SCSSV Full Report

Project Report On “Tubing Retrievable Sub-Surface Safety Valves” Summer Internship 1st June-25th July2008 At

Submitted To:

Mr. Cecil Antao (Ops/Mktg Account Manager) Submitted By:

Ashwin Soni

Abhishek Bansal

Metallurgical Engineering & Material Science

Gas Engineering

2005-2010

2005-2009

IIT Bombay, Powai

UPES, Dehradun

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ACKNOWLEDGEMENT We sincerely thank Mr. C.K. Pathak (Country Manager, India & Bangladesh, BOT) for providing us with this opportunity to learn and be part of this prestigious organization. We would give our special thanks to Mr. Cecil Antao (Ops/Mktg Account Manager, BOT) for guiding us throughout the eight week summer internship program and helping us in each and every aspect as our mentor regardless of the busy schedule he had which kept our morals high. We give special thanks to Mr. Abhishek Kaushic (Sales Manager, BOT), Mr. Sushil Keshkar (Ops/Mktg Account Manager, BOT), Mr. D.K. Shayamal (Ops/Mktg Account Manager, BOT) and Mr. Rudappan Silvaguru (Field Service Manager, BOT) for providing us support and a platform to interact with the BOT team. We extend our sincere thanks to the Field Engineers, Commercial Team, Logistics and Supply Chain Management Team, IT and Finance Department for providing us with the knowledge of the operations and sharing their vast experiences with us. This summer internship has been a valuable learning experience and has helped us gain a perspective of the MNC culture and the corporate environment. We respect the core values of the company “Integrity, Teamwork, Performance and Learning “and will try our best to incorporate them into our actions. We thank Baker Oil Tools for providing us all the information required and allowing us to use it in this report. All in all being a part of Baker Hughes has been memorable and overwhelming.

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CERTIFICATE This is to certify that the project entitled “Tubing Retrievable Sub-Surface Safety Valves” Submitted by Mr. Abhishek Bansal B.Tech., Gas Engineering (2005-09) from University of Petroleum & Energy Studies, Dehradun & Mr. Ashwin Soni Dual Degree, Metallurgical Engineering & Material Science (2005-10) from IIT Bombay, Powai is an approved record of work carried out by them at Baker Oil Tools, Baker Hughes, India Project Office, Mumbai under proper guidance for a period of eight weeks (w.e.f. 1st June to 25th July, 2008).

____________ Cecil Antao (Ops/Mktg Account Manager) Baker Oil Tools, Baker Hughes Asia Pacific Ltd. Mumbai

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1. A Brief Review of the Summer Internship The summer internship at Baker Oil Tools started w.e.f. 1st June to 25th July i.e. for a period of eight weeks. On the first day, the HSE orientation took place wherein we were told about the Safety Policies of BOT. It was followed by a presentation on the core values of Baker Hughes “Learning, Performance, Teamwork and Integrity”. In the following two weeks presentations were delivered by the Finance Team, IT Team, Logistics and Supply Chain Management Team and the Commercial Team. They envisioned us about the task their team performs in order to carry out smooth and unrestricted operations in BOT. For the next 6 weeks we were taken to workshops at ITS (International Tubular Services) at Ghansoli and British Gas, Wadala situated in Mumbai. In the workshops we gained valuable experience by working along with the Field Engineers. We learned about various products of Baker Oil Tools such as Liner Hangers, Multilateral Assembly, Full Bore Isolation Valve, External Casing Packer etc. We also assisted the Field Engineers working on live project for the BOT customers like GSPC, BG and ONGC and participated in breaking and redressing of various tools. We also were taken to Baker INTEQ workshop for one day visit to have a glance of the equipments available there. On the last day of the Internship we delivered a presentation on the project to the BOT team on the Project assigned to us i.e. “Tubing Retrievable Sub Surface Safety Valves”.

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2. CONTENTS

ACKNOWLEDGEMENT ........................................................................................................................................ 5 1.

A Brief Review of the Summer Internship ......................................................................................... 7

2.

CONTENTS ..................................................................................................................................................... 8

3.

LIST OF FIGURES AND TABLES .......................................................................................................... 12

4.

INTRODUCTION ........................................................................................................................................ 13

5.

BAKER HUGHES INCORPORATED ..................................................................................................... 14 5.1

About Baker Hughes ........................................................................................................................ 14

1.1.1 Drilling & Evaluation .................................................................................................................... 14 1.1.2 Completion & Production ........................................................................................................... 16 1.1.3 Reservoir Technology and Consulting................................................................................... 17 5.2 6.

7.

Financial Highlights ......................................................................................................................... 19

BAKER OIL TOOLS.................................................................................................................................... 20 6.1

THE Completion Company ............................................................................................................ 20

6.2

THE Workover Company ............................................................................................................... 20

6.3

THE Fishing Company .................................................................................................................... 20

SUB-SURFACE SAFETY SYSTEMS....................................................................................................... 22 7.1

Introduction ........................................................................................................................................ 22

7.2

Overveiw .............................................................................................................................................. 23

Rating Envelope ........................................................................................................................................ 23 RBT Threads ............................................................................................................................................... 23 Unique Flapper Design ........................................................................................................................... 24 Chemical Injection Capabilities ........................................................................................................... 26

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Control Line Connection ........................................................................................................................ 27 7.3

Basic Principle ................................................................................................................................... 29

1.

Sub-Surface Controlled SSSV’s: ............................................................................................... 29

2.

Surface Controlled SSSV’s: ........................................................................................................ 29

Contrast between SSCSV’s and SCSSV’s: .......................................................................................... 30 Versions of Safety Valves:...................................................................................................................... 30 7.4 8.

Industry Standards for Subsurface Safety Valves ................................................................ 31

Tubing Retrievable Surface Controlled Sub Surface Safety Valve (TRSCSSV) .................. 34 8.1

Assembly Drawing and Component List ................................................................................. 34

8.2

Working of a TRSCSSV .................................................................................................................... 36

8.3

Models Available ............................................................................................................................... 37

CEMENTSAFE™ SERIES SUBSURFACE SAFETY VALVE ........................................................... 38 Onyx™ SERIES SUBSURFACE SAFETY VALVES............................................................................. 39 REALM™ SERIES SUBSURFACE SAFETY VALVE ........................................................................ 41 TITAN™ SERIES SUBSURFACE SAFETY VALVE ............................................................................ 42 SelecT™ SUBSURFACE SAFETY VALVE ............................................................................................ 44 NEPTUNE™ SERIES NITROGEN-CHARGED SUBSURFACE SAFETY VALVE ....................... 45 TRITON™ SERIES BALANCE LINESUBSURFACE SAFETY VALVE .......................................... 47 T-SERIES™ SUBSURFACE SAFETY VALVE ...................................................................................... 49 8.4

Models available in T-Series ......................................................................................................... 50

T (E) Series .................................................................................................................................................. 50 TM (E) Series .............................................................................................................................................. 50 TSM (E) Series and TUSM (E) Series ................................................................................................. 50 8.5

The Basic Hydrostatic Pressure Calculations ........................................................................ 51

8.6

Fail-Safe Setting Depth ................................................................................................................... 51

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Fail-Safe Setting Depth Calculations ................................................................................................. 52 Opening and Closing Pressure Calculations ................................................................................... 53 8.7

Design Principles and Philosophy .............................................................................................. 56

Flow Tube Design Features .................................................................................................................. 56 Debris Exclusion/Control Design Consideration:- ...................................................................... 57 Scale Deposition prevention: ............................................................................................................... 57 Flow Tube Closure Assist Tool ............................................................................................................ 57 How side loading and torsional forces on a rod piston are perceived and designed for......................................................................................................................................................................... 58 Dual opposite wound Power Spring.................................................................................................. 59 8.8

Technical Evaluation of the ‘T’ Series SSV Equipment ....................................................... 59

Outer Housing thread seal design philosophy .............................................................................. 59 Permanent Lock Open Features.......................................................................................................... 60 Evaluation of dynamic seal assembly and metal-to-metal stop seals .................................. 60 Components of dynamic seal assemblies and metal-to-metal stop seals: .......................... 61 Baker Oil Tools' Detent System for the 'T'-Series Safety Valves ............................................ 63 Flapper and hinge pin design............................................................................................................... 64 Table 3- Features and Benefits of Wedge Shape Flapper ......................................................... 65 Table 4- Features and Benefits of Curved (Slim line) Flapper ................................................ 66 Self-Equalizing Mechanism ................................................................................................................... 68 Control Line Jam Nut Connection ....................................................................................................... 72 Debris and Sand exclusion barriers .................................................................................................. 73 8.9

‘T’ Series accessory tools ............................................................................................................... 74

Flapper Lock Open Tool ......................................................................................................................... 74 Wireline Insert Safety Valve ................................................................................................................. 75 Tubing Retrievable Sub Surface Safety Valve

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Separation Sleeve ..................................................................................................................................... 76 Control Pressure Communication Tool............................................................................................ 77 9. 10.

CONCLUSION .............................................................................................................................................. 78 BIBLIOGRAPHY ...................................................................................................................................... 79

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3. LIST OF FIGURES AND TABLES Table 1- List of TE 5 (5.5") Components ................................................................................................... 35 Table 2- Fail Safe Setting Depth Calculations for the T (E) - 5 (5.5”) model (7) ........................ 55 Table 3- Features and Benefits of Wedge Shape Flapper ................................................................... 65 Table 4- Features and Benefits of Curved (Slim line) Flapper ......................................................... 66 Figure 1- RBT Thread Performance Envelope ........................................................................................ 24 Figure 2- Self Equalizing Mechanism ......................................................................................................... 25 Figure 3-Curved Flappers ............................................................................................................................... 26 Figure 4-Chemical injection feature simplifies the completion and maximizes the benefits from injection process ............................................................................................................................ 27 Figure 5- Control line and its connections ............................................................................................... 28 Figure 6- A Sub Surface Safety Valve .......................................................................................................... 29 Figure 7- Model "T (E)-5" Safety Valve (Assembly Drawing) (7) .................................................... 34 Figure 8- Subsurface Safety Valve Type .................................................................................................... 37 Figure 9- RBT Thread connection................................................................................................................ 59 Figure 10- Dynamic Seal Assembly ............................................................................................................. 61 Figure 11- Location of Metal to Metal Stop Seal .................................................................................... 62 Figure 12- Detent System/Shock Absorber ............................................................................................. 63 Figure 13- Wedge Shaped Flapper (Three point contact shown above) ...................................... 64 Figure 14- Curved Flapper Design .............................................................................................................. 66 Figure 15- Single Hinge Flapper Assembly .............................................................................................. 67 Figure 16- Baker Jam Nut ............................................................................................................................... 72 Figure 17- Debris and Sand Exclusion Barriers ..................................................................................... 73 Figure 18- Flapper Lock Open Tool ............................................................................................................ 74 Figure 19- Wireline Insert Safety Valve .................................................................................................... 75 Figure 20- Control Pressure Communication Tool ............................................................................... 77

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4. INTRODUCTION The safety systems are required for the protection of the personnel around the platform, the environment and to prevent any production losses. It is also required for shutting in a well, in case of emergency shut down due to catastrophe, production testing, inspection and other routine operations. The safety valves keep the well shut in when the control line pressure is released and open up when the pressure is again maintained (in surface controlled type safety valves). There are various versions of such subsurface safety valves available with Baker Oil Tools. They are either surface controlled or subsurface controlled. The surface controlled one is available in two types, one is tubing retrievable and other is wireline retrievable. The tubing retrievable subsurface safety valves are most widely used in the oil industry and are available in various models for various applications. They are available in various designs offering different features which have been discussed further.

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5. BAKER HUGHES INCORPORATED 5.1 About Baker Hughes

(1)Baker Hughes provides the worldwide oil and natural gas industry products and services for drilling, formation evaluation, completion and production. We create value for oil and gas producers by providing advanced, reliable technology to find, develop, produce and manage oil and gas reservoirs. We also provide reservoir engineering and other consulting services. Baker Hughes operates in over 90 countries serving independent, international and national oil companies. Baker Hughes is the only major oilfield service company structured around strong productline divisions that are focused on Best-in-Class products and services. Our divisions are organized in two segments -- Drilling & Evaluation and Completion & Production -- which share common opportunities in developing and delivering technology solutions during distinct phases of oil and gas development. The newly-formed Reservoir Technology and Consulting Group includes two consulting firms – Gaffney, Cline & Associates and GeoMechanics International – that provide technical and commercial consulting, with unique capabilities in reservoir engineering and geomechanics.

1.1.1 Drilling & Evaluation Our Drilling & Evaluation segment includes divisions that apply their products and services primarily during the drilling process to improve efficiency, reduce risk and acquire accurate information. The segment includes Baker Atlas, Baker Hughes Drilling Fluids, INTEQ and Hughes Christensen.

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Baker Atlas Baker Atlas offers a complete range of down-hole well logging services for every environment including advanced formation evaluation, production and reservoir engineering, petro-physical and geophysical data acquisition services. In addition, perforating and completion technologies, pipe recovery, and processing and analysis of open and cased hole data complete the service range. Baker Hughes Drilling Fluids Baker Hughes Drilling Fluids provides fluids systems and services that help optimize the drilling and completion processes maximize hydrocarbon production and manage drilling waste. Leading technologies include environmentally compliant water-based and synthetic-based mud systems and remediation fluids that can restore productivity from damaged wells. INTEQ INTEQ provides real-time services to help oil companies drill more efficiently, evaluate geologic formations, and place wells in productive zones within the reservoir. Important technologies include automated rotary steerable directional drilling systems, high performance drilling motors, and integrated logging-while-drilling assemblies. INTEQ also provides data communications, data management and expert centers to improve drilling operations and enhance formation evaluation. Hughes Christensen Hughes Christensen is the leader in Tricone™ and PDC drill bit, ream-while-drilling and casing drilling technology. Hughes Christensen application and design engineers work with customers to provide the best drill bit for the application to continuously improve drilling performance.

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1.1.2 Completion & Production Our Completion & Production segment includes divisions that apply their products and services primarily during the well completion, field production, transportation and refining processes. The segment includes Baker Oil Tools, Baker Petrolite, Centrilift, and the Production Optimization business unit. Baker Oil Tools Baker Oil Tools provides completion and intervention solutions that help manage cost and reduce risk while optimizing production. The division has a comprehensive line of completion systems, which maximize performance and safety from the reservoir to the surface. Wellbore intervention solutions address issues ranging from temporary well abandonment and fishing to casing exits, wellbore cleaning, and isolation, remediation and stimulation operations. Baker Petrolite Baker Petrolite provides chemical technology solutions for hydrocarbon production, transportation and processing, and also delivers pipeline integrity services. Baker Petrolite is a leader in oil/water separation technology and in solutions to control corrosion, deposition, bacteria and H2S in producing wells and production facilities. To serve refinery and petrochemical customers, Baker Petrolite provides chemicals and technical support to enhance plant processes, improve productivity, manage water treatment, and resolve environmental issues. Centrilift Centrilift provides artificial lift systems, including electric submersible pumps (ESP) and progressive cavity pump systems, as well as specific engineering, project management and well monitoring services. Centrilift has expanded the applications for ESP systems to harsh downhole environments that include high gas to oil ratio, heavy oil, high temperatures and abrasive laden fluids. New systems also address the needs of coalbed methane and subsea production.

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ProductionQuest Baker Hughes formed its ProductionQuest business unit to provide technology and services that help maximize recovery from both new and mature fields. The unit provides production optimization services centered on the well bore, including permanent monitoring, chemical automation, intelligent production systems, and consulting services. The unit also includes the Baker Hughes Integrated Operations group, which manages projects and combines technologies and services from Baker Hughes divisions and subcontractors to meet customer objectives for both well construction and production optimization. 1.1.3 Reservoir Technology and Consulting Baker Hughes recently formed the Reservoir Technology and Consulting Group to enhance the company’s capabilities in reservoir engineering, geomechanics and energy consulting services. The group currently includes Gaffney, Cline & Associates and Geomechanics International, Inc., which continue to operate as stand-alone consulting firms. Gaffney Cline & Associates Gaffney Cline & Associates is an international advisory firm focused on providing integrated technical and managerial services to all sectors of the oil and gas industry. For more than 45 years GCA has provided strategic and detailed advice aimed at achieving practical and commercially viable results. In addition to reservoir engineering, GCA advises a wide group of clients in exploration, reservoir evaluation, field development, drilling and production, pipeline, refining and LNG projects throughout the world. GeoMechanics International GeoMechanics International is a leader in consulting, training and software in the field of geomechanics and its application to oil and gas reservoirs. GMI was founded in 1996 by a team of experts from Stanford University's Department of Geophysics, and each of its Tubing Retrievable Sub Surface Safety Valve

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consultants is a recognized leader in the field of geomechanics. GMI methods are focused on applying geomechanics modeling to the entire life of a reservoir and are based on 20 years of R&D and more than 12 years of practical application to oilfield problems. These methods have been proven to reduce exploration risk, save Non-Productive Time (NPT) and help increase production and recoverable reserves.

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5.2 Financial Highlights (2) Price & Volume Recent Price $

81.36

52 Week High $

100.29

52 Week Low $

62.65

Average Vol (Mil) (RTMA)

89.629

Beta

1.36

Share Related Items Market Cap. (Mil) $

25,060.540

Shares Out (Mil)

308.020

Float (Mil)

305.600

Dividend Information Yield %

0.64

Annual Dividend

0.52

Payout Ratio (TTM) %

10.69

Financial Strength Quick Ratio (MRQ)

1.87

Current Ratio (MRQ)

2.79

LT Debt/Equity (MRQ)

16.87

Total Debt/Equity (MRQ)

25.09

Mil = Millions RTMA = Rolling Three Month Average TTM = Trailing Twelve Months MRQ = Most Recent Quarter Asterisk (*) indicates numbers are derived from Earnings Announcements Pricing and volume data as of Jul 11, 2008.

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6. BAKER OIL TOOLS (3)Baker Oil Tools leads the world in completion, workover and fishing solutions that help exploration and production companies maximize value from their hydrocarbon-bearing assets. Since its earliest days, the Baker name has been synonymous with excellence in down-hole and surface technology, performance and reliability. In the current era of riskier environments and higher stakes, those qualities are more valuable than ever.

6.1 THE Completion Company Baker Oil Tools′ undisputed role as the industry leader in reliable, performance-based completion solutions is based on the world′s most reliable sealing and anchoring technologies, meticulous planning, and a no-nonsense approach to risk avoidance. From the Model D Packer to the FORMation Junction™ Multilateral Completion System, H2OPAQSM and H2O-FRAQSM production enhancement processes, and InForce™ and InCharge™ Intelligent Well System and High-pressure/high-temperature environments – Baker has built a track record second to none by working closely with its customers to meet or exceed their needs in virtually every completion application.

6.2 THE Workover Company When well maintenance or remediation operations become necessary, Baker Oil Tools applies more than five decades of industry-leading mechanical and inflatable packer technologies to provide integrated solutions that maximize productivity and minimize cost. At the forefront of Baker′s capabilities are its award-winning through-tubing workover technologies, which allow zonal isolations, water shutoffs and well cleanouts to be performed simply, without killing the well or pulling the production tubing.

6.3 THE Fishing Company Fast, reliable solutions and around-the-world/around-the-clock service make Baker Oil Tools the preferred provider for both traditional and through-tubing fishing and re-entry projects. Baker engineers apply practical field experience to industry-leading cutting,

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fishing and milling capabilities to provide a range of solutions that are the most advanced and comprehensive available.

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7. SUB-SURFACE SAFETY SYSTEMS 7.1 Introduction (4)In 1969, an operator lost control of a platform and spilled 4.2 million gallons of crude into the ocean, killing birds and contaminating beaches. Over 10,000 Loons and Western Grebes were killed. This spill was off the coast of Santa Barbara, encircled Anacapa and the eastern each of Santa Cruz Island, and earned the distinction of being the largest oil spill in California not to mention the most publicised. The Santa Barbara oil spill is considered one of the key events responsible for promoting the modern environmental movement. A post-mortem on the accident showed that the well developed a leak in the tubing and casing between the ocean floor and ocean surface. This allowed the oil to flow, unchecked, into the ocean. Several attempts to regain control proved to be unfruitful. The well was finally brought under control by drilling a relief well and pumping in heavy fluids. This highly visible spill brought public attention to the need of safety equipment. A Subsurface Safety Valves would have allowed the operator to regain control of the oil flow immediately. Shortly after the Santa Barbara oil spill, the petroleum industry began an accelerated program for the development of standards in relation to safety valves. The American Petroleum Institute’s Production Department in Dallas, took the lead in developing specifications and funding an independent test laboratory. Initial testing was done from 1973 - 1974 at Southwest Research Institute in San Antonio, Texas.

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7.2 Overveiw Baker Oil Tools (BOT) is one of the leading suppliers of subsurface safety system equipment. Full line of subsurface safety valves are available for surface-controlled and subsurface-controlled tubing retrievable and wireline retrievable applications. Each valve includes Baker's proven technologies and innovations that have set many industry standards. Rating Envelope The combination of innovative computer programs and exhaustive laboratory testing has enabled Baker Oil Tools to develop an industry standard for predicting safety valve housing performance capabilities under all loading conditions. This conservative design approach ensures the thread's ability to withstand aggressive down-hole environments. The results of this evaluation are plotted in a graphical format which provides visual indication of the safe operating range for the safety valve. With this load envelope, operators can safely plan their completions with confidence that Baker Oil Tools' safety valves will protect their people and investments. RBT Threads Through extensive FEA analysis and technical research, Baker Oil Tools offers RBT premium thread connections. The efficiency of the RBT thread design allows Baker Oil Tools to offer the smallest OD's for a given tubing size across the safety valve portfolio. The RBT premium thread connections bring the superior protection and life extending advantages of metal-to-metal sealing technology to thousands of Baker safety valves. The connection's two-step design distributes thread load to impart greater strength than single-step designs. The metal-to-metal seal points at the box and pin noses provide enhanced pressure-containing capabilities. The combination of this two-step, ultra slimprofile thread and the use of high tensile strength materials allows for the slimmest outside diameters on the market.

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Figure 1- RBT Thread Performance Envelope

The RBT thread also includes an innovative center torque shoulder design. The torque shoulder provides superior resistance to back-off in down-hole service. In addition, damage is prevented to the metal-to-metal seals during high torque loads and precisely controls make-up loss. Unique Flapper Design Focusing on providing customer solutions along with using state of the art engineering practices, Baker Oil Tools has introduced several industry firsts relating to its unique flapper design. Baker Oil Tools was the first to offer a patented through the flapper selfequalizing feature which has proven to reduce operating costs for operators. The selfequalizing feature allows operators to open subsurface safety valves against differential pressure.

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Figure 2- Self Equalizing Mechanism

This unique design is resilient to debris and erosion which provides ultimate long-term reliability. The equalizing system has been used successfully in HP/HT and Big Bore applications where equalizing high pressures and large volumes can prove challenging. Baker Oil Tools also provided the industry's first wireline damage resistant flapper design. This design was created after careful review of mean-time-to-failure statistics relating to all subsurface safety valve designs. This analysis revealed that a good portion of failures could be eliminated with a wireline damage resistant flapper. The new flapper design protects the seal surface from wireline damage if an operator accidentally closes the valve during wireline operations. The protection offered by the wireline damage resistant flapper extends the safety valve life for operators. Baker Oil Tools was the first company to design a 4-1/2 in. safety valve to be installed inside 7 in. casing and a 7 in. safety valve to be installed inside 9-5/8 in. casing. The key ingredient to this success was the unique curved flapper design. The curved flapper design was made possible by advanced machining processes, innovative engineering practices, and exceptional quality control. These ultra-slimline curved flappers allow operators to reduce their overall costs and maximize their return on investment by maintaining a large bore ID while reducing the casing sizes needed for the completion.

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Figure 3-Curved Flappers

For high flow rate natural gas applications, Baker Oil Tools recognized the need to design and manufacture one of the world's most rugged flapper designs. Every flapper design goes through an intricate engineering process to ensure the flapper can meet the demands of high gas velocities. Baker Oil Tools' flapper designs have been verified by gas slam tests to the highest rates available in the world. Chemical Injection Capabilities Scale, paraffin, or hydrate formation continues to pose significant risks to operators in obtaining desired returns on their investments. Formation of these solids can jeopardize safety valve function by impeding flow tube movement, thereby requiring intervention. With this in mind, it is the culture within Baker Oil Tools to look for ways to simplify completion designs that will increase system reliability and decrease operator cost while maximizing performance.

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Figure 4-Chemical injection feature simplifies the completion and maximizes the benefits from injection process

A result of this culture is the optional chemical injection feature available with the Titan™ Series Subsurface Safety Valve. This innovative design incorporates a field-proven doublepoppet system that permits chemical injection directly into the safety valve. Combining this feature with a Titan Valve will virtually eliminate the need for any chemical injection mandrel in the tubing string above the safety valve. This will save the customer money and simplify the completion by reducing the number of components and tubing connections. Injecting chemicals directly into the spring cavity also ensures that the customer will receive the maximum benefit of the injection process by allowing injection directly where it is needed. For valve designs that do not offer the integral chemical injection feature, Baker Oil Tools offers a chemical injection sub that can be mounted directly on top of the Tubing Retrievable Safety Valve (TRSV). Control Line Connection Baker Oil Tools offers control line in a variety of lengths and materials. The standard control line provided is welded and drawn and complies to ASTMA269 specifications. Seamless and encapsulated control line is available upon request. Encapsulation improves the crush and abrasion resistance of the control line and can be offered in a variety of materials to suit the customers' down-hole environment. Baker Oil Tools offers a variety of control line connections to match the application. The Baker metal-to-metal jam nut, which Tubing Retrievable Sub Surface Safety Valve

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is standard for valve working pressures of 10,000 psi (689 bar) and below, provides reliable control line connections at the safety valve. This jam nut features a front and rear ferrule design that reduces the potential leak path from control line to annulus. For working pressures greater than 10,000 psi (689 bar), Baker Oil Tools offers Autoclave connections. (5)

Figure 5- Control line and its connections

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7.3 Basic Principle Depending on the environment and on the type and pressure of the produced effluent, it may be necessary to place a SubSurface Safety Valve, SSSV, inside the well itself. It supplements the one(s) on the wellhead if they should happen to be out of order (valve failure, wellhead torn off, etc).

Figure 6- A Sub Surface Safety Valve

(6)There are two types of SSSV’s: 1. Sub-Surface Controlled SSSV’s: These valves that were often called storm chokes are now termed SSCSV (SubSurface Controlled Subsurface Safety Valves). They are set and retrieved by wireline. They close the well following a modification in flow conditions where they are located: a) Either when the ambient flow rate increases (and so the pressure loss across the valve also increases) b) When there is a pressure drop opposite the valve. Baker Oil Tools Manufactures injection valves and velocity valves which fall under SSCSV’s 2. Surface Controlled SSSV’s: The SCSSV’s (Surface Controlled Subsurface Safety Valve), of the fail safe type, are controlled from the surface by hydraulic pressure in the control line and are normally closed (i.e. closed when no pressure is applied in the control line). The control pressure acts n a jack which pushes a sleeve back thereby opening the valve. At the same time it compresses a powerful return spring. As long as the control pressure is kept at the set Tubing Retrievable Sub Surface Safety Valve

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operating value, the valve remains open. However, if it falls below a certain threshold then the valve will close automatically solely under the effect of the return spring. Contrast between SSCSV’s and SCSSV’s: The SCSSV does not depend directly on ambient flow conditions in the well, but rather on one or more parameters measured at the well head. This also allows the subsurface valve to be controlled via a number of safety systems connected to process facilities. The well’s safety can therefore be achieved manually or automatically whether the trouble is directly related to the well or not: fire, explosion or impact, process problem, etc. Depending on the degree of safety required, the wellhead safety valve alone can be closed or, in conjunction with it, the subsurface safety valve can also be closed. Due to the design of the hydraulically controlled valve, the depth at which it can be installed in the well is limited by the capacity of its running string. The spring must be sufficiently compressed to overcome the opposing force due to the weight of the hydrostatic column of the hydraulic fluid in the control line that governs the valve and acts directly on the jack. Also due to its design, the valve could not be opened as long as the pressure difference between above and below the closing and sealing mechanism exceeds an average of 0.7 MPa (100 psi), so that the valve will not be damages when it opens. Some valves are equipped with an internal equalization device. Here, all that is required to reopen the valves is to increase the pressure in the control line with the well head closed. Otherwise it is also necessary to recompress the tubing above the valve (by means of a pump, a nearby well, etc.) The SCSSV closing and sealing mechanism is either a flapper valve or a ball valve. For a long time preference was given to ball valves, mainly because of the sealing quality, even though the sleeve weldment (pivot cage) is complex and fragile. Currently check valves seem to be preferred choice as they are much simpler, more rugged and robust (i.e. safer). Also, a lot of progress has been made regarding the reliability and tightness of flappers. Versions of Safety Valves: 1. Wireline Retrievable: Set in a special landing nipple and retrieved by wireline. Tubing Retrievable Sub Surface Safety Valve

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2. Tubing Retrievable: Screwed onto the tubing and pulled out with all or part of the equipment in the well.

7.4 Industry Standards for Subsurface Safety Valves The recognized industry standard for Subsurface Safety Valve systems is published in the American Petroleum Institute Specifications, API Spec 14A and API RP 14B. These two documents prescribe the minimum standards for quality assurance and performance to provide the maximum reliability of Subsurface Safety Valve equipment. They also provide guidelines for the design, installation and operations of safety valve systems. The following is a brief overview of these standards. API 14A The API 14A specification covers Subsurface Safety Valves, Safety Valve Locks, Safety Valve Landing Nipples, and all components that establish tolerance and/or clearances which may affect performance or interchangeability. Classes of Service Subsurface safety valves, safety valve locks and safety valve landing nipples must meet acceptable standards for materials manufacturing and testing for one of four classes of service. Class 1 - Standard Service is for use in oil or gas wells which do not exhibit the detrimental effects caused by sand or stress corrosion cracking. Class 2 - Sandy Service is for use in oil or gas wells where a substance such as sand could cause valve malfunction or failure (this valve must also meet the Class 1 service requirements). Class 3 - Stress Corrosion Cracking Service is for use in oil or gas wells where corrosive agents could cause stress corrosion cracking. This valve must meet the requirements for a Class 1 and Class 2 valve and be manufactured from materials which are resistant to stress corrosion cracking. Within this service class there are two sub-classes, 3S for sulfide stress cracking service and 3C for chloride stress cracking service. Metallic material, suitable for a 3S environment, shall be in accordance with NACE MR0175.

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Class 4 - Weight Loss Corrosion Service is for use in oil or gas wells where corrosive agents could be expected to cause weight loss corrosion. Class 1 or Class 2 and be manufactured from materials which are resistant to stress corrosion cracking. A Subsurface safety valve which has qualified for Class 1 or Class 2 service will be considered qualified for Class 3 service without requalification testing, when it is manufactured from materials resistant to stress corrosion cracking. Traceability All components, weldments, subassemblies and assemblies of SSSV equipment shall be traceable except, Springs, Beans, Common hardware. Hardness Each pressure containing part shall be hardness tested in accordance with API. Equipment Marking SSSV equipment marking on the exterior surface with the manufacturer’s name or trademark, monogram, rated working pressure, class of service, model number, serial number, date of manufacture, and pressure classifications. This list is a general requirements, see specification of specific requirements. Supplied Documentation Each monogrammed SSSV, SV Locks and Nipples shall be delivered to the operator with a Manufacturer’s Shipping and Receiving Report and an Operating Manual. Dimensional Inspection All traceable components, except elastomeric seals, must be dimensionally inspected to assure proper function and compliance with design specifications and drawings. Welding No Welding is performed on a Broken Arrow SSSV.

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API RP 14B The API RP 14B specification covers considerations for system design, instructions for safe installation, repair, and guidelines for operating and testing to assure sage and efficient performance of the SSSV system. Also included are procedures for reporting failures. This recommended practice is directed toward wireline, tubing retrievable and pumpdown SSSV systems. Inspection and Testing Safety valve inspection begins on location where documentation should be checked to verify serial numbers, size in accordance with the design, and that the safety valve lock for a retrievable safety valve is compatible with the landing nipple in the well. Before running the SCSSV in the well, connections should be tightened or checked in accordance with operating manual. Ascertain that all visible sealing elements are not damaged or deformed, and that all other visible features do no exhibit marring distortion that may interfere with safety valve operation. On new and replaced SSSVs, the opening and closing hydraulics pressures should be verified according to the operating manual. Ascertain that the SSSV will operate fail-safe at the setting depth before installation. After installation of the SSSV in the well, the valve should be closed under minimum no-flow conditions by operations of the surface control. Verification of closure may be accomplished by wire-line, pressure build-up or flow test. If the well is capable of flow, the SSSV can be tested for leakage by opening the surface valves to check the flow. The SSSV is then reopened following the operation manual. The SSSV should be operated at least every six months. (4)

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8. Tubing Retrievable Surface Controlled Sub Surface Safety Valve (TRSCSSV) 8.1 Assembly Drawing and Component List

Figure 7- Model "T (E)-5" Safety Valve (Assembly Drawing) (7)

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Table 1- List of TE 5 (5.5") Components S.NO

Component Name

Quantity

1

Top Sub

1

2

Sliding Manderal Nut

1

3

Dynamic Seal Assmbly

1

4

Coupling Jamnut

2

5

Piston

1

6

Thread Protector

1

7

Cylinder Sub

1

8

Bearing

1

9

Set Screw

1

10

Coupling

1

11

Power Spring

1

12

Flow Tube

1

13

Spring Stop

1

14

C-Ring

1

15

Flapper Stop

1

16

Flapper Base

1

17

Spring Housing

1

18

Flapper Stop Seal Assembly

1

19

Flapper Pin

1

20

Torsion Spring

1

21

Equalizer Flapper Assembly

1

22

Flange Face Spacer

1

23

Resilience Seal

1

24

Rear Ferrule

2

25

Front Ferrule

2

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8.2 Working of a TRSCSSV The working principle for all TRSCSSV is same. These valves are controlled from the surface via a small diameter hydraulic control line connecting the safety valve to the surface Emergency Shut-Down System. Since the valve is of the normally closed type, when the applied control line pressure is removed, the valve returns to the closed position thus shutting in the well. The control line is connected to the top sub through the jam nut connection. The control line allows the control line fluid to fill inside the control chamber. The hydraulic oil used as the control line fluid is used to pressurize the piston in the control chamber. The piston inturn pushes down the power spring. The piston is connected to the flow tube through coupling thus allowing it to move down as the spring is compressed. As soon as the flow tube comes in contact of the closed flapper, it pushes the plunger of the equalizing port. The equalizing port allows the differential pressure across the flapper to equalize. As soon as the differential pressure is equalized, the flow tube pushes down the flapper to open position. To again close the flapper, the pressure in the control line is bled off. This decompresses the spring and the flow tube moves up. The flapper then closes and the metal to metal seal doesn’t allow any fluid to pass through it. Thus the flow from the well is suspended and the well is shut in.

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8.3 Models Available [Source: Baker Oil Tools Catalog]

Figure 8- Subsurface Safety Valve Type

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CEMENTSAFE™ SERIES SUBSURFACE SAFETY VALVE DESCRIPTION The CEMENTSAFE™ Series tubing retrievable surface controlled subsurface safety valve is designed specifically for use in cement-through and frac-through applications. In addition, the CEMENTSAFE offers superior performance in applications that require the exclusion of flowing debris from the working components of the TRSV. The CEMENTSAFE utilizes a piston with non elastomeric dynamic seals to isolate the control chamber and spring cavity from cement and produced fluids. This exclusion feature not only protects the sealing surfaces of the actuation system but also excludes cement or other debris from entering the flapper cavity of the safety valve. The CEMENTSAFE incorporates the successful features from the T-Series™ product offering such as metal-to-metal housing seals, metal-to-metal containment below the flapper, thruthe-flapper self equalizing, and secondary puncture communication. This combination of features ensures the performance required to meet the demands of harsh environments in cement-through and frac-through applications. FEATURES/BENEFITS • Complete exclusion of well bore fluids from the spring and flapper cavity - Ensures smooth and reliable operation in cement-through and frac-through applications • Non elastomeric piston actuator system - elimination of elastomers and their inherent problems • Unique curved flapper - optimizes OD to ID relationships • Metal-to-metal seal technology - 100% metal-to-metal sealing and containment of well bore fluids when the valve is in the closed position • Patented thru-the flapper equalizing system - most successful and widely used system available to the market • RBT Housing Seals - two step metal-to-metal sealing system provides strength and sealing under the harshest conditions • Patented radial punch control fluid communication system – eliminates accidental communication primarily associated with linear shifting sleeves

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Onyx™ SERIES SUBSURFACE SAFETY VALVES DESCRIPTION The Onyx™ Series, is the industry's first 7 in. tubing Retrievable Safety Valve (TRSV) that can fit inside a 9-5/8 in. casing with cable bypass capabilities. In addition, Baker Oil Tools has designed the industry's first 4-1/2 in. TRSV to fit inside a 7 in. casing. The Onyx Series of tubing retrievable surface controlled subsurface safety valves are specifically designed for big bore applications. Onyx Series safety valves are based on the successful T-Series™. The Onyx Series combines a patented, state-of-the-art closure mechanism and premium housing threads to produce the industry's first tubing retrievable safety valves that offer full-opening production in smaller casing sizes. As a result, operators get multiple benefits: the lower cost of smaller-OD casing, flexibility in designing their completions, and higher production rates typical of larger tubing sizes. FEATURES/BENEFITS • Slimline OD - enables larger tubing to be installed without sacrificing the full opening for maximized production • Reduces completion cost (CAPEX) - the valve permits operators to use smaller casing programs • Broader application coverage - ability to run capillary lines for downhole instrumentation or chemical injection and/or cables for electric submersible pump operation as well as dual completion installations • RBT Housing Seals - two step metal-to-metal sealing system provides strength and sealing under the harshest conditions • Non elastomeric dynamic seal assembly - withstands extreme pressures and temperatures exceeding 28,000 psi and 450°F • Metal-to-metal seal technology - 100% metal-to-metal sealing and containment of well bore fluids when the valve is in the closed position • Patented thru-the flapper equalizing system - most successful and widely used system available to the market

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• Ultra strong curved flapper design - resistant to high impact loads in high flow rate applications

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REALM™ SERIES SUBSURFACE SAFETY VALVE DESCRIPTION The new REALM™ Series tubing retrievable surface controlled subsurface safety valves are specifically designed for high pressure / high temperature (HP/HT) applications. REALM Series safety valves build upon the success of the T-Series™ and use state-of-the-art technology to provide the industry's most reliable safety valve for these critical applications. The REALM Series reduces operating expenses by providing absolute pressure ratings. The control chamber, dynamic seal system and rod piston are capable of withstanding full differential pressures. This capability eliminates the requirement to stage tubing pressures during installation, thus reducing installation cost and risk of over pressuring the valve. Baker Oil Tools utilizes a unique design approach combining cutting edge design techniques with the industry's most rigorous test program to provide safety valves specifically designed for HP/HT applications. FEATURES/BENEFITS • Absolute pressure ratings - no staging of tubing pressure • Non elastomeric dynamic seal assembly - withstands extreme pressures and temperatures exceeding 28,000 psi and 450°F • Metal-to-metal seal technology - 100% metal-to-metal sealing and containment of well bore fluids when the valve is in the closed position • Patented thru-the flapper equalizing system - most successful and widely used system available to the market • Ultra strong curved flapper design - designed to withstand extreme differential pressures • RBT Housing Seals - two step metal-to-metal sealing system provides strength and sealing under the harshest conditions • HP/HT Leader - successful field experience minimizes operating risk

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TITAN™ SERIES SUBSURFACE SAFETY VALVE DESCRIPTION Baker Oil Tools' commitment to innovation has resulted in the Titan™ Series surface controlled subsurface safety valve. Innovative field-proven technology that reduces the number of typical safety valve failure modes has been a hallmark of Baker Oil Tools' safety valves through the years. Titan standard features include: wireline damage resistant flapper, non elastomeric seal technology, and metal-to-metal containment of wellbore fluids in the closed position. These standard features deliver unprecedented reliability, efficiency, and adaptability. One-quarter of all safety valve failures occur due to wireline damage during interventions into the wellbore. The Titan incorporates the damage resistant characteristics of the successful SelecT™ flapper design to virtually eliminate this failure mode. This design ensures all seal surfaces are protected from wireline contact even during accidental closure of the valve during wireline operations. The Titan can be tailored to your specific needs, with available options such as integral chemical injection capability, wireline damage resistant seal bores, and various control system stop seal versions. An optional thru-the-flapper self equalizing system is also available to minimize operational expenses while maximizing productivity. FEATURES/BENEFITS • Field-proven technology - basic design features have been carried over from the highly successful T-Series™ and SelecT portfolios • Patented thru-the-flapper self-equalizing - most successful and widely used system available to the market • Non elastomeric dynamic seal assembly - withstands extreme pressures and temperatures exceeding 28,000 psi and 450°F • Wireline damage resistant flapper - design protects sealing integrity during wireline operations • Patented lock open system - achieved via one wireline trip and allows flow through the locked open valve with no ID restriction

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• No shifting sleeves required to communicate - impossible to inadvertently communicate the hydraulic chamber • Metal-to-metal seal technology - 100% metal-to-metal sealing and containment of wellbore fluids when the valve is in the closed position • Optional chemical injection capability - injection mandrel within the TRSV eliminates the need for a mandrel above the valve and allows injection of fluids directly into spring cavity for maximum effectiveness • Optional damage resistant seal bores - ensures seal bore integrity when it is needed

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SelecT™ SUBSURFACE SAFETY VALVE DESCRIPTION The SelecT™ is a tubing retrievable surface controlled subsurface safety valve that is designed to address the unique challenges that shallow set safety valves (typically