Gas lift valve having shear open mechanism for pressure testing
For gas lift, gas lift valves install on a completion in a wellbore. The gas lift valve has a pressure-sensitive valve and a check valve configured to control communication in the valve. A piston is held closed with a first connection relative to the valve's outlet exposed to tubing pressure, while the check valve is held open in the valve with a second connection. Pressure testing can be performed on the integrity of the tubing and casing by increasing the tubing and annulus pressures while the piston stays closed. The gas lift valve is then actuated for operation by increasing the tubing or annulus pressure beyond a predetermined limit of the first connection to release the piston to move open relative to the outlet. The movement of the piston releases the hold of the second connection on the check valve so the check valve can function normally as a one-way valve.
1. An apparatus for a gas lift valve on tubing in a wellbore, the gas lift valve having a pressure-sensitive valve and a check valve, the pressure-sensitive valve configured to control communication from an inlet toward an outlet, the inlet exposed to one of annulus pressure of the wellbore and tubing pressure of the tubing, the outlet exposed to the other of the annulus pressure and the tubing pressure, the check valve configured to prevent communication from the outlet toward the inlet, the apparatus comprising:
a piston disposed between the check valve and the outlet and exposed to a pressure differential between the annulus pressure and the tubing pressure, the piston movable from a closed condition to an opened condition relative to the outlet;
a first connection holding the piston in the closed condition and configured to release hold of the piston in response to a predetermined level of the pressure differential; and
a second connection connecting the piston to the check valve, the second connection with the piston in the first position holding the check valve open, the second connection with the piston in the second position releasing the hold of the check valve to close.
2. The apparatus of claim 1 , wherein the piston comprises:
a piston body sealed in the valve, the piston body exposed to the pressure differential between the annulus pressure in the valve and the tubing pressure via a tubing port of the valve; and
a sleeve body sealed in the valve and movable from the closed condition to the opened condition relative to the outlet port,
wherein the first connection connects the piston body to the sleeve body, and
wherein the second connection connects the sleeve body to the check valve.
3. The apparatus of claim 2 , wherein the first connection comprises a rod having a first end coupled to the piston body and having a second end coupled to the sleeve body, the rod breakable in response to a predetermined load between the first and second ends caused by the annulus pressure greater than the tubing pressure.
4. The apparatus of claim 2 , wherein the second connection comprises a wire having a first end affixed to the check valve and a second end affixed to the sleeve body, the sleeve body in the closed condition holding the check valve open with tension of the wire, the sleeve body in the opened condition releasing the tension of the wire on the check valve to close.
5. The apparatus of claim 1 , wherein the piston comprises:
a sleeve body sealed in the valve and exposed to the pressure differential, the sleeve body movable from the closed condition to the opened condition relative to the outlet; and
wherein the first connection connects the sleeve body to a fixed portion of the valve, and
wherein the second connection connects the sleeve body to the check valve.
6. The apparatus of claim 5 , wherein the first connection comprises a rod having a first end coupled to the sleeve body and having a second end coupled to the fixed portion of the valve, the rod breakable in response to a predetermined load between the first and second ends caused by the tubing pressure greater than the annulus pressure.
7. The apparatus of claim 5 , wherein the second connection comprises a wire having a first end affixed to the check valve and a second end affixed to the sleeve body, the sleeve body in the closed condition holding the check valve open with tension of the wire, the sleeve body in the opened condition releasing the tension of the wire on the check valve to close.
8. The apparatus of claim 1 , wherein the first connection comprises a rod having a first end coupled to the piston and having a second end coupled separately, the rod breakable in response to a predetermined load between the first and second ends caused by the pressure differential.
9. The apparatus of claim 1 , wherein the second connection comprises a wire having a first end affixed to the check valve and a second end affixed to the piston, the piston in the closed condition holding the check valve open with tension of the wire, the piston in the opened condition releasing the tension of the wire on the check valve to close.
10. The apparatus of claim 1 , wherein the piston comprises a lock locking the piston in the opened condition once moved.
11. The apparatus of claim 10 , wherein the lock comprises a collet disposed on the piston engageable with a shoulder defined in the valve.
12. The apparatus of claim 1 , wherein the piston comprises seals sealing off the outlet with the piston in the closed condition.
13. The apparatus of claim 1 , wherein the piston comprises an aperture communicating an interior of the piston outside the piston, the aperture misaligned from the outlet with the piston in the closed condition, the aperture aligned with the outlet with the piston in the opened condition.
14. The apparatus of claim 1 , wherein the piston comprises a biasing element biasing the piston from the closed condition toward the opened condition.
15. The apparatus of claim 1 , further comprising a housing having the piston, the first connection, and the second connection, the housing being integral to the gas lift valve or being separately affixable to the gas lift valve.
16. An apparatus on tubing in a wellbore, the apparatus comprising:
a gas lift valve disposed on the tubing and having an inlet and an outlet, the inlet exposed to one of annulus pressure of the wellbore and tubing pressure of the tubing, the outlet exposed to the other of the annulus pressure and the tubing pressure;
a pressure-sensitive valve disposed in the gas lift valve and configured to control communication from the inlet toward the outlet;
a check valve disposed in the gas lift valve and configured to prevent communication from the outlet toward the inlet;
a piston disposed in the gas lift valve between the check valve and the outlet and exposed to a pressure differential between the annulus pressure and the tubing pressure, the piston movable from a closed condition to an opened condition relative to the outlet port;
a first connection holding the piston in the closed condition and configured to release hold of the piston in response to a first predetermined level of the pressure differential; and
a second connection connecting the piston to the check valve, the second connection with the piston in the first position holding the check valve open, the second connection with the piston in the second position releasing the hold of the check valve to close.
17. The apparatus of claim 16 , wherein the check valve comprises a dart body biased with a biasing element toward a seat in the gas lift valve.
18. The apparatus of claim 17 , wherein the first connection is configured to release the hold of the piston in response to the first predetermined level of the annulus pressure greater than the tubing pressure, or wherein the first connection is configured to release the hold of the piston in response to the first predetermined level of the tubing pressure greater than the annulus pressure.
19. The apparatus of claim 17 , further comprising:
a plurality of the gas lift valve disposed on the tubing; and
a shearable orifice disposed on the tubing downhole of the gas lift valves, the shearable orifice being configured to open in response to a second predetermined level greater than the first predetermined level.
20. A method for gas lift in a completion string disposed in a wellbore, the method comprising:
configuring a gas lift valve having an inlet and an outlet by holding a piston in the gas lift valve with a first hold in a first closed condition relative to the outlet and holding a check valve in the gas lift valve with a second hold in a second opened condition between the inlet and the outlet;
installing the gas lift valve on the completion string disposed in the wellbore, whereby the inlet is exposed to one of annulus pressure of the wellbore and tubing pressure of the tubing, whereby the outlet is exposed to the other of the annulus pressure and the tubing pressure;
testing pressure integrity of the completion by alternatingly increasing a pressure differential (i) between the tubing pressure relative to the annulus pressure and (ii) between the annulus pressure relative to the tubing pressure; and
actuating the gas lift valve for operation after testing the pressure integrity by:
releasing the first hold on the piston to move from the first closed condition toward a first opened condition relative to the outlet by increasing the pressure differential beyond a predetermined limit of the first hold; and
releasing, in response to the movement of the piston, the second hold of the check valve to move from the second opened condition toward a second closed position between the inlet and outlet.