Author: Leonardo Jorge Hernandez

1. New Designed Method for Valve Internals (Trim), to Optimize the Process Author: Leonardo Jorge Hernandez Paper Reference: WHOC11-124

2. Content WHOC11-124 • Objective • Introduction • Background • Description of “New Design” Valve Internals • Evaluation • Analysis of Field Results • Conclusion

3. Objetive WHOC11-124 To show the results of the evaluation of a new valve with a “New Method” (Trim) to control the diluent and gas injection in order to optimize well production.

4. Location Caracas Puerto la Cruz Jose FPO CARABOBO AYACUCHO BOYACÁ JUNÍN ORINOCO RIVER R í o O r i n o c o ZUATA MAIN FIELD WHOC11-124 297 MMM BLS 55314 Km 2

5. Introduction The efficiency of oil producing wells is related to the precision of the instruments. The diluent injection and Gas Lift (GL) flow rate has to be precisely controlled by the selected valve to run fluids into the wells. In today’s oil demanding world, precision is an urgent need for well optimization and efficient production. This development results in the world’s most accurate “New Method”. The optimization of Heavy, Extra-Heavy and Light crude oil production, demands precision in the control of the viscosity and the gas flow rate. Diluent injection is the most common practice used in the Faja Petrolífera del Orinoco (FPO), but it also demands high precision on the injected volumes. Other variables hard to control in GL wells is the gas flow to optimize the production. WHOC11-124

6. Flow Set Point Fig. 1 Background Valve with “New Method” installed for diluent injection. WHOC11-124

7. Automatic and manual installation of valves with the “New Method”. For ether installation, the valve has to set the requested flow rate, with the same precision. Automatic Manual WHOC11-124

8. Description of “New Design” Valve Internals 1.- Three dimensional movements. 2.- There is not a mechanical fix contact between the “New Method” and the valve. 3.- Self lubricating. 4.- Low torque. 5.- Low power consumption. 6.- Reduction of the erosional wear. Fig.2 WHOC11-124

9. Comparison Chart for the New Trim Valve and others Existing Valve, Used on Diluent Injection & Gas Lift Process Variable New Method Plug Valve Globe Valve Needle valve Ball valve or Condition Above Year Failures Less than 2% Above 70% Above 20% Above 20% 10% Needle and Floating Trim Rigid Rigid Seat Rigid seat Maintenance Simple Complicated Complicated Complicated Easy Very Good Very Low Precision Low 20% Good 5% Low 20% (+/- 0,01 %) 30% Repeatability Excellent Low Little High Poor Down Stream Class 7 Seal High High Little Seldom Leak Torque Very Low High High High Low Very Low Energy (Auto Very High High High Low Consume Lubricated) Erosion Protected High High High Low Internals Jam None High Little High Seldom Micrometric Direct 3/4 Threaded 5 Direst ¾ Position Ratio Direct 40:1 Turn turns Turns

10. Analysis of Field Results After installing the valve with the “New Method” the recorded flow follows the indicated set point, with high precision. Flow Set Point Fig. 1 Fig. 1 WHOC11-124

11. For wells with diluent injection, these curve shows the impact of not controlling the exact volume of diluent required by each well, which ends up having delay of production; it is evidenced by high well head pressure, uncontrolled API°, and poor field fluid distribution. The underflow produces high well head pressure and the overflow also produces high well head pressure. With the “New Method” valve, it is possible to control the exact volume of diluent required for each well. Optimum Flow area WHOC11-124

12. For Gas Lift wells these curve shows the impact in the production having poor control on the volume injected. Well Performance, 24 API° 600 Maximum Flow area 500 400 Optimum Flow area Prod. BLD 300 200 100 180 0 0 100 200 300 400 500 600 Gas Injection KSCFD WHOC11-124

13. Three hundred (300) of these “New Method” valves have been installed in PDVSA, with the following achievements: 01.- Optimum fluid control rate. 02.- Well head pressure stabilization. 03.- Significant failure rate reduction. 04.- Easy maintenance. 05.- Increase the mean time between failures (MTBF). 06.- High erosion reduction. 07.- Auto lubricating. 08.- No seat and needle mechanical jam. 09.- No leaks. 10.- Very low torque. 11.- Very low energy consumption. 12.- Excellent repeatability. 13.- High precision (0.01% Range). PDVSA is currently working to massify the use of this “New Method”. WHOC11-124

14. Fig. 3 Repeatability: from either position (100% open or close), the valve moves toward the set point with a precision of +/- 0.01%. WHOC11-124

15. “New Design” Method (Trim) 569 600 500 400 Failure 216 300 181 200 20 19 17 17 2 100 Year 0 2000 2001 2002 2003 2004 2005 2006 2007 The installation of valves with the “New Method” began in 2001. By 2007 there where three hundred (300) valves installed with a failure reduction less than 0,35%. WHOC11-124

16. Conclusion 1.-The optimum is more than the maximum. 2.-To make oil production safer, more reliable and more profitable, it is very important to have equipments and control instruments that can perform with high precision the control of the process. 3.-Since the installation of the valve with the “New Method”, it has shown a remarkable savings controlling the exact diluent and gas volume, preventing production delay and low efficiency from over use or under use of the fluids. WHOC11-124

17. Conclusion 4.-It has been use in others application: level control for compressor inter stages and pump cooling system. 5.-High reliability, and less maintenance. 6.-Three hundred (300) of this “New Method” valves have been installed at PDVSA on the FPO since 2001 with excellent performance, and a failure rate less than 0,35%. 7.-PDVSA has decided to apply the use of this “New Method” on a massive scale. WHOC11-124

18. Thank you Questions? Paper Title: “New Design Method” for Valve Internals (Trim), to Optimize the Process Author: Leonardo Jorge Hernandez Paper Reference: WHOC11-124