of
Thailand had been improved many times and well completion with
Φ73-mm tubing had been achieved. The borehole size changed from
large to small, and the hole structure decreased from four to three
layers. Using the monobore well completion technique, the well
construction period of the oil and gas fields in the Gulf of Thailand was
shortened and well construction costs were decreased, as shown
in Figure 2-44. The further significance of reducing drilling and
completion costs is that the saved costs increased the quantity of
wells drilled and completed, and more oil and gas reserves were
found.

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Figure 2.43. The hole structure improvements of wells drilled by Unocal in the Gulf of
Thailand.

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Figure 2.44. The operation technique improvements and corresponding well
construction period and drilling and completion cost changes of Unocal in the Gulf of
Thailand in 1980–2002.
Main Features of Monobore Well Completion
(1)
The monobore well completion technique decreases borehole
size. Production casing size is decreased from Φ177.8 mm
(7 in.) to Φ73 mm (2 7/8 in.). The matching techniques and tools
have been had.
(2)
When the monobore well completion technique is used for
development well drilling and completion, tubing may be run in
and the well cemented after drilling. Then the drilling rig and drill
vessel can be evacuated from the site and the through-tubing
wireline perforating can be conducted on the well site or
platform, thus the rental of a drilling rig or drill vessel can be
decreased.
(3)
The monobore well completion technique can also be used for
drilling exploration wells. For conventional well completion,
during a drillstem test [Figure 2-45(a)], a series of downhole
tools, including packer, circulating valve, jar, and killing valve,
should be run in, long running-in and pulling-out time and a large
amount of materials will be consumed, and high costs are
required. Under monobore well completion [Figure 2-45(b)], after
tubing running-in, cementing, and wireline perforating, testing
may be conducted. When testing of the lowest zone is ended, a
bridge plug is set at its top to conduct testing at the next zone.
After the testing task is finished, a bridge plug is set at the
uppermost zone and the upper tubing is cut using cutting bullets.
After the cement plug is set using tubing string, the exploration
well operations may be finished. By comparison with the string
operations, the wireline operations are quite timesaving.

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Figure 2.45. Conventional DST (a) and monobore structure tubing (b) testing
diagram.
(4)
The monobore well completion technique changes operation
mode from the traditional bibore operation mode able to conduct
circulating well killing to the monobore operation mode able only
to conduct squeezing well killing. In order to solve the difficulty of
induced flow of oil and gas in the production well, in addition to
coiled tubing for induced flow, diesel oil can also be used as the
tail slurry for cementing. The underbalance condition may be
formed by diesel oil in the wellbore, thus the well can be put into
production just after perforating.
(5)
If monobore well completion is adopted, the downhole safety
valve is run in before the cementing operation and may be
affected negatively by the cementing fluid. Therefore, the
downhole safety valve should be moved many times in the
cementing operation process in order to prevent the safety valve
from being stuck by the cementing fluid.
(6)
For wells completed using the monobore well completion
technique, operations including perforating, setting bridge plug,
induced flow operation, and downhole safety valve servicing
operation may only be conducted using wire, wireline, and coiled
tubing, and because the well servicing operations of running or
pulling string cannot be conducted, higher quality wire and
wireline operations are required.
(7)
The monobore hole structure has no traditional circulating and
killing channel, thus generating oil and gas well operation risk to
some extent. However, the experiences of a large number of
applications in the Gulf of Thailand indicate that this risk may be
controlled by installing a downhole safety valve and taking other
risk-controlling measures so that the operations are also safe.
(8)
 The monobore hole structure is simple and the operational
measures are limited. If downhole problems occur and repair is
needed, the side-tracking method may often be used but not
traditional repair measures. Hence, the requirement of side-
tracking should be considered when the cement return height is
designed in the cementing design.
During the monobore well completion operations, the matching
technology and management concept optimization, including large-
scale, three-dimensional seismic survey and interpretation for
enhancing the accuracy of reservoir interpretation, integrally
completed well-site design for batch drilling and centralized drilling
wells with the same borehole size, using more logging while drilling for
decreasing wireline logging, drilling two monobore wells within the
same marine riser for reducing surface engineering and riser building
costs, and optimizing the drilling rig evacuation and emplacement and
the drilling fluid properties, for enhancing integral benefit of the
monobore well completion technique, is required. Drilling two
monobore wells within the same marine riser and the monobore well
drilling and completion technique are shown in Figure 2-46.

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Figure 2.46. Drilling two monobore wells within the same marine riser and the monobore
well drilling and completion technique.
In general, monobore (2 7/8-in. tubing) well completion is relatively
suitable for gas wells of gas fields that have low reserves, low
permeability, low individual-well production rates, no sand production,
and no need of dewatering gas production for the following reasons.
1.
The gas production of gas wells is generally flowing production.
2.
The downhole operation workload is relatively low during the gas
production of gas wells.
3.
The downhole technology and tools, including perforating and
separate-zone testing, have been matched for 2 7/8-in. tubing
well completion.
4.
When the 2 7/8-in. tubing well completion is adopted, a 7-in.
intermediate casing is needed to be run to some depth in order
to produce the remaining natural gas by late side-tracking if
necessary.
A large amount of investment can be saved and better economic
benefits of gas field production can be achieved by adopting
monobore well completion. However, for the oil fields of pumping
production, small-hole oil production is limited by reservoir depth and
has to solve downhole production technology and tool problems;
therefore, specific studies and economic benefit analysis should be
conducted in accordance with the practical conditions of the field and
then a strategic decision can be prudently made