Optimax@ TRSV@ Operations@ Manual
Optimax@ TRSV@ Operations@ Manual
For
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Table of Contents
1. Description................................................................................................................................................................. 3
Fail Safe Setting Depth (FSSD) Calculation: ................................................................................................................ 3
2. Assembly Procedures ............................................................................................................................................... 4
Assembly Testing .......................................................................................................................................................... 4
Drift ................................................................................................................................................................................ 4
3. Disassembly Procedures ........................................................................................................................................... 4
4. Handling & Storage ................................................................................................................................................... 5
Recommended Handling Guidelines ............................................................................................................................ 5
Shipping Guidelines ...................................................................................................................................................... 5
Storage Guidelines........................................................................................................................................................ 5
Cross-Over Flow Coupling Torque Procedure .............................................................................................................. 6
5. Hydraulic Control Line Fluid ...................................................................................................................................... 8
Special Considerations ................................................................................................................................................. 8
6. Maintenance / Service Testing .................................................................................................................................. 9
Maintenance .................................................................................................................................................................. 9
Service Testing ............................................................................................................................................................. 9
7. Running and Pulling Procedures ............................................................................................................................. 10
Running Procedure/Opening and Closing Procedures ............................................................................................... 10
Preparations for running the valve; while on the rig floor verify the following: ........................................................ 10
Running the Valve with Zero Differential Pressure Across Valve ........................................................................... 10
Running the Valve with Differential Pressure Across Valve .................................................................................... 11
Operating Procedures ................................................................................................................................................. 11
Tubing pressure sensitive valve .............................................................................................................................. 12
Tubing pressure insensitive valve ........................................................................................................................... 12
Control Line Fitting Installation to the Safety Valve .................................................................................................... 13
Jam Nut and Externally Checkable Jam Nut ........................................................................................................... 13
Primary: Jam Nut Fitting .......................................................................................................................................... 14
Optional: Externally Checkable Jam Nut Fitting ...................................................................................................... 14
Optional: Autoclave KCGL Fitting............................................................................................................................ 15
Pulling Procedure for the TRSV .................................................................................................................................. 15
8. Trouble Shooting ..................................................................................................................................................... 16
Excessive Opening Pressures .................................................................................................................................... 16
Unable to open valve .................................................................................................................................................. 16
Surface Control System .............................................................................................................................................. 19
Control Line Leak ........................................................................................................................................................ 20
Valve Leaking/Sticking ................................................................................................................................................ 22
9. Field Repair ............................................................................................................................................................. 24
10. Valve Redress .................................................................................................................................................... 24
11. Valve Repair ....................................................................................................................................................... 24
General Requirements ................................................................................................................................................ 24
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1. Description
The Optimax™ Tubing Retrievable Safety Valves are self-equalizing or non-equalizing tubing mounted safety valves.
These valves are designed to minimize the loss of reservoir resources, or production equipment resulting from
catastrophic surface or subsurface events, by shutting in the well. This is achieved by design; the normally closed
safety valves are controlled from the surface via a hydraulic control line that extends from the valve, through the
wellhead to a surface controlled emergency closure system. Hydraulic pressure applied through the control line
maintains the valve in the opened position. Removal of control line pressure returns the valve to its normally closed
position. Setting depth directly affects the operational characteristics of the valve. Therefore, these valves are offered
in various setting depth configurations to ensure that failsafe operation is achieved.
Maximum fail safe setting depths have been calculated considering seawater as the heaviest fluid gradient in the
completion. Completions utilizing annulus fluids may offer fluid gradients greater than that of seawater. Failsafe
closure is directly affected by and dependent on the level of hydrostatic pressure developed by these fluids and
should be adjusted accordingly to accommodate heavier fluid gradients in the annulus in the event that the control line
should break.
Optimax™ Tubing Retrievable Safety Valves are offered with a full compliment of remediation tools to either lock the
valve opened or establish hydraulic communication.
The Optimax™ Lock Open Tool permanently locks the valve in the full opened position allowing the valve to be pulled
from the well or accept an Optimax™ Wireline Retrievable Safety Valve, a separation sleeve, or any other equipment
that may require the safety valve to be permanently locked open.
The Optimax™ Communication Tool is used to penetrate the tubing retrievable safety valve’s hydraulic Piston bore,
establishing control line pressure to the bore of the valve. This allows the existing hydraulic control system utilized for
the tubing retrievable safety valve to be used to operate the Optimax™ Wireline Retrievable Safety Valve set within
the tubing retrievable valve, providing continued failsafe operation.
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2. Assembly Procedures
Assembly should only be performed by qualified personnel at an authorized WCS service center. For
assembly instructions please refer to separate document for that specific valve.
Assembly Testing
Functional testing per Engineering Test Procedures ETP-SRO-F001 shall be performed on every
monogrammed safety valve prior to shipping from manufacturing facility. This procedure has been developed
using API-14A and internal quality assurance standards. Test information will be found on form ETP-SRO-
F001 located in valve packet.
Drift
Refer to the latest version of engineering design standards EDS-003 for appropriate drift bar sizes and
tolerances.
3. Disassembly Procedures
Disassembly should only be performed by qualified personnel at an authorized WCS service center. For
disassembly instructions please refer to separate document for that specific valve.
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Damage resulting from the mishandling of SCSSV equipment, rendering dents, gouges and or nicks can be
detrimental to a components ability to resist stress corrosion and cracking, regardless of the material type.
Stainless and nickel-based materials are more susceptible to surface damage due to galling and cold working at
metal-to-metal and high-pressure contacts such as thread connections. Galling is aggravated by nicks and dings.
File, grind or sand any and all such damaged areas completely to blend the damaged surface into the
surrounding area.
If there are questions regarding the acceptability of a repair (i.e. reduced wall thickness in the Bottom Sub,
damage to critical contact surfaces on threads, etc.), consult Weatherford’s completions engineering group for
guidance.
Shipping Guidelines
1. Ensure Thread Protectors are installed at both ends of the safety valve prior to any movement, shipping
or handling of any kind.
2. If hydraulic control line test fluid is different than hydraulic fluid utilized in the field, remove all hydraulic
control line test fluid from the system before shipping.
3. Ensure a plug is installed into the control line port of the hydraulic chamber housing to prevent any debris
from contaminating the hydraulic cylinder, minimizing hydraulic seal damage.
Storage Guidelines
2. Verify that a pipe plug has been installed into the control line port. The control line port must remain
plugged when the valve is not being tested. Plugging the control line port will prevent debris from
contaminating the hydraulic Piston bore.
4. Store tools vertically, when possible, with an open-ended protector at the bottom to allow for moisture
drainage.
5. Thoroughly dry tools tested with water and coat ID’s and OD’s with corrosion inhibitor or oil.
7. Store spare elastomeric and rubber components in sealed bags away from direct sunlight, ultraviolet
light, or electric motors or generators. Always reseal the bags containing elastomeric components.
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While making up Cross-Over Flow Couplings to the top and bottom end connections of a tubing mounted safety
valve, it is important to follow the procedure below. Gripping the safety valve OD in the wrong place could
severely damage parts of the safety valve that are required for pressure and operational integrity downhole.
Failure to follow this procedure could be detrimental to the integrity of any of the WFT metal sealing connections
or reduce the rated working pressure of the safety valve.
Grip Here
Grip Here
Top Tubing WFT Thread WFT Thread WFT Thread Bottom Tubing
Thread Thread
NOTE: NON-MARKING TONG JAWS ARE RECOMMENDED ON ALL SAFETY VALVE OD’s.
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3” Grip
Grip 6” Max Here
Here Do Not Exceed
3.00 [76.20] From Taper
NOTE: NON-MARKING TONG JAWS ARE RECOMMENDED ON ALL SAFETY VALVE OD’s.
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Cleanliness - Hydraulic fluids must remain clean and free from solids to minimize the potential for seal wear and or
damage. Hydraulic fluids should maintain a cleanliness consistent with NAS-1638 Class 7 or better.
A filtering system with a suction filter of 40 microns or better may need to be installed into the
hydraulic system to achieve the required hydraulic fluid cleanliness.
Response Time – The duration of time that elapses from the instant surface pressure is released to closure of the
SCSSV. Factors that directly influence response time are control line length, control line size
(determined by wall thickness), fluid viscosity, and well temperatures, amid other considerations.
(Lower viscosity fluids may need to be considered in unusually cold environments or for
completions where excessively long control lines are utilized.)
Temperature Effects – Primarily temperature effects alter the viscosity of the hydraulic fluid, however, the fluid
selected must also remain thermally stable if elevated temperatures are a factor. At extreme
temperatures, oil based hydraulic fluids may tend to break down, leaving deposits on wetted
components. Therefore, ensure the fluid selected is stable beyond the operating temperature
for which it will be exposed.
Water-Based Hydraulic Fluid – Control line fluids that primarily consist of 50-75% water, 25-50% glycol, and
between 0-10% corrosion additives. Water based fluids are widely used in sub
sea applications for environmental consideration and for low viscosities, to
minimize response time in longer sub sea control lines. However, metallic
components exposed to water-based control line fluids may corrode, therefore,
careful selection of metallurgy exposed to the fluid in combination with corrosion
inhibitors added to the fluid will minimize correctional effects.
Special Considerations
Water-based control line fluids require special handling to prevent contamination either by debris or from other
hydraulic control fluids. Avoid cross contamination of water-based control line fluid with hydrocarbon-based
fluids (oil, grease, diesel, etc.). If a new SCSSV is required to utilize a water-based hydraulic fluid, the safety
valve manufacturer must be notified in advance of the intent to use a water-based hydraulic fluid to ensure
proper SCSSV preparation (See API 14A/ISO 10432:1999 Annex F, Checklist of Suggested Ordering
Information for SSSV Equipment). For redress of SCSSVs, only those lubricants specified by the fluid
manufacturer should be used in or around the hydraulic control fluid chamber.
Recommendations specific to control line fluid applications can be obtained from Weatherford’s Completions
Engineering Department. This document includes some typical hydraulic fluids used for SCSSV application and
their respective properties.
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Maintenance
To ensure proper valve operation after installation in a well, a maintenance program should be established. API
RP 14B, the most current edition, will provide guidance with respect to maintenance/service testing frequency.
Service conditions may dictate that more frequent operation of the valve is necessary. NOTE: Only qualified
personnel should perform Service testing.
As a routine function of the maintenance program, all accessible control line connections should be checked for
leakage. Additionally, the control line fluid should be kept clean and free from debris, which could cause seal
damage. NAS CLASS 7 or better is recommended, or consult with specific client requirements on fluid
cleanliness levels.
Service Testing
Service testing an installed valve includes cycling the valve through one complete cycle, opening the valve and
closing the valve in the well. Periodic service testing will minimize the potential for wellborn deposits to
accumulate in and around critical dynamic components in the valve.
Record the opening and closing pressures in a log for future reference. Use this recorded pressure as the basis
of comparison over the valve’s life to monitor friction in the valve. Increased opening pressure and decreased
closing pressure may indicate that scale, sand, or some other deposits are building up in the valve.
If a valve fails to close, open or malfunctions in any other way, a failure report form must be filled out.
Complete the trouble shooting guide per section 8 to determine the appropriate course of action. Required
actions may include exercising, flushing, lock out and communication in preparation for running an insert valve or
pulling the valve for repair or replacement.
API monogrammed safety valves in need of repair must be sent to an authorized service center for repair.
Once a valve has been pulled from the well proper handling procedures should be followed to ensure further
damage to the valve does not occur. Reference the Handling & Storage procedures manual.
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Preparations for running the valve; while on the rig floor verify the following:
If there are questions regarding the acceptability of a repair (i.e. reduced wall thickness in the Bottom Sub,
damage to critical contact surfaces on threads, etc.), consult Weatherford’s completions engineering group
for guidance.
4. Prior to running the valve ensure all transportation devices (Thread protectors, plugs, etc.) are removed.
5. Install the control line fitting (See Control Line Fitting Installation below) and attach the control line to a
pump. Open the valve by applying hydraulic pressure through the control line per Operating Procedures
below. While in the open position, hold hydraulics on the valve for ten minutes to verify Piston seal
integrity. Bleed hydraulic pressure to zero to close the valve and record the returns volume. Record the
opening, hydraulic hold open and closing pressures.
NOTE: REFER TO SUPPLIED VALVE ATTRIBUTES FOR OPENING AND CLOSING PRESSURES.
6. Replace the control line fitting with plug if the valve is not to be run at this time.
1. If the Flow Couplings have been previously installed to the Safety Valve, position the Safety Valve in
the tubing string and torque as required. Do not grip on the Safety Valve OD’s.
2. If the Flow Couplings are being installed at the rig site, use strap or chain wrenches to attach them to
the Safety Valve hand tight prior to final torque, (see diagram of Cross-Over Flow Coupling Torque
Procedure in this manual for gripping locations on the Safety Valve). Non-marking tong jaws are
recommended on the Safety Valve OD’s.
3. Verify tubing thread connections receive appropriate torque values for make-up.
4. Install control line fitting and control line to the valve (Refer to control line fitting installation in this
manual).
5. Apply full opening pressure to the hydraulics to maintain the valve opened while tripping tubing and
control line down hole.
6. Clamp or band the control line to the tubing as required, maintaining the control line tight and close to
the tubing. Extreme care must be exercised to prevent control line damage while running.
7. Prior to setting the tubing hanger, bleed hydraulics to zero. Cut sufficient control line length to thread
through the tubing hanger if applicable, or make up to the hanger using the appropriate fittings.
8. Once the control line has been reattached to the rig’s hydraulic control system, apply hold open
pressure, per Operating Procedures below. Block the valve in to maintain the valve in the opened
position.
9. Monitor hydraulic pressure for ten minutes for any deviations from the blocked in pressure.
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Note: To open the valve with differential pressure, the differential must be equalized to less than 20
psi across the Flapper prior to opening.
1. When the valve is positioned for make up to the tubing string use a strap or chain wrench, if necessary,
to make the valve up to the tubing string. Do not use pipe wrenches on critical ODs if possible.
2. Verify tubing thread connections receive appropriate torque values for make-up.
3. Install control line fitting and control line to the valve (Refer to control line fitting preparation and
installation in this manual).
4. Apply hold open pressure, per Operating Procedures below, to the valve hydraulic control line to
maintain the valve opened while tripping tubing and control line down hole.
5. Clamp or band the control line to the tubing as required, maintaining the control line tight and close to
the tubing. Extreme care must be exercised to prevent control line damage while running.
6. Prior to setting the tubing hanger, bleed hydraulics to zero. Cut sufficient control line length to thread
through the tubing hanger if applicable, or make up to the hanger using the appropriate fittings.
7. For a valve with a self-equalizing feature, apply hold open pressure, per Operating Procedures below,
to hydraulics once the control line has been reattached to the rig’s hydraulic control system. If the valve
does not have a self-equalizing feature, pump down through the valve until the valve has been equalized
to less than 20 psi differential. Block the control line in to maintain the valve in the opened position.
8. Monitor hydraulic pressure for ten minutes for any deviations from the blocked in pressure.
Operating Procedures
The operating pressures can either be tubing pressure sensitive or insensitive (see attribute page). If a valve is
tubing pressure sensitive, then the internal well bore pressure will need to be overcome in order to open the
closure mechanism. A tubing pressure insensitive valve operates independently of the well bore pressure which
means that the shut in tubing pressure does not need to be added to the opening pressure. If the valve does not
have a self-equalizing feature, pump down through the valve until the valve has been equalized to less than 20
psi differential.
Definitions:
OPEN: OPENING PRESS MAX TEST RACK WITH ZERO TUBING PRESS (psi)
CLOSE: CLOSING PRESS MIN TEST RACK WITH ZERO TUBING PRESS (psi)
MACLP (Max Allowable Control Line Press): CONTROL CHAMBER PRESSURE MAXIMUM AT MAX TEMP
(psi)
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Closing pressure
Closing pressure
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1. Use a tube cutter to cut the control line and verify the cut is square and free from burrs both internally
and externally.
2. Remove the pipe plug from the hydraulic chamber housing control line port.
3. Slide the jam nut over the control line.
4. Slide the back ferrule over the control line; ensure that the smaller shoulder is toward the cut end of the
control line (see diagram).
5. Slide the front ferrule over the control line, with the tapered end toward the cut end of the control line.
6. Examine the control line and the Jam Nut components to ensure they are free from debris.
7. Insert the end of the control line into the hydraulic chamber housing control line port. Make sure the
control line has been inserted to its deepest point and lightly hold in place.
8. Next slide the front and back ferrules into the hydraulic chamber housing control line port.
9. Move the jam nut into position and make it up in the control line port hand tight.
10. Tighten the jam nut with a wrench until either the torque value or turn position from the chart below is
achieved based on the control line material. The chart is for ¼” control line with either 0.049” or 0.065”
wall thickness.
11. Back the jam nut out to inspect the ferrules, ensuring they have properly crimped the control line. The
ferrules should not slide up or down the control line.
12. File the end of the control line slightly, in a downward facing direction, to remove between 0.01” – 0.03”
(1/64” – 1/32”) of material, being careful not to introduce debris to the system. Clean the end of the
control line to remove any filings.
13. Reinstall and tighten the jam nut as before using the chart below.
14. Connect the other end of the control line spool to a hand pump and apply either full open pressure or
test pressure to the valve. Block in the pressure and monitor the fitting for ten minutes to verify Jam
Nut seal integrity.
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1. Use a tube cutter to cut the control line, verify the cut is square and free from burrs.
2. Cone and thread tubing per Parker Autoclave Threading instructions using the high pressure kit KMCT-
HT. The extra allowance for engagement will be 0.50 inches for the ¼” control line.
3. Slide collet assembly onto control line and install collar leaving one to two threads exposed between the
collar and the cone.
4. Apply moly spray to male threads on gland nut.
5. Torque gland nut to 25 ft-lbs.
1. Apply maximum control line pressure to the valve. Maintain the valve in the open position.
2. Begin tripping out tubing.
3. Remove control line straps as they become available and wrap the control line on a spool while the
tubing is being pulled.
4. At the tubing hangar bleed hydraulics, and remove the control line from the hanger.
5. Re-establish hydraulic communication with the valve, maintain hold open pressure.
6. At the valve bleed hydraulics and disconnect the control line fitting.
7. Remove the valve from the tubing string.
8. If the valve will not open, refer to the Trouble Shooting Manual for guidance.
9. If the valve remains inoperable, refer to the Lock Out Procedure Manual.
10. Once the valve has been locked–out, retract the valve as outlined in steps 2 through 7.
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8. Trouble Shooting
The purpose of this procedure is to document the minimum steps required to properly troubleshoot a Subsurface
Safety Valve that is experiencing operational problems. Historically, valves have been locked open and
communicated prematurely due to lack of a proper failure investigation prior to abandoning the valve.
1. Refer to required control line pressures to open the valve. This is pressure at the valve, not at the wellhead.
Hydrostatic pressures must be considered when determining the opening and closing pressures at the
valve.
2. Verify/Test the instrumentation measuring the opening and closing pressures to ensure its accuracy.
3. Confirm the valve has been fully equalized. If a differential pressure exists (i.e. upstream pressure
trapped below the Flapper in excess of downstream pressure), the opening pressure of the valve will
increase. With the valve fully equalized, open and close the valve five (5) times recording the full open
hydraulic pressure each time. If the average opening pressure is unacceptable, contact the nearest WCS
service center.
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Unable to open
Valve
Valve Serial Number:____________
Valve Type:____________
Close Production
Wing Valve
Pressure Up CL
and monitor
Open CL Valve pressure response Does CL
pressure drop
(pump stroke)?
Yes Yes
No Cycle pressure on
CL several times
Check Wellhead Rapid Increase in CL and observe
Open? Yes
Valve on CL Pressure? results.
No
Is valve
operating?
Pressure Observe Tubing Equalizing
Yes
Increasing? and CL Pressure Valve?
Yes No No
Continue to
observe tubing Pressure up above No
and CL until Valve Open? No flapper to equalize
Pressure valve
Stabilizes
Continue to
observe tubing
Complete Yes and CL until
Pressure in Tubing
Stabilizes
Yes
Go to Panel
Trouble Shooting
Flow Chart
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Diconnect CL at
tree and pump a
Clean or replace
volume of fluid.
No valve.
Catch fluid
sample.
Yes Yes
Trace CL from
Wellhead to panel
checking for Flush panel and
Sample Clean? No
damage/blockage. lines to clean fluid.
Pump through at
any splices.
No Yes
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Diconnect CL at
tree and pump a
volume of fluid.
Catch fluid
sample.
Yes
Pressure test CL
port at tree.
Pressure Test
Fault is at tree. No
OK?
Yes
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Valve Leaking/Sticking
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Valve Leaking/Sticking
Cycle pressure to
Yes maximum rating
and remove Flow Tube
Yes
rapidly with full Stuck?
tubing pressure on
valve.
No
Yes
Flapper is
Valve still
probably cut by
leaks?
wireline.
No
Yes
LO and COM.
Put well on line.
Install insert.
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9. Field Repair
Field repair of the valve is not permitted.
Only “Qualified Personnel” must perform a valve redress. Qualified Personnel as defined by API RP 14B are those
individuals with the characteristics or abilities gained through training or experience or both as measured against
established requirements, such as standards or tests that enable the individual to perform a required function.
Records of these standards and tests are to be placed in the individual’s training file and maintained in the authorized
service center.
General Requirements
All replacement parts shall be qualified parts. Qualified parts are those parts that have been manufactured
in accordance with the WCS quality assurance program, and must meet or exceed the performance
requirements of the original part.
Note: Repairs to API regulated safety valves and related equipment are to be performed by qualified personnel,
at an authorized WCS service center. Repair, as defined by API RP 14B, is an activity involving disassembly,
reassembly and functional testing of SSSV equipment with or without the replacement of qualified parts. Repair
does not under any circumstances include machining, welding, heat treat or any other manufacturing process.
Qualified Personnel as defined by API RP 14B are those individuals with the characteristics or abilities gained
through training or experience or both as measured against established requirements, such as performance
standards or tests that enable the individual to perform a required function. Records of these standards and or
tests are to be placed in the individual’s training file and maintained at the authorized service center.
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France
Chemin de l’Esperance
64270 Bellocq
FRANCE
Tel.: 33-559-652-630
Fax: 33-559-652-028
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REVISIONS
REV DESCRIPTION DATE REVISED BY
Removed specification for using 10 to 3 grit diamond lapping
compound from page 11, step 5.a and replaced with lapping
1.0 19-Jun-2013 D. Trowbridge
compound conversion chart to reflect compounds and equivalents
used during manufacture.
Revised to generic document for all Optimax TRSVs. Updated to API
2.0 14A 12th edition guidelines. Removed the assembly/disassembly 06-Aug-15 C. Golsch
sections.
3.0 Added Operating Procedures section and Jam nut installation chart. 03-March-16 C. Golsch
Modified wording in Running Procedure to refer to the Operating
3.1 25-May-16 C. Golsch
Procedure for opening valve.
Added Autoclave KCGL fitting instructions and diagram. Added
4.0 14-June-16 C. Golsch
externally checkable jam nut fitting diagram.
4.1 Added more details and flow charts to troubleshooting section. 02-Aug-16 C. Golsch
Minor editorial changes to improve clarity and added steps for
4.2 20-Feb-17 D. Trowbridge
measuring control line returns.
5.0 Changes made to include Optimax Select. 21-May-2020 D. Gilstrap
6.0 Changes made to include Optimax Gen Z. 31-Aug-20 [Link]
6.1 Revised name from Optimax Gen Z to Optimax Z-Series 23-Sep-20 C. Golsch
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