Gas Lift Valve with Redundant Sealing Mechanisms Suitable for Harsh Environments

by:
Daniel Murski – Liberty Lift

Presentation describes a new gas lift valve featuring robust and redundant sealing mechanisms, designed to address significant challenges in harsh operational regions like the Eagle Ford and Bakken. Traditional Injection Pressure Operated (IPO) valves frequently face issues such as elastomer deterioration caused by wellbore heat, fluids, and gases, as well as infiltration by pressure, contaminants, and debris, which collectively diminish efficiency and valve lifespan. The valve discussed here aims to enhance operational effectiveness and extend service life by providing multiple layers of protection against these adverse factors. Key design improvements in the new valve include a more uniform crush gasket, a threaded primary dome plug with Aflas elastomers, and an encapsulation fixture with an opposing metal-to-metal seal. These features create a more secure system designed to prevent pressure loss or intrusion, even if initial barriers fail.

Third-party testing under demanding conditions (5,000 PSIG and 325 degrees Fahrenheit) confirmed the robust valve’s resilience, demonstrating no intrusion of outside pressure or fluid into its bellows charge chamber and excellent elastomer performance. In contrast, post-testing photographs revealed obvious signs of elastomer degradation in conventional IPO valves. Real-world feedback from Eagle Ford operators indicated a substantial reduction in bellows leaks (from 21% to 2%) and tail plug leaks (from 19% to 12%) after adopting the redesigned valve. As of May 2025, with over 6,500 units installed, there have been no reported operator pulls due to a failed robust valve with multiple seals, underscoring its success in improving gas lift system operations and equipment longevity in demanding environments.