August 2011

TOP-CO TECH NEWS

Discussion centers on what applications are benefited by the running of Auto-Fill equipment. Read the report for more information, including test results from TopCos flow loop test facility.

Volume 2, Issue 4

TOP-CO AUTO-FILL EQUIPMENT

APPLICATIONS Auto-fill refers to equipment that allows the casing to be run partially open at the float shoe or float collar. Some of the applications and benefits include: Eliminating the need to fill up the casing from surface Reducing surge pressure by displacing mud through both the casing and the annular space Reduce risk of formation fracture or damage Increasing casing running speeds and reducing collapse risks Reducing total casing running time the Top-Co Type 525 Float Collar & Shoe with Top-Flo valve are run open during the casing run by using two balls set into a groove on the plungers shaft. This creates a space between the plunger and the seal through which mud can flow up into the casing. Conversion is done by circulating through the valve at a minimum of 8.3 bbls/ min, fully depressing the plunger and releasing the balls. Once converted, the valve will perform like a regular float valve. Top-Cos Type 525 / 526 Top-Flo auto-fill valve is available in IIB (12 hrs of flow at 10 bpm, 3000psi back pressure) and IIIC ratings (24 hrs of flow at 10 bpm, 5000psi back pressure). The main advantage of this type of system over other auto-fill systems is that they can be converted circulating through the valve. This means that the valve can be converted relatively quickly if needed. When running this type of auto-fill equipment, special care must be taken not to run in too fast as the u-tubing effect that will occur as the fluid levels inside and outside the casing balance can trip the valve. Likewise, reciprocating the casing can cause fluid to surge through the valve converting it. An Insert Float valve as exemplified by the Top-Co Type 207, is a flapper type valve installed in short 8 Round API casing couplings in shallow well applications. In auto-fill mode, the flapper is held open by installing an auto fill-up pump-out sleeve. Conversion is done by pumping a weighted ball (supplied with the valve) through the valve. The maximum differential pressure range is from 707 psi (4,880 kPa) in 13-3/8 equipment to 1620 psi (11,170 kPa) in 4-1/2 equipment and

Type 525 Float Collar

Type 207 Insert Float Valve

Minimizing the amount of cuttings, cavings, or LCM that may bridge the valve by limiting the fill up mud to the conditioned mud already in the hole Reduce mud static time Help identify fluid gains or losses Although running in auto-fill mode reduces surge pressure, it is important to determine the maximum casing running speed to prevent fracturing the formation. Auto-fill equipment is not recommended when encouraging high concentrations of LCM. Upon landing the casing (and sometimes earlier), auto-fill equipment is converted to conventional float equipment by closing the valves. The conversion mechanism depends on the valve type as described below. OPTIONS

Type 535 Float Collar

Type 537 Top-Fill Float Collar

Conventional plunger type float valves such as

TOP-CO TECH NEWS

TOP-CO AUTO-FILL EQUIPMENT
OPTIONS (continued)
Being a ball converted valve it is important to remember that these tools cant be run in wells that are deviated more than 30 degrees. The reason for this is that the balls are dropped and rely on gravity to reach the valve. If the inclination is too severe, the ball will either take a long time to reach the valve or get hung up never reaching the valve at all. One big disadvantage of this type of ball converted auto-fill equipment is that it cant be converted quickly since you need to wait for the I N S I D E S T O R Y H E A D L I N E To catch the reader's attention, place a n i n t e r e s This t i n g s e n t e is nce o r q u o t e ideal from ball to drop. not in the case of a kick. Circulatthe story here. ing after the ball has been dropped will help increase the rate of descent. This story can fit 100-150
Collaboration by: Alfredo Sanchez - Senior Petroleum Engineer Greg Andrigo - Director, Engineering

In addition to reducing surge pressures and formation damage risks, differential fill valves are also used to reduce the risk of differential pressure sticking. Furthermore, they also allow circulation (prior to releasing the ball) at higher rates without the risk of premature conversion. It should be noted however that since these valves are mechanically complex, it is not recommended that they be run with large amounts of LCM. Top-Cos T535/536 float equipment is currently rated to IIB with a IIIC version under development.

For maximum casing run in speed, a large bore open hole auto fill valve as per the Top-Co Type 537 / 538 Top-Fill Valve is recommended. This valve is similar to the Type 207 and consists of a flapper valve that is run fully open and converted by dropping a ball. The main advantage of big bore auto-fill equipment employeesis ora top customIf the newsletter is distriblarger fill-up area that reducesers surge presor vendors. words. uted internally, you might sures and allows theprocecasing to fill up faster. Differential fill manufactured under the Top-Co Type 535 / comment upon new The subject that It isdures also or less susceptible 536 Differential Valve work both as auto-fill andmatter convenimprovements to to LCM since appears in newsletters is there are fewer moving parts. Top-Cos tional valves as they are run down into the hole. As the the business. Sales figures virtually endless. You can Type 537 / 538 float equipment is currently casing is run down the valve opens automatior earnings will show how to IIB with a IIIC version currently uncally to allow fluid to enter the casing. include The stories that focus rated your business is growing. on current technologies or der development. valve remains open and casing fill up contininnovations in your field. Some newsletters include ues until the casing is 85%-90% full; at that a column that is noted updated It should also be that both the Type point, the valve closes automatically, preventYou may also want to note every issue, forand instance, 535 Differential Type 537 Top-Fill open ing any more fluid from entering the casing. It business or economic anvalves advice column, a book with different size hole are available is important to understand however that until trends, or make predicconversion balls. This is important for liner review, a letter from the the differential valve is converted, it does not tions for your customers or applications oran when other ball activated tools are used president, or editorial. offer protection against pressure kick from clients. above the also differential valve. All Top-Co auto-fill valves You can profile new below. This opening and closing sequence will work with standard cementing plugs (Type 252 / 253) continues until the valve is permanently conI N S I D E S T O R Y H E A D L I N E or the non-rotating Top-Co Type 547 / 548 Kwik Drill plug. verted from a differential valve to a dual flapper valve by dropping a ball and pressuring up TESTING & DEVELOPMENT to pump it through the valve. The act of that appear to be out of story can fit 75-125 article. Be sure to place pumping the ball through the valve willThis release context. words. the caption of falls the image The performance rating for auto-fill valves under API the upper flapper and lock the lower sleeve in near the image. Recommended Practice 10F. It requires that an auto-fill place. Microsoft Publisher inSelecting pictures or valve be reverse circulated for 6 hours prior to convercludes thousands of clip graphics is an important sion. After conversion the valve will be flowed through for art images from which you part of adding content to either 12 or 24 hours and back pressure tested to either can choose and import your newsletter. Caption describing 3000 psi @ 300F (II-B) or 5000 psi @ 400F (III-C). into your newsletter. There picture or graphic. Think about your article In addition to standard testing as per API RP-10F, each are also several tools you and ask yourself if the Top-Co valve undergoes additional testing to measure can use to draw shapes and verify the performance of the valves under various picture supports or enand symbols. conditions. All valves have been extensively tested to hances the message determine pressure drop across the valve during run Once youthe have chosen an youre trying to convey. in. image, place it close to the Avoid selecting images
Page 2

TOP-CO TECH NEWS

TOP-CO AUTO-FILL VALVES
T525/526 (TOP-FLO) AUTO-FILL PERFORMANCE: Auto-Fill Position 1
65 60 55 50 45 40 Pressure, psi 35 30 25 20 15 10 5 0 0 2 4 6 8 10 12 14 16 18 Flowrate, bpm Upstream Downstream Pdrop Water based mud:
- Density: 12.1 lb/gal - Plastic viscosity: 47 cp - Yield point: 37 lb/100ft2 - 10-s gel strength: 4.5 lb/100ft2 - Sand content: 3% by vol.

Collaboration by: Alfredo Sanchez - Senior Petroleum Engineer Greg Andrigo - Director, Engineering

Conversion rates have been accurately determined by testing under simulated flow conditions in Top-Cos flow loop test facility; conversion flow rate for the Type 525 valve and conversion pressures on ball converted valves.

The Type 535 valve has been tested to ensure the valve will convert at temperature. It has also been tested to determine the affect the use of different conversion ball materials will have on the performance of the valve.

Back pressure and no leak indicate valve converted during at the last flow rate, 8.28 bpm

Leak through valve indicates valve is still open

Phenolic Conversion Ball vs. Standard Zinc Conversion Ball

Page 3

TOP-CO TECH NEWS

TOP-CO AUTO-FILL VALVES
VALVE SPECIFICATIONS