Tubing Retrievable Safety Valves

Troubleshooting Procedures
The following information has been put together to assist operators in troubleshooting Halliburton Tubing
Retrievable Safety Valves (TRSV). The information includes a breakdown of various problems that may
occur with a tubing retrievable flapper valve and the steps that can be taken to uncover the source of the
problem. Steps to remedy the problem are given in an effort to make the valve functional again.

Problems addressed are:

• TRSV does not open; control system has no leaks.
• Manifold continues pumping slowly when the TRSV is open or the TRSV cannot be opened due
to control pressure leakage.
• TRSV does not close.
• Unacceptable leakage across the TRSV closure mechanism (pressure build-up in the tubing
above the closed TRSV).

To Determine Piston Movement

Checking the piston displacement volume

Disconnect the control line from the manifold and attach it to a hand pump so that volumes can
be measured and strokes counted accurately. When the 1/4 inch control line is used to furnish
pressure to a TRSV, there is a definite indication on the surface that the valve is opening. As the
control line is pressured, there is an initial volume required to compress any air or gas in the
system and then the pressure starts up rapidly. As the pressure increases to a point above
tubing pressure (point 1 in Figure 1), the control line pressure levels out for a period of strokes of
the pump as the piston moves down, opening the TRSV ( from points 1 through 2 in Figure 1).
This is referred to as leveling off.

Once installed in a well, each valve has a characteristic curve. The total number of strokes can
vary slightly, depending on how solid the column of fluid is in the control line; however, the curve
remains basically similar. If the valve only partially opens, it has a similar pattern, but the
number of strokes between points 1 and 2 is considerably less than if the valve is fully opened.
If the valve is not moving open at all, there is no "leveling off" of pressure. Once it begins to
increase, it increases approximately the same amount with each stroke.

The volume required to move the piston to the full open position (piston displacement volume) is
listed in the Engineering Data Sheet. The displacement per stroke of the pump being used may
be checked by pumping fluid from the pump into a graduated cylinder or measuring cup. By
counting the number of strokes of the pump, the volume of control line fluid pumped can be
estimated. By comparing this volume to the piston displacement volume, the piston movement
can be determined.

If this procedure is used, the closure device must be fully equalized to allow piston movement. If
possible, the valve should be pumped through continuously at a slow to moderate rate during the
procedure. This will ensure that pressure is properly equalized across the closure device.

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 Pressure Curve for
Halliburton Safety Valves

1. Start to Open
3
2. Full Open Pressure
3. Hold Open Pressure
Pressure 4. Start to Close
5. Full Close Pressure

Piston Travel Piston Travel

4
Tubing Pressure

Control Line Pressure

Time
Figure 1
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Problem:

The valve not opening, control system has no leaks.

Follow the operating procedure closely to ensure that proper control line pressure is applied and
that the closure mechanism is fully equalized.

Check for a problem in the hydraulic manifold.

1. Remove the manifold from the system.
2. Use a hand pump to operate the valve.

Check the control line for air or gas.

1. Pressure the control line to 4,000 psi and hold for 20 minutes.
2. Slowly bleed off the control line pressure and observe for any passage of air or gas.
3. Repeat steps 1 and 2 until the control line returns are only fluid.
4. Perform the “Opening Procedure.”

Cycle the control line pressure to free the operation mechanism.

1. Determine the piston movement.
2. Cycle the control line pressure from 0 to 4,000 psi above the tubing pressure ten times while
continuously pumping through the closure device to ensure equalization. Use fresh water if
possible as this may wash sand or debris from the operating mechanism.
3. Check the piston movement to determine if the valve opens further.
4. Repeat at least once.

Increase the control line pressure to attempt to free the operating mechanism. Maximum control
line test pressure for this procedure for the TRSV can be calculated as follows:

Maximum Control Line Pressure = TRSV Working Pressure + Opening Pressure

1. Cycle the control line pressure from 0 to the maximum determined in (2) above, measuring
the volumes to determine piston movement.
2. Do not exceed the maximum control line pressure.

Use an Exercise Tool or Check Open Tool to attempt to open the TRSV.
Note: Some TRSV designs do not include an exercise profile. Check design specifications to
confirm.
1. Refer to the procedure for running the Exercise Tool or Check Open Tool
2. If the TRSV opens, allow it to close and cycle it normally.

The TRSV should not be returned to production mode unless it opens/closes properly by
applying/bleeding control pressure.

If the TRSV is still not operable by the control line pressure only, refer to the “Procedure for
Locking TRSV Open.” If the TRSV is locked open, submit a full written report to Halliburton
Carrollton on circumstances, personnel, and tests conducted.

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Manifold continues pumping slow when the valve is open.

Check the Manifold.

1. Close the needle valve at the tree.
2. Start up the pump. It should build up pressure immediately and stop.

Check for possible leaks.

1. Set a positive plug in the top sub of the tubing-retrievable flapper valve and bleed the tubing
and control line to zero.
2. Use a hand pump on control line.
3. Pressure up the tubing string. If the control line pressure increases, then a possible leak in
the hanger is present.
4. Pressure up the control line. If the pump must be stroked to maintain pressure above the
well shut-in pressure, then there is a leak between the control line and the casing in the
hanger or annulus and/or there is a leak in the valve packing.
5. Pressure up the casing, if possible, and observe for an increase in control line pressure
indicating a control line-to-casing leak.
6. Maintain pressure on the control line to ensure that the valve is open. Set an isolation
assembly across the valve. If the control line pressure stabilizes, then the source of the
problem is probably a leak in the valve.

If any of the above steps indicate possible leakage in the hanger, advise the oil company representative
that the hanger should be inspected. If the problem is in the valve, the valve must be locked open. If
the valve is locked open, submit a full written report to Halliburton Carrollton on circumstances,
personnel, and tests conducted.

Valve does not close.

1. Remove the manifold and install a hand pump to the control line at the tree.
2. Pressure the control line to 4,000 psi above the well pressure. Close the needle valve on the
tree.
3. Disconnect the hand pump, open the needle valve, and check volume of return from the
control system to determine if there is any piston movement in the valve.
4. Cycle the control line pressure from 0 to 4,000 psi above the well pressure ten times in an
effort to get some movement in the valve.
5. Pump fresh water down the tubing and through the valve while cycling the control line
pressure as in step 4.

Use an Exercise Tool or Check Open Tool to attempt to close the TRSV
Note: Some TRSV designs do not include an exercise profile. Check design specifications to
confirm.
1. Refer to the procedure for running the Exercise Tool or Check Open Tool
2. If the TRSV closes, cycle it open and closed per normal procedure.

The TRSV should not be returned to production mode unless it opens/closes properly by
applying/bleeding control pressure.

If the valve is still not operable by the control line pressure only, refer to the “Procedure for
Locking Valves Open.” If the valve is locked open, submit a full written report to Halliburton
Carrollton on circumstances, personnel, and tests conducted.

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Valve closing is confirmed with unacceptable pressure build-up in tubing above valve.

Debris clean up.

1. With the TRSV in the equalized position (shut-in well pressure on the tubing), apply sufficient
control line pressure to open the TRSV.
2. Allow the well to go to production for a few hours. This will help to clear away any debris that
may be in the vicinity of the TRSV flapper closing mechanism.
3. Shut in the production line. (Wing valve)
4. Bleed the control line pressure to 0 psi to allow the TRSV to close and shut-in the well.
5. Bleed off the tubing pressure through the wing valve to line pressure. (Any alternate process
will suffice.)
6. Monitor the tubing pressure to ensure the TRSV does not leak past the API allowable
leakage rate of 15 SCF/minute. This is the API 14B allowable leakage rate for installed
safety valves and is not necessarily that of the operator.
7. If the leak rate is still at an unacceptable level, spot fresh water or some other clean fluid on
top of the closed flapper.
8. Pump down the tubing. (Note: This should help to wash any debris across valve seat.)
9. Repeat Steps 1 – 6.
10. If the leak rate is still at an unacceptable level after performing the above procedure,
proceed to performing slam closures of valve.

Slam closure of valve. (Debris across seat suspected in equalizing/non-equalizing valves)

1. With TRSV in the open position and the well producing, choke the well flow back partially.
Note: Limit flow rates to that of the API 14A closure test flow rates as per Tables 1 and 2
below.
2. Bleed control line pressure to 0 psi, closing the flapper while the well is flowing at flow rates
described above.
3. Conduct the leak off test.
4. If situation improves, but leak rate is still at an unacceptable level, steps 1 through 5 can be
repeated as required.

Open valve against a slight differential. (Debris across seat suspected in non-equalizing valves)
1. Follow procedure in the BDMI for applying control pressure to TRSV.
2. Pressure up on the tubing to open against a slight differential. (Note: This assumes there was
a differential under the flapper when the opening procedure was initiated.)

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 Table 1 - Gas Flow Rates
Nominal
TRSV Attempt 1 Flow Rate Attempt 2 Flow Rate Attempt 3 Flow Rate
Size
SCFD×106 M3/d×106 SCFD×106 M3/d×106 SCFD×106 M3/d×106
3
2 /8 2.6 0.07 5.1 0.14 7.7 0.22
2 7/ 8 4.0 0.11 8.0 0.23 12.0 0.34
3 1/ 2 5.8 0.16 11.5 0.33 17.3 0.49
4 7.9 0.22 15.7 0.44 23.6 0.67
4 1/ 2 10.3 0.29 20.5 0.58 30.8 0.87
5 13.0 0.37 25.9 0.73 38.9 1.10
5 1/ 2 16.0 0.45 32.0 0.91 48.0 1.36
6 1/ 2 23.1 0.65 46.1 1.30 69.2 1.96
7 31.6 0.89 63.1 1.79 94.7 2.68

Table 2 - Liquid Flow Rates

Nominal
TRSV Attempt 1 Flow Rate Attempt 2 Flow Rate Attempt 3 Flow Rate
Size
B/D m3/d B/D m3/d B/D m3/d
3
2 /8 500 79 1000 159 1500 238
2 7/ 8 780 124 1560 248 2340 372
1
3 /2 1120 178 2240 356 3360 534
4 1500 238 3000 477 4500 715
4 1/ 2 1920 305 3840 610 5760 915
5 2430 386 4860 722 7290 1159
1
5 /2 3000 477 6000 954 9000 1431
1
6 /2 4320 686 8640 1373 12960 2060
7 5880 935 11760 1869 17640 2804

If an acceptable leak-off test cannot be obtained on the TRSV, then it will have to be locked open and an
insert valve set. Refer to the “Procedure for Locking TRSVs Open.” If the TRSV is locked open, submit a
full written report to Halliburton Carrollton on circumstances, personnel, and tests conducted.