OISD-GDN-193-Gas Lift Opr & Mtce

Sr.
Number:OISD/DOC/2016/419
Page No. I
OISD-GDN-193
First Edition
September, 2001
FOR RESTRICTED
CIRCULATION
GUIDELINES FOR
GAS LIFT OPERATIONS AND
MAINTENANCE
First Edition September, 2001
Oil Industry Safety Directorate

Government of India
Ministry of Petroleum & Natural Gas
8th Floor, OIDB Bhavan, Plot No. 2, Sector – 73, Noida – 201301 (U.P.)
Website: www.oisd.gov.in
Tele: 0120-2593800, Fax: 0120-2593802
Sr.Number:OISD/DOC/2016/419
Page No. II
OISD-GDN-193
First Edition
September, 2001
GUIDELINES FOR
GAS LIFT OPERATIONS AND
MAINTENANCE
Prepared by
COMMITTEE ON “ GAS LIFT OPERATIONS AND MAINTENANCE ”

Government of India
Tele: 0120-2593800, Fax: 0120-2593802
Page No. III
Preamble
Indian petroleum industry is the energy lifeline of the nation and its continuous performance is
essential for sovereignty and prosperity of the country. As the industry essentially deals with
inherently inflammable substances throughout its value chain – upstream, midstream and
downstream – Safety is of paramount importance to this industry as only safe performance at all
times can ensure optimum ROI of these national assets and resources including sustainability.
While statutory organizations were in place all along to oversee safety aspects of Indian
petroleum industry, Oil Industry Safety Directorate (OISD) was set up in 1986 Ministry of
Petroleum and Natural Gas, Government of India as a knowledge centre for formulation of
constantly updated world-scale standards for design, layout and operation of various
equipment, facility and activities involved in this industry. Moreover, OISD was also given
responsibility of monitoring implementation status of these standards through safety audits.
In more than 25 years of its existence, OISD has developed a rigorous, multi-layer, iterative and
participative process of development of standards – starting with research by in-house experts
and iterating through seeking & validating inputs from all stake-holders – operators, designers,
national level knowledge authorities and public at large – with a feedback loop of constant
updation based on ground level experience obtained through audits, incident analysis and
environment scanning.
The participative process followed in standard formulation has resulted in excellent level of
compliance by the industry culminating in a safer environment in the industry. OISD – except in
the Upstream Petroleum Sector – is still a regulatory (and not a statutory) body but that has not
affected implementation of the OISD standards. It also goes to prove the old adage that self-
regulation is the best regulation. The quality and relevance of OISD standards had been further
endorsed by their adoption in various statutory rules of the land.
Petroleum industry in India is significantly globalized at present in terms of technology content

requiring its operation to keep pace with the relevant world scale standards & practices. This
matches the OISD philosophy of continuous improvement keeping pace with the global
developments in its target environment. To this end, OISD keeps track of changes through
participation as member in large number of International and national level Knowledge
Organizations – both in the field of standard development and implementation & monitoring in
addition to updation of internal knowledge base through continuous research and application
surveillance, thereby ensuring that this OISD Standard, along with all other extant ones,
remains relevant, updated and effective on a real time basis in the applicable areas.
Together we strive to achieve NIL incidents in the entire Hydrocarbon Value Chain. This,
besides other issues, calls for total engagement from all levels of the stake holder
organizations, which we, at OISD, fervently look forward to.
Jai Hind!!!
Executive Director

Page No. IV
FOREWORD
The Oil Industry in India is more than 100 years old. Because of various collaboration
agreements, a variety of international codes, standards and practices have been in vogue.
Standardisation in design philosophies and operation and maintenance practices at a national
level was hardly in existence. This coupled with feed back from some serious accidents that
occurred in the recent past in India and abroad, emphasised the need for the industry to review
the existing state- of- the-art in designing, operating and maintaining oil and gas installations.
With this in view, the Ministry of Petroleum and Natural Gas in 1986 constituted a Safety
Council assisted by the Oil Industry Safety Directorate (OISD) staffed from within the industry in
formulating and implementing a series of self regulatory measures aimed at removing
obsolescence, standardising and upgrading the existing standards to ensure safe operations.
Accordingly, OISD constituted a number of functional committees of experts nominated from the
industry to draw up standards and guidelines on various subjects.
The present guidelines are prepared by the Functional Committee on“ Gas lift
operations and maintenance”. The document is based on the accumulated knowledge and
experience of industry members and the various national and international codes and practices.
These guidelines are meant to be used as supplement and not as a replacement for
existing codes and practices.
It is hoped that provisions of guidelines, if implemented objectively, may go a long way

to improve the safety and reduce accidents in Oil and Gas Industry. Users are cautioned that no
standard can be substitute for the judgement of responsible and experienced Engineers.
Suggestions are invited from the users after it is put into practice to improve the document
further. Suggestions for amendments to this document should be addressed to the Coordinator,
Committee on “Guidelines and recommended Procedures for gas lift operations and
maintenance”,
Government of India
Tele: 0120-2593800, Fax: 0120-2593802
These guidelines in no way supersedes the statutory requirements of
bodies like DGMS, CCE or any other Government Body which shall be
followed as applicable.
Page No. V
NOTE
OISD (Oil Industry Safety Directorate) publications are prepared for use
in the Oil and Gas Industry under Ministry of Petroleum & Natural Gas. These
are the property of Ministry of Petroleum & Natural Gas and shall not be
reproduced or copied and loaned or exhibited to others without written consent
from OISD.
Though every effort has been made to assure the accuracy and
reliability of the data contained in these documents, OISD hereby expressly
disclaims any liability or responsibility for loss or damage resulting from their
use.
These documents are intended to supplement rather than replace the

prevailing statutory requirements.
Page No. VI
COMMITTEE MEMBERS
FOR PREPARATION OF GUIDELINES ON
" GAS LIFT OPERATIONS AND MAINTENANCE ''
NAME ORGANISATION POSITION
S/SHRI
1. V.V.Manchalwar ONGC LEADER
2. Girdhar Kumar, ONGC MEMBER
3. Gulab Singh, OISD Member-CO-ORDINATOR

Page No. VII
CONTENTS
S.N. TOPICS PAGE NO.
1. INTRODUCTION 1
2. SCOPE 2
3. DEFINITIONS 2
4. SAFE OPERATING PRACTICES 3
4.1 EQUIPMENT HANDLING

4.1.1 TRANSPORTATION AND STORAGE
4.1.2 ASSEMBLY AND SERVICING
4.1.3 TESTING AND CALIBRATION
4.2 FACTORS TO BE CONSIDERED BEFORE

PUTTING A WELL ON GAS LIFT
4.3 LOWERING
4.4 UNLOADING
5. REGULAR OPERATION AND MONITORING 10
6. QUALITY OF INJECTION GAS 11
7. LAYOUT OF SURFACE HOOK UP 12
8. WIRELINE OPERATION 13
9. POCKET GUIDE 14
10. REFERENCES. 14
OISD – GDN – 193 Page No. 1

GUIDELINES FOR
GAS LIFT OPERATIONS AND MAINTENANCE
"GUIDELINES FOR GAS LIFT OPERATIONS AND

MAINTENANCE"
1. INTRODUCTION
In the life of an Oil well, Gas Lift operation comes in to picture when
the natural pressure energy of the reservoir declines in due course of time. At
this stage, it becomes essential to artificially supplement energy in some form to
the well fluid to keep the well flowing. There are many methods to artificially
lift the well fluid. Prominent among them are Gas Lift, Sucker Rod pumping
(SRP), Electrical Submersible pumping (ESP), Hydraulic pumping etc.
In off-shore operations, Gas-Lift is the most prominent method of

Artificial Lift and in on-shore, it is the second or third most important position
in Artificial Lift modes.
In Gas Lift operation, high pressure natural gas is injected in to the tubing
string at pre-determined depths through either a Gas Lift Valve (GLV) or
through a Circulating Valve (CV). High pressure natural gas, when injected in
to the tubing, and as the gas expands with decreasing pressure energy from the
gas transfer to the well fluid and the fluid column gets lightened and flows up
the tubing and finally the well fluid is delivered to the surface hook up. The
surface facilities are to be designed and operated in such a fashion as to create
minimum back pressure to the fluid flow thus reducing the gas energy
consumption to the minimum.
In all stages of Gas-lift operations, operator plays an important role.

Hence, it is imperative that the operators shall be fully aware of the safe
operating practices to be followed in Gas-lift operation. Formulation of these
guidelines are a step in the direction to provide adequate safe operating
knowledge to the people involved in Gas lift operations.
These guidelines are to provide recommended procedures for gas lift operations
for ensuring :-
• safety of the persons involved in the operations,
• safety of the equipment,
• safety of the well.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”

GUIDELINES FOR
• Minimal Environmental Impact.
2. SCOPE
Guidelines covers recommended practices for safe handling,

installation and operation of :-
• Gas lift equipment, both surface and sub-surface.

• Testing and calibration of the equipment.
• High-pressure gas injection lines and flow lines.
• Installation, trouble shooting, maintenance operations
• Continuous gas lift and intermittent gas lift.
Guidelines covers Gas-lift operations involving use of Casing pressure

operated, Nitrogen charged Bellows type valves only.(Different type of gas lift
installations are indicated at fig 1 to 2 )
3. DEFINITIONS
• Continuous gaslift:

The process of injecting high pressure gas continuously in to the tubing through
Gas lift valve(s).
• Intermittent gas-lift :
In this type of gas lift operation, injection gas is allowed to pass in to the tubing
not on continuous basis at predetermined periodic time intervals for a specified
period.
• Un-loading:
It is defined as the process of displacing the “Kill-Fluid” trapped in the tubing-
casing annulus through U-Tubing the fluid through the Gas Lift valves by
applying Gas or Air pressure to the annulus till the operating valve is uncovered
with fluid.
• Wireline retrievable GLV :

A Gas lift valve which can be run or retrieved by wireline and is set in a
receiving pocket inside a Wireline Retrievable Valve Mandrel (WRVM).
• Wireline Retrievable Valve Mandrel (WRVM) :

The equipment used to house the GLV in a pocket on the inside of the tubing
and having holes in the body to allow gas passage from casing-tubing annulus in
to the GLV. The side pocket for housing GLV, protrudes on one side so as to

GUIDELINES FOR
maintain full bore equivalent to tubing inside diameter. It is sometimes also

called side pocket mandrel.
• Tubing retrievable Gas Lift valve ( Fig – 3 ) :

Gas lift valve which is mounted in the pocket on the outside of the tubing on a
Tubing retrievable mandrel. This type of valve can not be retrieved by wireline
and tubing has to be pulled out for its retrieval.
• Tubing retrievable GLV mandrel :

The equipment used to house the GLV in a threaded pocket outside of the body.
GLVs are fitted in to the pockets of these mandrels before lowering them in to
the well. To retrieve a GLV, these mandrels are to be pulled out along with
tubing.
• Wireline Operations :
Various operations performed in a well using a long continuous length of solid
or stranded metal wire and appropriate spooling equipment at the surface with
specialised tools attached to the well end of the wire. In gas lift operations,
wireline jobs are carried out for the purpose of insertion or retrieval of GLVs,
for recording pressure and temperature surveys and also for tagging the fluid
levels in the tubing.
• Pressure survey :
It is a wireline operation in which a pressure recording device is lowered in to
the well by wireline and downhole pressures are recorded at different depths in
either flowing or shut-in condition of the well.
• Temperature Survey
It is a wireline operation in which a temperature recording device is lowered in
to the well by wireline and downhole temperatures are recorded at different
depths in either flowing or shut-in condition of the well.
• Probe test
The purpose of the Gas Lift valve Probe test is to determine the relative
“stiffness” of a gas lift valve and to determine the maximum stem travel of the
stem tip.
4. SAFE OPERATING PRACTICES :
4.1 Equipment handling :
4.1.1 Transportation and Storage :

GUIDELINES FOR
a) GLV :
While transporting GLVs, they should be properly protected against
mechanical damage, preferably packed in a shock proof container.
During transportation and storage, threads of the GLV should always be
kept properly greased and covered with a thread protector.
Tail plug should be in place to avoid accidental damage to the charging pin
of the dome.
Care should be taken that GLVs are not dropped from height or hit against
any objects.
The gas passage holes in the GLV should always be covered during
transportation and storage, to avoid plugging by foreign material/dust.
It should be ensured that calibrated valves should be tagged properly
indicating the information of set-pressures, depths and well numbers before
either transporting them to the well or sending them for temporary storage.
It is to be ensured that the various joints of a charged GLV should be
properly tightened before transportation.
b) Mandrel :
Threads should be properly greased and protected by thread protectors

during transportation and storage.
In case of Wireline retrievable valve mandrels, holes in the mandrel should
be covered properly so that no foreign material should enter inside the
mandrel and plug the holes as well as damage the polished bore of mandrel.
It is advisable to keep a dummy valve in the side pocket during long periods
of storage to prevent rusting and corrosion of polished bore portion.
4.1.2 Assembly and Servicing :
a) GLV:
• Before dismantling the GLV for servicing/ repair, bellow/dome should be
depressurized.
• Pipe wrench or vice should never be used on the round portion of the GLV
for assembly and dismantling. They should be applied in the grooves
provided for the purpose if any. If no grooves are provided on the GLV,
then Strap wrench/Parmalee type of wrenches are only to be used for
assembling and dismantling.
• Bellows are the most sensitive part of any GLV. So, after dismantling,
bellows should be handled with utmost care to avoid physical damage to
them.
• In order to prevent deformity to the convolutions of the bellows, bare
bellows should never be stretched or bent side ways.
• As Stem and Seat come in pairs, they should always be kept together and
different seats and stems should not be mixed.

GUIDELINES FOR
• Proper depressurising tool to be used to avoid damage / injury to the

operator.
• It is to be ensured that the Silicon fluid is not lost while servicing GLV.
b) Mandrel :
• Before re-using the pulled out Mandrels from the well, they should be
hydraulically tested to confirm their pressure integrity.
• Threads of the Mandrel should also be checked before lowering to avoid
complications later on.
4.1.3 Testing and Calibration :
a) Test Site recommendations:
The testing facilities necessary to perform gaslift valve testing will require a
high pressure, high volume source of Nitrogen gas. Safe recommended
practices for the same are as under:-
• Local, state and national and international codes and practices should be
followed when constructing the facility. The piping, valves, and surge
vessels comprising the gas – lift valve testing system will be subjected to
high pressure gas. As such, the fabrication, testing and valve selection
should adhere to the established codes governing piping systems and
vessels.
• Surge or other vessels with diameters exceeding 6 inches ( 152 mm) should
adhere to ANSI / ASME sec VIII DI-89 “ Rules for Construction for
Pressure Vessels Division 1” or Sec VIII D2-89 “ Rules for construction of
pressure Vessels Division 2 – Alternatives rules”. These rules provide
requirement for design, fabrication, inspection, and certification of
applicable vessels.
• The piping consisting of materials, wall thickness, and related pressure
ratings, should adhere to ANSI / ASMEB31.8-89 "Gas transmission and
distribution piping systems” and subsequent addenda. Piping material
should be specified as grade B. Flanges should adhere to ANSI/ASME
B16.5-88 “ Pipe Flanges and Flanged Fittings” and errata; valves are
covered by ANSI/ASME B16.34-88 “ Valves –Flanged , Threaded, and
welded End”.
• The design pressure for piping, valves, flanges, or pressure vessels should
be at least
20 % greater than the highest working pressure anticipated during the gas
lift valve tests.

GUIDELINES FOR
b) Testing
All the valves shall meet the following requirements. (As followed
during manufacturing stage as described in API 11V1.)
I. The test equipment
• Test rack (Fig-4) : This is the equipment used to set the opening and
closing pressure of the gas lift valve. There are two general types in use: The
“sleeve tester” and the “ encapsulated” tester. The piping, pressure gauges,
connections and joints should follow the standards mentions above.
• Water bath
This is water filled container where several gas lift valves are immersed in the
water to bring them to some pre-determined controlled temperature. This device
is absolutely essential for pressure charged gas lift valves. Most gas lift
installations calculate the gas lift set pressure at 60 degree F, thus the
temperature of the water-bath is usually controlled to 60 degree F. If the water
temperature is other than 60 degree F, then the pressure used for setting the gas
lift valves should be corrected for the temperature of the water bath..
• Pressure chamber or Ager

This device is a water filled chamber capable of at least 5000 psig. The gas lift
valves are inserted into the chamber and subjected to a predetermined external
pressure for some predetermined length of time and number of cycles. The
aging chamber used for this purpose has heavy cap. Proper provision should be
made to lift with some mechanism such as chain pulley block etc. otherwise it
may lead to an injury to the persons handling it due to sudden fall of the cap.
- Proper care should be taken while pressurising / depressurising the

chamber to avoid any damage / injury to the equipment operator.
• Probe
This device is a micrometer to measure the stem travel as pressure is applied to
the bellows. A continuity tester determines when the rod touches the valve
stem.. the rod of the probe is insulated electrically from the valve.
The equipment should have following :

- A means to control the pressure applied to the gas lift valve sleeve.
- The stem position measurement method should be capable of
determining the stem position within +/- 0.005 inches.
- The gauges used measure pressure should have an accuracy such that
measurement errors are no greater than +/- 0.255 of the value.

GUIDELINES FOR
- The rod of the probe micrometer should be smoothly tightened to avoid

slippage, which may indicate wrong readings.
- Care should be taken to avoid bending of the probe rod and trapping of
high pressure gas between the Teflon gaskets.
- The probe set up must be completely leak proof.
• Flow test system

The flow test system should include following items.
- Test specimen
- Test section
- Throttling control valve
- Pressure surge tanks
- Flow measuring device
- Pressure taps
- Temperature sensors
- Equalizing control valves
- Production run tests
II. All the valves shall successfully meet the following requirements.
• Bellow Assembly test:

Each bellow assembly shall be tested in accordance with B.3 in
Appendix B of the API 11V1.
• Valve setting :
Each gas lift valve shall be set and pressure tested in accordance with
section B.3 in appendix B of API 11V1.
Following safety precautions should be taken during this operation:-
- Entire set up should be tested for no leakage with dummy valve in place.
- The system should be fully depressurized before inserting or taking out the
valve in the test fixture.
- It should be ensured that valve is properly inserted in the test fixture and is
properly secured in the groove. Popping up of the valve may lead to an
accident.
• Stem-seat Leakage test( Fig-5) :

Each gas lift valve shall be tested for leakage across the stem and seat in
accordance with B.4 in appendix B of API 11V1. The leak shall not exceed 35
scft/d when the downstream pressure on the valve is zero and the upstream
pressure on the valve is greater than Pvct with the valve in fixture. Pvct is test
rack opening pressure at ambient temperature. The safety precautions as
mentioned above should be adhered to in this test also.

GUIDELINES FOR
• Reverse flow valve leakage test:

Reverse flow valve shall be tested with air, nitrogen, helium, or other
compressed gas for leakage in accordance with the manufacturer’s
specifications. The leak shall not exceed 35 scft/day with a 100 +/- 10 % psi
differential pressure. The safety precautions as mentioned in appendix B above
should be adhered to.
• Bellow stabilisation test:
Each gas lift valve after setting shall be subjected to aging in accordance
with section B.4 in appendix B of API 11V1.Following safety precautions
should be taken during the test:
Tail plug shall be installed on the gas lift valve prior to putting it in the
aging chamber.
The test set up with all the piping shall be pressure tested to at least 20 %
excess of the pressure to which the test is to be conducted.
The aging chamber used for this purpose has heavy cap. Proper provision
should be made to lift the cap.
Every time the cap is to be taken out, it should be ensured that the system is
depressurized fully.
After every aging the valve has to be put in water bath for temperature
stabilization prior to testing change in the setting of the valve.
• Probe test( Fig-6)
Prior to starting testing all the lines should be properly anchored and secured
for safety.
The test set up should be pressure tested with dummy valve in place for
pressure integrity of the test set up.
4.2 Factors to be ensured before putting a well on gas lift :
While selecting a well to be put on gas lift, pressure integrity of production

casing shall be ascertained and ensured to prevent the gas injection pressure
being communicated to the outer annuli during continued exposure of casing
to the injection pressure.
The checking of the integrity of the primary and secondary seals and the
proper cement rise behind the casing can prevent the communication
between the production casing and the outer casings.
There should be a schedule of regular checking of the communication
between the outer casings and the production casings.
If any communication is observed between the production casing and outer
annuli, suitable remedial measures should be taken to stop communication

GUIDELINES FOR
so that injection gas pressure is not communicated to the outer annuli. This
is to avoid any leakage of gas and ultimate blow out situation.
In such situations, where the gas injection pressure is getting communicated
to the outer casings from the production casing, a proper mechanism has to
be installed so that the outer annuli can be automatically bleed off. Such
wells should be kept under high alert level and should be repaired at the
earliest.
Gas Composition of the injection gas is of prime importance for the

corrosion effect on the casing, specially in case of carbon dioxide and
hydrogen sulfide in presence of water. For details of permissible limits of
partial pressure of CO2 and H2S to avoid/minimize corrosion, relevant API
specifications should be referred.
4.3 Lowering :
If the GLVs are being lowered along with Mandrels, sequence of the
Mandrels, serial wise and depth should be clearly marked on the Mandrels.
While inserting the GLV in side pocket mandrel , excessive force should not
be applied which may cause problems during subsequent retrieval by
wireline.
After inserting the GLV in to the pocket and before lowering the Mandrel,
they are to be hydro tested to ensure pressure integrity.
In the case of tubing retreavable conventional mandrel, ensure that the GLV
is guarded by the protector to avoid damage to the GLV by friction /
abrasion with the casing valves while lowering the valves.
4.4 Un-loading :
Maximum damage to GLV’s occurs during un-loading operation. Hence,

utmost care should be taken for proper and safe un-loading of Gas Lift well.
Unloading of the well is the first operation in a gas lift well. Subdued fluid
from the casing is U-tube into tubing through gas lift valves by applying air
/ gas pressure in the annulus.
Recommended procedures as per API RP 11 V5 should be followed while
unloading a gas lift well.
Large quantities of gas released during unloading operations is generally
piped away from the installation and flared.

GUIDELINES FOR
4.4.1 Onshore Operations:
If the well is unloaded into the pit, all the joints in the temporary flow line
from well to pit shall be properly tightened.
Temporary flow line shall be anchored properly to avoid any accident in
case of sudden jerking of the line caused by flow of gas.
No un-authorised person should be allowed in the area.
A bend should be fitted to the end of pipe line so that flow is always
directed downward into the pit..
If the well is to be unloaded through the permanent flow line connected to
installation, concerned Incharge/Shift Incharge shall be informed
beforehand to avoid upset in process in the separation / liquid handling
facilities
4.4.2 Offshore Operations
If the unloading is not done into the regular system then the discharge from
the well should be diverted into burner / sea.
While discharging the initial subdued fluid into sea, care should be taken to
divert the flow to burner, as soon as oil/gas surfaces.
Depending on the wind direction suitable burner either on star board side or
port side shall be chosen so as to avoid the flow of gas / heat towards the
rig.
For the rig safety, adequate cooling water is to be sprayed towards the flame
so that heat is effectively dissipated .
The temporary line connection used to divert the well fluid to the sea/burner,
shall be pressure tested, tightened properly and anchored.
High liquid velocities occurring at GLV’s in case of a fast un-loading
causes abrasion/cutting of GLV seat, thus the valve becomes defective and
will pass gas during GL operation. To avoid damage to GLV and upsets in
surface facilities, proper unloading procedures as per section III-1 of API
RP 11 V5 to be followed.
5. Regular operation and monitoring:
A gas lift installation is usually unmanned and main hazard is that due to
fire, the other hazard being the failure of pipeline or control valves due to high
pressure.
Standard check list shall be prepared to check following : -
In live and pressure charged lines/flow arms, no operational adjustments

should be carried out unless that portion of the line/flow arm is isolated
from both upstream and downstream sides and pressure is bleed-off through

GUIDELINES FOR
cock valve/bleed valve. Before putting into operation , all bleed/cock valves
should be closed.
Two/three pen recordings are very common monitoring tools in gas lift
operations. When connecting and disconnecting the pen recorders, special
care should be taken to isolate the connecting tube to recorders/sensors and
pressure bleed off.
Flammable oil and gas are constantly present at the gas lift installation and
unless sources of ignition like naked lights, frictional sparks, electrical
sparks, static electric charges, lighting overheated surfaces, are carefully
controlled, fire could be a major hazard. In some cases, even auto-ignition
takes places.
No welding or cutting job should be allowed near the well while the well is
in operation. If such jobs are unavoidable, then well shall be closed and
source of injection gas should be cut-off and all the lines near the wellhead
area are to be de pressurized. OISD standard 105 may be refereed and
permit shall be issued as per standard.
Every person permitted to enter the production installation, if carrying any
smoking item cigarettes and matches shall be deposited at the gate. Suitable
notice to this effect should be prominently displayed at the gate
Injection gas shall be dehydrated properly before its entry into the gas
injection network to avoid corrosion and hydrate formation.
No smoking board and pictorials should be displayed.
Hammers and other handling tools made of Brass should only be used for
undertaking any mechanical work involved on the injection gas lines.
The pressure and DP recorders of two / three pens recording assembly
should be periodically calibrated to avoid errors in readings.
The air / gas used for the control instruments should be dry to avoid
malfunctioning.
6. Quality of injection gas ;
All the high pressure components should be hydrotested once in two years
in corrosive atmosphere and once in three years in normal atmosphere.
Surface condition of these equipment also should be maintained in good
condition by regular surface preparation and painting. Furthermore,
periodical corrosion studies should be carried out to compare data against
base data to find out any decrease in thickness.
The safety valves, pressure gauges, flanges & extra tapings, shutdown
valves need regular checks for any hydrocarbon leakage. In case of any
leakage, it should be immediately rectified.
As the gas lift installation involves high pressure valves and other
components at the wellhead, it is recommended that all the gas lift wells
should be fenced upto 15 meters from the well head area to restrict the

GUIDELINES FOR
access to un authorised persons and straying of animals towards the well

site.
The material guidelines for metals and elastomers for the gas lift valves and
other sub surface equipment are indicated in API spec 11V1, section.4. For
the initial installation in a H2S environment, the equipment should comply
with NACE-specification. .
It should be ensured that , as far as possible, the injection gas should not
contain corrosive gases like H2S and CO2. But if injection gas contains
some quantity of H2S and CO2, then all the flow lines and valves in the line
injection gas passage should be of suitable material.
If the injection gas contains some quantity of corrosive gases, then a proper
strategy should be adopted to prevent corrosion to the casing. Either gas
should be injected through another concentric string (Not through casing), or
alternately some corrosion inhibitor should be injected along with injection
gas if, gas is injected through casing.
7. Lay out of surface hook up:
Lay out of gas injection line hook up is to be made keeping the following
factors in mind,
A clear access shall be available for the movement of rig, wireline winch
and minimum hindrance to carry out any work over job on the well.
No tapping should exist upstream of the main isolation valve.
Minimum required number of tapings should be provided in the hook up to
the well.
All the valves and tapings should be of suitable pressure rating to match the
expected pressures in the line.
Number of bends in the line hook up should be kept to minimum and sharp
bends should be avoided as far as possible.
It shall be ensured that valve is provided on both sides of the annulus to
facilitate de pressurizing of the annulus. Bull plug with flange should not be
used in casing spools.
A non-return valve should be installed immediately after the annulus valve
for preventing the back-flow of well fluids in to the gas injection line
network.
For Off shore operations, a shut down valve on the gas injection line as well
as on the production flow arm is required to be installed for emergency shut
down purposes.
Surface line should be hook up with proper engineering drawing.
Injection gas lines should be pigable.
Undulations in elevation should be avoided as far as possible because liquid
accumulation will take place in low points which in turn will become
potential spots for increased corrosion.

GUIDELINES FOR
Corrosion monitoring of injection lines should be carried out periodically to

identify trouble spots to initiate timely action.
As a good house keeping measure, all the high pressure instrument lines
leading to two/three pin recorder should be laid and maintained in a
systematic way and secured properly.
All temporary lines used during well activation should be removed and
replaced as quickly as possible. All the gas injection as well as well fluid
lines should be properly designed and should be permanent.
8. Wireline operations :
In gas lift operations, wire line operation is frequently used either to retrieve and
replace the GLV, to record the bottomhole pressure/ Temperature, and to tag the
fluid level.
8.1 General :
Before undertaking any wire line operation, functioning of the Christmas

Tree valves is to be checked and ensured for full closure and opening.
Sub surface safety valves (SSSV) should be checked for proper functioning.
It should be ensured that lubricator stuffing box packing are in good
condition to prevent leakage of well fluids in to the atmosphere.
Lubricator, along with stuffing box shall be pressure tested in the shop prior
to usage in the well.
For preventing fall of personnel while fitting lubricator or lowering the
tools, proper arrangement should be provided for the safety.
Wireline operations should be carried out as per recommended procedures.
8.2 Gas lift valve insertion and retrieval :
Gas lift valves can be inserted or retrieved from the mandrels in the well by
wireline operation when side pocket type mandrels are used.
In order to ensure smooth passage of the GLV and tools in to the well,
tubing clearance should be checked and ensured by dummy run along
scrapper prior to the lowering of the GLV with tool.
To prevent the blowing up of the tool, pressures in the tubing and annulus
should be equalised before de-plugging GLV from any mandrel.
8.3 Pressure and temperature surveys :
Flowing pressure and temperature surveys are one of the important

diagnostic tools for analysing the performance of any gas lift operation.

GUIDELINES FOR
A pressure recording instrument is lowered into the well and bottom

hole flowing pressures are recorded either at selected valve depths or at specific
intervals. Such pressure data will give indication of the point where gas is to be
injected , tubing loads at different points etc.
a) Continuous Gas Lift:
Unless the gas flow rate is very high in tubing, chances of instrument
blowing up the hole are very less. However, it may be safe to attach some
weight bars to the string where gas flow rates are very high, then a ‘no-blow’
device should be attached below the instrument in addition to the weight bars.
b) Intermittent Gas Lift:
Chances of the instrument being blown up the hole are high while
lowering the instrument in intermittent gas lift well. So, either the gas injection
shall be stopped while lowering the instrument or when the instrument is being
lowered in flowing condition, sinker bars should be added above the instrument
and also ‘no blow’ device should be used along with the instrument. ‘No blow’
device is useful in preventing the instrument being blown up the hole because
any upward movement of the device will activate the upward slips in the device
which will clutch to the tubing walls and prevent the string from being blown up
the hole. Recording should be in stabilized condition only. Preferably, well
testing should be carried out during Pressure/Temperature survey.
9. A suitable pocket guide should be made available to the operator for

ready reference. Operators should be given hand on training before deploying
them on actual job for avoiding accidents.
11. References:-
API Standard 11 V 1 to 5
OISD standard 105

GUIDELINES FOR
Fig.: 1 DIFFERENT TYPES OF GAS LIFT INSTALLATIONS

GUIDELINES FOR
Fig.: 2 CASING PRESSURE OPERATED GAS LIFT VALVE

WITH CONVENTIONAL MANDREL

GUIDELINES FOR
Fig.: 3 GAS LIFT VALVE

GUIDELINES FOR
Fig.: 4 TYPICAL SLEEVE TESTER

GUIDELINES FOR
Fig.: 5 TYPICAL STEM AND SEAT LEAKAGE

TESTERS

GUIDELINES FOR
Fig.: 6 TYPICAL GAS LIFT VALVE PROBE TEST FIXTURE

GUIDELINES FOR
Fig.: 7 TYPICAL ENCAPSULATED TESTER

OISD-GDN-193-Gas Lift Opr &amp; Mtce

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Sr.

Oil Industry Safety Directorate

COMMITTEE ON “ GAS LIFT OPERATIONS AND MAINTENANCE ”

Oil Industry Safety Directorate

Petroleum industry in India is significantly globalized at present in terms of technology content

Oil Industry Safety Directorate

It is hoped that provisions of guidelines, if implemented objectively, may go a long way

These documents are intended to supplement rather than replace the

FOR PREPARATION OF GUIDELINES ON

" GAS LIFT OPERATIONS AND MAINTENANCE ''

NAME ORGANISATION POSITION

1. V.V.Manchalwar ONGC LEADER

2. Girdhar Kumar, ONGC MEMBER

3. Gulab Singh, OISD Member-CO-ORDINATOR

S.N. TOPICS PAGE NO.

4. SAFE OPERATING PRACTICES 3

4.1 EQUIPMENT HANDLING

4.1.2 ASSEMBLY AND SERVICING

4.1.3 TESTING AND CALIBRATION

4.2 FACTORS TO BE CONSIDERED BEFORE

5. REGULAR OPERATION AND MONITORING 10

6. QUALITY OF INJECTION GAS 11

7. LAYOUT OF SURFACE HOOK UP 12

OISD – GDN – 193 Page No. 1

"GUIDELINES FOR GAS LIFT OPERATIONS AND

In off-shore operations, Gas-Lift is the most prominent method of

In all stages of Gas-lift operations, operator plays an important role.

• safety of the persons involved in the operations,

• safety of the equipment,

• safety of the well.

OISD – GDN – 193 Page No. 2

• Minimal Environmental Impact.

Guidelines covers recommended practices for safe handling,

• Gas lift equipment, both surface and sub-surface.

Guidelines covers Gas-lift operations involving use of Casing pressure

• Continuous gas- lift:

• Wireline retrievable GLV :

• Wireline Retrievable Valve Mandrel (WRVM) :

OISD – GDN – 193 Page No. 3

maintain full bore equivalent to tubing inside diameter. It is sometimes also

• Tubing retrievable Gas Lift valve ( Fig – 3 ) :

• Tubing retrievable GLV mandrel :

4. SAFE OPERATING PRACTICES :

4.1 Equipment handling :

4.1.1 Transportation and Storage :

OISD – GDN – 193 Page No. 4

 Threads should be properly greased and protected by thread protectors

4.1.2 Assembly and Servicing :

OISD – GDN – 193 Page No. 5

• Proper depressurising tool to be used to avoid damage / injury to the

4.1.3 Testing and Calibration :

a) Test Site recommendations:

OISD – GDN – 193 Page No. 6

I. The test equipment

• Pressure chamber or Ager

- Proper care should be taken while pressurising / depressurising the

The equipment should have following :

OISD – GDN – 193 Page No. 7

- The rod of the probe micrometer should be smoothly tightened to avoid

• Flow test system

• Bellow Assembly test:

• Stem-seat Leakage test( Fig-5) :

OISD – GDN – 193 Page No. 8

OISD-GDN-193-Gas Lift Opr & Mtce

OISD-GDN-193-Gas Lift Opr & Mtce

Threads should be properly greased and protected by thread protectors

While selecting a well to be put on gas lift, pressure integrity of production

Gas Composition of the injection gas is of prime importance for the

Maximum damage to GLV’s occurs during un-loading operation. Hence,

In live and pressure charged lines/flow arms, no operational adjustments

Corrosion monitoring of injection lines should be carried out periodically to

Before undertaking any wire line operation, functioning of the Christmas