Well Test Operational Guidelines PDF

EXPRO
WELL TEST OPERATIONAL GUIDELINES
THIS MANUAL IS CONTROLLED
CONTROLLED COPY NO: _____
This manual and the information contained therein is the property of Expro. It must not be reproduced in whole or in part or
otherwise disclosed without the prior consent in writing from the Manager Operations Support.
DISTRIBUTION LIST

Page 1 of 1
DISTRIBUTION LIST
TITLE BASE NAME REF
OPERATIONS MANAGER HOUSTON T PARKIN 001

PRODUCT SUPPORT SPECIALIST ABERDEEN 003
REGION DIRECTOR ABERDEEN N ASHTON 004
WELL TEST MANAGER ABERDEEN G SIMS 030
WELL TEST SUPERVISOR ABERDEEN G MACDONALD 027
PRODUCT DEVELOPMENT MANAGER ABERDEEN D CLELAND 028
OPERATIONS SUPPORT ENGINEER ABERDEEN C CRAIG 011
TECHNICAL MANAGER ABERDEEN R MAIR 034
AREA MANAGER YARMOUTH W OWEN 008

WELL TEST SUPERVISOR YARMOUTH A ROSS 010
OPERATIONS SUPPORT ENGINEER YARMOUTH B GOOCH 012
AREA MANAGER SINGAPORE D BOWMAN 015
BUSINESS DEVELOPMENT MANAGER AFSU M MOXEY 013
OPERATIONS SUPPORT MANAGER YARMOUTH G PEEK 031
TECHNICAL SUPERVISOR AFSU D WOODEN 014
HSEQC MANAGER AFSU A HANNAH 079
WELL TEST SUPERVISOR AFSU T JONES
WELL TEST SUPERVISOR AFSU D BROWNE
TECHNICAL MANAGER AFSU B LESTRANGE
BUSINESS DEVELOPMENT MANAGER AFSU T CAMMERATA
AREA MANAGER WEST AFRICA AFSU G MORGAN
REGION DIRECTOR HOLLAND A KITCHENER 017

OPERATIONS SUPPORT HOLLAND M MEINSTER 019
WELL TEST SUPERVISOR HOLLAND C SOUTER 018
MAINTENANCE SUPERVISOR HOLLAND H EVERS 035
REGION DIRECTOR AUSTRALIA S ASHTON 021

WELL TEST MANAGER AUSTRALIA K McCARTAN
REGIONAL OPERATIONS MANAGER AUSTRALIA P BURTON
GENERAL MANAGER NORWAY J MACBEATH 005
OPERATIONS SUPERVISOR TUNISIA S DRAKE 009
OPERATIONS MANAGER VIETNAM S MOLLOY 022 & 023
GROUP MANAGER NIGERIA P STYLES 025
AREA MANAGER CHINA K CRAWFORD 007
BUSINESS DEVELOPMENT MANAGER AMERICA J LOAFMAN 029
CLIENT ACCOUNT MANAGER P GHEZ 033
OPERATIONS LIBYA S DRAKE 031
OPERATIONS ABERDEEN G MACDONALD 050 to 059
OPERATIONS YARMOUTH A ROSS 070 to 079
OPERATIONS HOLLAND N TIELENS 090 to 099

&
100 to 109
OPERATIONS VIETNAM S MOLLOY 110 to 119

&
130 to 134
OPERATIONS AFRICA/FSU D WOODEN 140 to 143
DATE: OCTOBER 1999 ISSUE 2 REVISION O

INTRODUCTION

Page 1 of 1
INTRODUCTION
This manual and revisions to it are under controlled distribution. Your name, and the number of the manual assigned to you, is
kept on a master list maintained by the Surface & Environmental Systems Business Stream. Manuals for Operational use are
assigned to the relevant Supervisor or Manager and it is their responsibility to ensure that all copies are updated with relevant
amendments as issued.
Receipt of this manual and subsequently revised pages shall be acknowledged in writing, by signing or initialling a copy of the
transmittal memo and returning same to the Surface & Environmental Systems Business Stream. Outdated pages shall be
destroyed and revised pages inserted in the manual. Each transmittal memo to you should be inserted in the manual behind
the index.
Un-registered copies of this manual are available for the use of Clients and prospective Clients.
This manual is the property of The Expro Group and is to be returned upon request, or termination of its usefulness to the holder
in conduct of Expro business.
Custody of this manual may be transferred to another employee only with the knowledge and approval of the Surface &
Environmental Systems Business Stream.
Surface & Environmental Systems Business Stream

Aberdeen

AMENDMENTS & RE-ISSUES

Page 1 of 1
AMENDMENTS AND RE-ISSUES
1 The Testing & Environmental / Support Department reviews the Manual periodically with other departments to re-affirm
its adequacy and conformity to current requirements. The minimum frequency for review of the Manual is once each 2
years.
2 Amendments to the Manual when requested are undertaken to reflect the current Company Safety Standards, legal
requirements and additional, new and modified equipment. The amendments are made by replacement of applicable
page(s). Each amendment page is identified by amendment number and date of each amendment. Amendments will
be issued to the relevant sub-sub-section but only recorded on the Amendment Record of each sub-section.
3 Amendments are numbered consecutively until such times as a new issue incorporates all changes. When changes
affect a considerable number of pages and in any case after not more than ten amendments to one issue, the Manual is
re-issued. Issues are identified by letters in alphabetical order. Each issue cancels and replaces all previous issues
and amendments.
4 The Amendment Record indicates all the amendments to the latest issue of the Manual.
5 All Operating Guidelines clearly state whether Operating Guidelines revisions servicing is provided, and a complete list
of Manual holders is retained by the Manager, Operations Support. Amendments and re-issues of the Manual are
automatically distributed to all registered holders of controlled copies.
6 Personnel wishing to propose amendments or additions to this manual should use the Proposal Form or similar, outlining
the proposal and reasons for the amendment or addition. Proposals should be discussed in the first instance with the
immediate Supervisor or Manager who will then pass the proposal to the Manager, Operations Support for consideration
for inclusion. A sample Proposal Form can be found at the end of this manual.

AMENDMENT RECORD

Page 1 of 1
This procedure is a mandatory requirement and forms part of the Approved Well Test Operating Manual.
Alterations are not permitted without the prior approval of the Manager Operations Support.
AMENDMENT RECORD
REV No. DATE SUB-SECTION BY APPROVED SUMMARY OF CHANGE

INDEX RECORD

Page 1 of 6
1.0 GENERAL OPERATING GUIDELINES

1.0 Risk Assessment
1.01 Responsibilities
1.02 Definitions
1.03 Procedure
1.04 Risk Ratings
1.05 Actions
1.06 Records
1.07 Updating Risk Assessments
1.1 Pre-Test Planning
1.1.1 Rig Visit
1.1.2 Engineering Requirements
1.1.3 Hazop Studies
1.1.4 Equipment Maintenance
1.1.5 Certification
1.1.6 Pre-Test Meetings
1.1.7 Equipment Requirements
1.1.8 Personnel Mobilisation
1.2 Pre-Test Work Site Guidelines
1.3 Rig Visit Guidelines
1.4 Gas Well Testing
1.4.1 Problems
1.4.2 Operating Procedures
1.5 Oil Well Testing
1.5.1 Problems
1.6 Solids Management
1.6.1 General / Solids Production
1.6.2 Sand Frac-Clean ups
1.6.3 Sand Separator
1.7 High Pressure/Temperature Well Testing
1.7.1 Problems
1.7.2 Sub-Surface Capability
1.7.3 Data Acquisition
1.7.4 15,000 psi Equipment
1.8 Foaming Oil Well Testing
1.8.1 Problems in Handling Foaming Oil
1.8.2 Operational Guidelines
1.9 Sour Gas Well Testing
1.9.1 Effect of H2S on Equipment
1.9.2 Stress Cracking
1.9.3 Equipment Fabrication
1.9.4 Pyrophoric Ignition
1.9.5 Training for Personnel Prior to Test
1.9.6 Operational Guidelines
1.9.7 Supervisory Responsibility
1.9.8 Artificial Resuscitation Methods
1.10 Acid Clean Up Procedures
1.11 Post Test Guidelines
TABLES
1-1 Toxicity of Hydrogen Sulphide Gas

1-2 EXPRO's Recommended H2S Policy
APPENDIX 1
Fig. 1.1 Sour Gas Systems

Fig. 1.2 Sour Multiphase Systems
Fig. 1.3 Artificial Resuscitation Methods
Fig. 1.4 Artificial Resuscitation Methods
Fig. 1.5 Rig Visit Checklist (example)
Fig. 1.6 Risk Assessment Form

INDEX RECORD

Page 2 of 6
2.0 PRESSURE TESTING GUIDELINES

2.1 Pressure for Field Pressure Testing
2.2 Duration of Pressure Tests and Mediums Used
2.3 Pressure Test Guidelines for Individual Items of Equipment
2.3.1 Surface Test Tree (on Deck)
2.3.2 Sand Filters
2.3.3 4 Valve/5 Valve Choke Manifolds
2.3.4 Heat Exchangers
2.3.5 Separators
2.3.6 Gas Diverters
2.3.7 Oil Diverters
2.3.8 Surge Tanks
2.3.9 Gauge Tanks
2.3.10 Freestanding Valves
2.3.11 Screwed Pressure Fittings
2.3.12 Erosion Probes " NPT
2.4 Example Pressure Test Diagrams
2.5 Post Pressure Testing Guidelines
APPENDIX 2
Fig. 2.1 Line Up for Flushing System

Fig. 2.2 Starboard and Port Oil and Gas Lines to Burner, Surge Tank Inlet Valves
Fig. 2.3 Function Test High Pilot (PSH) between Heat Exchanger and Separator and
Actuated Surface Safety Valve
Fig. 2.4 Starboard and Port Oil and Gas Diverter Lines
Fig. 2.5 Oil Manifold Inlet Valves
Fig. 2.6 Surge Tank Body
Fig. 2.7 Separator Vessel and Outlet Valves
Fig. 2.8 Separator Inlet and Bypass Valves
Fig. 2.9 Heater Coils and Bypass Valves
Fig. 2.10 Heater Inlet and Bypass Valves
Fig. 2.11 Low Pressure Pilot (PSL2)
Fig. 2.12 Surface Safety Valve
Fig. 2.13 Choke Manifold and Downstream Valves
Fig. 2.14 Choke Manifold Upstream Valves
Fig. 2.16 Hydraulically Actuated Flow-Wing Valve and Flowhead Master Valve
Fig. 2.17 Remote ESD Stations
3.0 EQUIPMENT OPERATING GUIDELINES

3.1 Equipment Hook-up
3.1.1 Tubing Head Swivel
3.1.2 Surface Test Tree
3.1.3 Control Panel
3.1.4 Coflexip Hoses Hook-up
3.1.5 Pipework
3.1.6 Twin Pot Sand Filters
3.1.7 Data Headers
3.1.8 Choke Manifold Hook-up
3.1.9 Heat Exchanger
3.1.10 Relief Valve Skid
3.1.11 Phase Test Separator
3.1.12 Gas Diverter Manifold
3.1.13 Oil Manifold
3.1.14 Gauge/Surge Tank
3.1.15 Transfer Pump
3.1.16 Burner Booms
3.1.17 Burner/Ignition System
3.1.18 Burner Heads
3.1.19 Pressurised Laboratories
3.1.20 Dead Weight Tester
3.1.21 Surface Pressure/Temperature Recorder
3.1.22 Texsteam Chemical Injection Pump
3.1.23 Steam Generator
3.1.24 Air Lines

INDEX RECORD

Page 3 of 6
3.2 Lower Master Valve

3.2.1 Manual Valve
3.2.2 Hydraulically Actuated Valve
3.3 Temperature Sub
3.4 Chemical Injection Sub
3.5 Tubing Head Swivel
3.6 Surface Test Tree
3.6.1 Hydraulically Actuated Valves
3.6.2 Manual Valves
3.7 Control Panels
3.7.1 Resato SPP-10 Control Panel
3.7.2 Hydratron Single Circuit ESD Unit
3.8 Surface Safety Valves
3.9 Coflexip Hoses
3.10 Pipework
3.10.1 Minimum Allowable Wall Thickness
3.10.2 Thickness Checking
3.10.3 Hammer Unions
3.10.4 Clamp Connections
3.10.5 Flanges
3.10.6 Relief Line Capacities
3.11 Twin Pot Sandfilters
3.11.1 Equalising Pots
3.11.2 Diverting Flow via Duty Standard Pot
3.11.3 Switching from Duty to Standby Pot (Standard) Pots
3.11.4 Diverting Flow via Duty Pot (Double Block Pot)
3.11.5 Switching from Duty to Standby Pot (Double Block) Pots
3.11.6 Draining Standby Pot
3.11.7 Using the Dual Isolation System
3.11.8 Switching from Duty to Standby Pot
3.12 Data Headers
3.13 Chokes and Choke Manifolds
3.13.1 Choke Manifolds
3.13.2 McEvoy Model 'H2'
3.13.3 Foley Model 'FH2'
3.13.4 Masterflo Chokes
3.14 Heat Exchangers
3.15 Freestanding Relief Valves
3.16 Gas, Oil and Water Separators
3.16.1 General Operating Guidelines
3.16.2 Setting Back Pressure with Wizard 4150 Controller
3.16.3 Lowering/Raising Orifice Plate
3.16.4 Setting Liquid Level with Fisher 2500 Controller
3.16.5 Setting Liquid Level with Fisher 2900 Controller
3.13.6 Diverting Flow via Liquid Meters
3.16.7 Reading Barton Recorder
3.16.8 Using Sight Glasses
3.16.9 Meter Factors
3.16.10 Shrinkage Factors
3.17 Gas Diverter Manifolds
3.17.1 Operating Guidelines
3.17.2 To Switch Flares
3.18 Oil Diverter Manifolds
3.18.1 Oil Flow from Separator to Burner
3.18.2 Oil Flow to Gauge/Surge Tank
3.18.3 Oil Manifold Operation to Pump Out Tank to Burner
3.19 Surge/Gauge Tanks
3.19.1 Start-Up and Gauging Flow
3.19.3 To Switch Sides on both Surge and Gauge Tanks
3.19.4 To Pump Out one or both Components
3.20 Transfer Pumps
3.20.1 Electrical Pumps
3.20.2 Air Driven Pump Diaphragm Pump
3.21 Ignition Systems
3.21.1 Magniter Ignition System
3.21.2 Diesel Ignition System
3.21.3 Electric Ignition System

INDEX RECORD

Page 4 of 6
3.22 Burners
3.22.1 Supergreen Crude Oil Burner Maintenance Guidelines
3.23 Pressurised Laboratories
3.24 Ancillary Equipment
3.24.1 Deadweight Testers
3.24.2 Pressure/Temperature Recorders
3.24.3 Chemical Injection Pumps
3.24.4 Ranarex Gravitometer
3.24.5 Ultrasonic Thickness Gauges
3.24.6 Fisher 67FR Air Regulators
3.24.7 Pressure Gauges
3.24.8 Stick Thermometers
3.25 Valves
3.25.1 McEvoy
3.25.2 Foley
3.25.3 Magnum Converted
3.26 Third Party Equipment
3.26.1 Compressors
3.26.2 Steam Generators
3.27 Proppant Knockout Vessel
3.27.1 Initial Job Start Up
3.27.2 End of Test Clean Out Procedures
TABLES
3-1 Required Number of Turns to Fully Open/Close a McEvoy Valve

3-2 Rislan Hoses
3-3 Coflon Hoses
3-4 List of Hoses in Service
3-5 Minimum Allowable Wall Thickness for A106B Steel
3-6 Thickness Checking
3-7 Typical Range of Unions Used by EXPRO
3-8 API Rated Flange Pressure Ratings
3-9 ASA Rated Flange Pressure Ratings
3-10 Pipeline Capacities (mmscf/d) from High Pressure Relief Valves
3-11 Pipeline Capacities (mmscf/d) from Heat Exchanger
3-12 Pipeline Capacities (mmscf/d) from Separator
3-13 Pipeline Capacities (mmscf/d) from Surge Tank
3-14 Pressure Ratings of Gauge
3-15 Required Number of Turns to Fully Open/Close a McEvoy Valve
APPENDIX 3
Fig. 3.1 Actuator Lock-Open Cap and Disc

Fig. 3.2 Pressure Pilot and Remote ESD Tie-in
Fig. 3.3 Handling Coflexip Hoses
Fig. 3.4 Preferred Hook-up on Semi-submersible Rigs
Fig. 3.5 Pipework Metal Band
Fig. 3.6 Barton Recorder Hook-up
Fig. 3.7 Sample Points
Fig. 3.8 Clean-up Choke Manifolds
Fig. 3.9 Separator Barton Hook-up
Fig. 3.10 Gas Diverter Hook-up
Fig. 3.11 Oil Manifold Hook-up
Fig. 3.12 Correct Installation of Dogs on Lines
Fig. 3.13 Enclosure Layout
Fig. 3.14 Rotational Direction of Impeller
Fig. 3.15 Typical Coflexip Hose Structure
Fig. 3.16 Hammer Union Mating Parts
Fig. 3.17 Clamp Connector Components
Fig. 3.18 Data Headers
Fig. 3.19 Flange Make-up Sequence
Fig. 3.20 Single Block Choke Manifolds
Fig. 3.21 Double Block Choke Manifolds
Fig. 3.22 Masterflo Micrometer Indicator
Fig. 3.23 Daniel Senior Orifice Meter
Fig. 3.24 Effect of Proportional Band on Liquid Level

INDEX RECORD

Page 5 of 6
Fig. 3.25 Liquid Meters Set-up

Fig. 3.26 Shrinkage Tester
Fig. 3.27 Gas Diverter Manifold
Fig. 3.28 Oil Diverter Manifold
Fig. 3.29 Winding Teflon Tape on a Thread
APPENDIX 3A
Fig 1- EXPRO 2" Supergreen Atomiser head Assembly - TED090101

Fig 2- EXPRO Lodge Ignition System (High Velocity) - TED080703
Fig 3- Typical Supergreen Burner Rig Up - TED090108
Fig 4- Fan Type Radiation Screen - TED080601
4.0 SURFACE SAMPLING GUIDELINES

4.1 PVT Sampling
4.2 Measuring Gas S.G.
4.3 Measuring Liquid S.G.
4.4 Measuring BS&W
4.5 Measuring Salinity (Chlorides)
4.6 Measuring Viscosity
4.7 Measuring Cloud/Pour Point
4.8 Measuring Resitivity of Water
4.9 Using Draeger Tester
APPENDIX 4
Fig. 4.1 Gas PVT Sampling Hook-up

Fig. 4.2 Oil PVT Sampling Hook-up
Fig. 4.3 Atmospheric Sampling
Fig. 4.4 Hydrometer in Cylinder
Fig. 4.5 Use of Draeger Tester
Fig. 4.6 Inserting Draeger Tubes
5.0 SAFETY GUIDELINES

5.1 General Safety
5.1.1 General
5.1.2 Emergency
5.2 Hook-up and Rig Down
5.2.1 Hook-up
5.2.2 Rig Down
5.3 Pressure Testing
5.4 Surface Sampling
5.5 Safety of Personnel While Working on Burner Booms
5.6 Corrosive and Hazardous Substances
6.0 CONTINGENCY GUIDELINES

6.1 Equipment Failure
6.2 Hydrates
6.3 Leaks
6.4 Suspension of Operations Due to Bad Weather
6.4.1 On Semi-Submersible Rigs
6.4.2 On All Rigs
6.5 High Temperatures
6.6 Miscellaneous
6.6.1 Contingency Procedures
6.6.2 Surface Data Logger
6.6.3 Data Points
6.7 Leaking Daniels Senior Orifice Meter
6.8 H2S Leak
6.9 Choke Manifold
TABLES
6-1 Freezing Points of Glycol/Freshwater Mixes

INDEX RECORD

Page 6 of 6
7.0 MULTI SENSOR RELIEF VALVE (MSRV)

7.1 Specifications and Features
7.1.1 MSRV Safety Head Drawing
7.1.2 MSRV Drawing
7.2 Dis-Assembly Procedures
7.3 Assembly Procedures
7.4 Parts List
7.5 Pressure and Function Tests
Maintenance Level 1
7.5.1 Impulse System Pressure Test
7.5.2 Internal Body Test
7.5.3 Closed Ball Valve Pressure Test
7.5.4 Ball Valve Gas Leak Test
7.5.5 Seat Leakage Criteria as per API 527
Maintenance Level 2
7.5.6 Impulse System Pressure Test
7.5.8 Closed Ball Valve Pressure/Function Test
7.5.9 Ball Valve Gas Leak Test
7.5.10 Seat Leakage Criteria as per API 527
7.6 Onshore - Maintenance Level 3
7.6.1 Impulse System Pressure Tests
7.6.3 Ball Valve Pressure/Function Test
7.6.4 Ball Valve - Gas Leak Test
Seat Leakage Criteria as per API 527
Post Operations Function Test
7.7 Installation and Testing of Rupture Disc
7.7.1 Onsite Testing - Rupture Disc Installed
7.8 Operations with Emergency Shutdown System
7.8.1 Installation
7.8.2 Operation Principle
7.9 Contingency Procedures
7.9.1 Onsite Pressure Testing - Valve Leaks
7.9.2 Well Operations - Valve Activated
APPENDIX 7
Fig 7.1 10K MSRV Job Card

Fig 7.2 MSRV Spare Parts List
Fig 7.3 Drawing Index

Fig 7.3.1 MSRV General Assembly TED180101
Fig 7.3.2 MSRV Sensor System Application (Standard) TED180121
Fig 7.3.3 MSRV Downstream Sensor Installation (Heater to Separator) TED180126
Fig 7.4 Document Change Request Form - AB/AD/0501Rev2

SECTION 1
GENERAL
WELL TEST OPERATIONAL GUIDELINES SUB SECTION 1.0
Page 1 of 3
1.0 RISK ASSESSMENT
INTRODUCTION
General hazards are identified in the Expro Group Safety Audit Procedure. This procedure detail the specific
assessments made for operations.
Specific assessments for manual handling and display screen equipment are contained in their relevant
procedures.
1.0.1 RESPONSIBILITIES
Base Managers are responsible for risk assessment being made in the areas they control.
Senior crew members are responsible for carrying out on the spot risk assessments for all operational activities
that are considered to be outside the scope of a normal well test/wireline operation. All "on the spot"
assessments will be approved/authorised by senior base management prior to work commencement.
The Safety department will support the Manager in making the assessment.
Staff are responsible to co-operate with the assessments.
1.0.2 DEFINITIONS
1. Risk Assessment
A risk assessment consists essentially of an identification of the hazards present in an operation and
an estimate of the extent of the risks involved, taking into account whatever precautions are already
being taken.
2. Hazard
A hazard is an incident with the potential to cause harm.
3. Risk
Risk is the likelihood of the potential hazard being realised.
1.0.3 PROCEDURE
The Base manager ensures a list of all hazards is prepared.
An initial assessment of the risk from the hazards is then made using the Expro risk assessment form - see
Appendix 1.
The detail required in the assessment report will vary greatly, depending upon the nature of the particular
hazard identified.
In carrying out this exercise a 'risk rating' number has been arrived at, this is achieved in the following manner.
Establish a probable frequency rating. To do this use the following scale:
1. A highly improbable frequency occurrence.

2. A remotely possible but known occurrence.
3. An occasional occurrence.
4. A fairly frequent occurrence.
5. A frequent and regular occurrence.
Now establish a potential severity rating for the identified hazard using the following scale:
1. Negligible Injuries.
2. Minor Injuries.
3. Major Injuries.
4. Single Fatality
5. Multiple Fatality.
6. Multiple Fatality (including ones off site).

SECTION 1
GENERAL
Page 2 of 3
1.0 RISK ASSESSMENT
1.0.3 PROCEDURE (CONT'D)
Compile a risk rating number, using the table (see below) multiply the numbers derived from steps above. The
risk rating enables the most serious hazard (those with the highest risk rating number) to be considered first.
NOTE: The scales listed above are included on the reverse side of the Risk Assessment Form.
SEVERITY
6 5 4 3 2 1
5 30 25 20 15 10 5
4 24 20 16 12 8 4
3 18 15 12 9 6 3
2 12 10 8 6 4 2
1 6 5 4 3 2 1
1.0.4 RISK RATINGS
Activities with a risk rating of 0-6 would generally be regarded as no further action required. The assessment
may also adequately cover a number of straightforward hazards.
Activities with a risk rating of 7-15 will require an individual risk assessment being carried out detailing:
- The nature of the hazard

- The degree of risk from the hazard
- The people affected
- The precautions taken
- The information and training required.
Activities with a risk rating of 15-30 will require a very detailed risk assessment and where necessary, a detailed
written safe system of work, which must identify all actions required to control the hazard.
1.0.5 ACTIONS
Actions should where possible, aim to prevent the risk at source by making machinery or operations safer, or to
control the risk by developing safe system of work, or as a last resort, providing personnel protection.
Staff must be provided with relevant information and training on risks, preventative and protective measures,
and emergency arrangements.
There are a number of established safety procedures in this manual to help with these assessments.
Where existing procedures do not cover the required assessment and the base manager decides he is unable
to make a comprehensive assessment, then the safety department is available for assistance.
1.0.6 RECORDS
An up to date record of assessments is maintained by the base manager.

SECTION 1
GENERAL
Page 3 of 3
1.0 RISK ASSESSMENT
1.0.7 UPDATING RISK ASSESSMENTS
Risk assessments are revised:
- When there are changes to equipment or in operations

- Following accident and dangerous occurrences
- When safety/quality audits identify new hazards
It is the responsibility of the base manager to ensure that an annual review is made of hazards and risk
assessments.
Copies of revised risk assessments will be sent to the manager quality assurance & safety, who will be
responsible for the re-distribution of the assessments to all group locations.

SECTION 1
GENERAL
Page 1 of 5
1.1 PRE-TEST PLANNING
This involves many departments from operations, engineering, materials, quality assurance and maintenance to provide
suitable equipment to be shipped for a well test.
The sequence of events prior to a test will generally be as follows:-
1. EXPRO awarded contract for well testing work.
2. Meetings between EXPRO and the client will be carried out as required, throughout the term of the contract, to
ensure the smooth running of operations to the clients satisfaction.
3. Rig visit will be carried out if files on rig not up-to-date or if the well test will be of a non-standard nature.
4. Operating company calls for equipment for a forthcoming well test. EXPRO will organise third party equipment
to be used on test e.g. steam generators etc.
5. The relevant operations supervisor / manager is responsible for producing proposed layout and P.I. / flow
diagrams for certification.
NOTE: Equipment Selection;

All components and equipment to be used on exploration wells which shall be exposed to a
combination of pressure and hydrocarbons must be suitable for sour service to the material
requirements as defined in NACE MR-01-75.
In certain cases a Hazop study will have been attended. All relief lines, safety devices etc. will
have been sized to expected well parameters (provided by operating company).
6. Routine maintenance is carried out on all equipment to maintain a pool of equipment ready to be shipped
offshore at short notice. Specific equipment will be assigned to the particular well test and a certification
package compiled, which will include the diagrams and information such as chemical data sheets. This
package will be submitted for approval by the relevant certifying authority.
NOTE:
Release notes for equipment may be issued by the rig certifying authority e.g. DNV. These may be issued
where the certifying body is not willing to certify some equipment for a year, but are willing to certify it for one job
e.g. if not sure that pipework is H2S rated then it may be certified for a 'sweet' test and have hardness checks
etc. carried out before the full certification is accorded.
7. A pre-test meeting may take place involving the well test supervisor or equivalent.
8. When equipment is required it will be shipped to rig (this will often be around the time when the liner / casing
string is set).
NOTE:
Consideration will obviously have to be given to distances that the equipment must be transported, and the
length of time it will take. It may be the case that the equipment will have been shipped before the logs have
been viewed resulting in a change of equipment required or possibly, in the case of a dry hole, the de-
mobilisation of the equipment.
9. Operating company will call for well test personnel.
10. Operations will mobilise a well test crew for equipment rig up.

SECTION 1
GENERAL
Page 2 of 5
POINTS DISCUSSED IN MORE DETAIL
1.1.1 RIG VISIT
Once it has been decided that a well test will take place on a rig (or platform) then a rig visit will take place. This
rig visit is to obtain at first hand information required for the success of a well testing programme and to
overcome any problems in the planning stage, thus preventing possible delays at a more critical stage. The
well tester carrying out the rig visit is expected to carry out the following:-
1. Initially make contact with operating and drilling company representatives to discuss the well testing
program to take place.
2. To establish the equipment required to carry out that programme.
3. Establish where the equipment will be sited in relation to safe access and exit, and the relative
proximity of hazardous areas for that particular installation.
NOTE: The safe routing of flowlines should also be considered.
4. Survey the flare boom installation i.e. take measurements required to hang booms and note any
problems.
From the information gained on the rig visit a proposed layout diagram, boom loading diagram and/or
a flow diagram/process and instrumentation diagram will be produced for certification by the rig
certifying authority. Prior to producing these diagrams, Engineering will have carried out a study into
the required size of relief lines and what safety devices should be installed and include these on the
relevant diagrams. A copy will also be passed to the operating and drilling companies for their
approval.
A file will be established for the rig for future reference and will be updated if future visits are carried
out.
1.1.2 ENGINEERING REQUIREMENTS
1. To size relief valves, lines, safety devices, etc. to reduce process pressure below the equipment
MAWP and to ensure that all pipework and equipment will remain within specification, in a worst case
scenario.
2. To produce required diagrams for operating company, which may be of the following:-
Equipment Layout Diagram
This diagram's main purpose is to highlight the rig's hazardous areas (around vents, electrical supply
points etc.) and add the hazardous areas around the well test equipment. This diagram will be
submitted for approval to the rigs certifying body before the well test to ensure no safety regulations
are infringed in the spotting of equipment.
NOTE: This drawing is for a proposed equipment layout, if for any reason, the equipment is relocated, it is
the rig owners responsibility to inform the certifying authority.

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Equipment Process and Instrumentation Diagram (P and I.D.)
This diagram shows the process flow and the instrumentation and safety devices attached to the well test
equipment. These diagrams also have to be approved by the rigs certifying body.
These diagrams are standardised but can be altered for specific well tests once the clients equipment
requirements are known.
There are also other constraints to be considered prior to the completion of these diagrams, in that when
working offshore the available deck space will play a major part in determining where, exactly, the larger items
of equipment are placed.
Consideration should also be given to the layout of flowlines in order to reduce the amount of elbows and
restrictions thus reducing turbulence and any pressure drop through the flowline.
Flow Diagram
This diagram is an elementary P and I.D. and shows the flow path through the well test equipment, with valve
configuration and will include safety devices.
The Engineering department will also attend HAZOP studies if required.
1.1.3 HAZOP STUDIES
These are discussions to look at potential hazards of operations on a WHAT IF basis. i.e. if this happens what
will be the result.
They are attended by all the companies involved in well operations i.e. the operating, drilling and all service
companies. A third party may also attend these discussions to put forth an independent point of view to promote
discussion.
Operations will be broken down into blocks and looked at in detail e.g. what are the consequences of opening
this valve, could it create a hazard. This will be carried out for the complete process train of the proposed well
programme.
1.1.4 EQUIPMENT MAINTENANCE
Routine maintenance procedures have been drawn up which are carried out on all equipment prior to shipping
for a well test.
Generally this maintenance will include the following: -
a) Visually inspected
b) Internal inspected where applicable
c) Thickness checked where applicable (when abrasive materials have been flowed through the
equipment or when a survey is required eg. a major survey).
d) Pressure tested
e) Non-routine repairs carried out as required
f) Paint and corrosion protection applied as per EXPRO maintenance procedures.
g) Slings inspected
h) Prepared for shipping

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1.1.5 CERTIFICATION
Certification is carried out on all equipment and is done on a 5 yearly (major) and yearly (annual) basis.
The annual surveys include a visual inspection and pressure test to full working pressure to check the
continuing functional ability of the equipment and any other requirements of the individual certifying authority.
NOTE: Before annual certification is issued the certifying authority must be satisfied as to the routine
maintenance program carried out on the equipment throughout the year (which is recorded on
maintenance records for each item of equipment).
Major surveys include all the features of an annual survey but generally speaking pressure tests are to 1-1/2
times maximum working pressure and the surveys may also include whatever the surveyor deems necessary
eg. hardness checks etc., dependant on the equipment's service history.
It should be noted that annual surveys have a 3-month period of grace after the 12 month period to allow for
equipment which is offshore on a long term contract, where certification may run out, to continue to be used for
the short term. If the contract is ongoing after the 3-month period of grace then the equipment must be changed
out and re-certified. If the equipment is not certified within the 3-month period (eg. due to transportation delays)
then it must have a full major survey carried out before it will be re-certified.
This 3 month period is not intended to allow for equipment to be sent offshore, short term, after the certification
has run out.
1.1.6 PRE-TEST MEETINGS
These are usually held shortly before the actual start date of operations and involve the operating and drilling
companies, and all the service companies who will carry out the operations during the course of the well test.
From EXPRO's point of view these meetings are normally attended by the supervisor who will carry out the test.
The purpose of these meetings is to run through the programme of operations and to discuss the safety aspects
of these operations. It is also to interface the equipment requirements between the different service companies,
to ensure that it is known who supplies what eg. the proper cross-overs etc.
The well test supervisor will take the proposed drawings produced by the engineering department to the
meeting and will be ready to discuss the nature of operations from EXPRO's point of view eg. the safety
aspects with regards to the well test equipment. He should also expect to answer specific questions related to
our equipment and queries as to how the equipment works.
Another topic that may be discussed are environmental issues e.g. noise pollution, oil spills, black smoke, etc.
1.1.7 EQUIPMENT REQUIREMENTS
The operations supervisor will have been liasing with the client from the outset as to the equipment required.
Together with the workshop foreman, he will assign it for that particular job and also deal with any special
requirements eg., third party equipment to be used, or any particular EXPRO equipment to be used eg. D30
vertical separator (for high deliverability wells).
Once the equipment has been selected, it will be logged on the ECS computer system for that job to ensure that
the whereabouts of all equipment is known at all times. The Materials / Transport department will complete the
relevant dangerous goods notes and ensure that all paperwork is in order (not including certification which will
be the responsibility of the Quality Assurance department).
The materials co-ordinator will also arrange for the transport of equipment to and from the required location of
the client e.g. which docks etc., on the proper dates.

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1.1.8 PERSONNEL MOBILISATION
This will be carried out, in the numbers required, when requested by the operating company.
Personnel will be provided with all the required safety clothing to comply with EXPRO's company safety policy
and COSHH regulations.
Generally once a test is known to be forthcoming personnel assigned to that job are placed on standby to go
offshore. This requires that they regularly check with the office and leave contact numbers if they plan to be
away from home, until told to stand down

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Page 1 of 1
1.2 PRE-TEST WORK SITE GUIDELINES
On arrival at the work site the EXPRO supervisor in charge of the job should follow the guidelines below to ensure that all
runs smoothly during the forthcoming well test.
1. The Supervisor should introduce himself to the Company man / Drilling supervisor and discuss the test
requirements. Also they should introduce themselves to any other people who may assist EXPRO during a well
test, eg. the Barge Engineer, Crane Operator, etc.
2. The equipment should be inspected on arrival to the rig, for damage in transit, in order to maximise the time for
EXPRO to respond. Particular attention should be placed on the availability of required instrumentation.
3. Work areas should be inspected to ensure equipment can be spotted as per the layout diagram, and escape
routes decided upon.
4. The separator should be checked, both for accessories (eg. orifice plates, etc.) and the operation of
equipment.
a) Sight glasses are clear and allow liquid level to rise and fall.
b) Dump valves stroke properly and travel correct distance.
c) Liquid meters should be checked that they are not seized, gearing should be checked, (meter factors
will be performed later).
d) Check the float retainers are removed (if fitted) and floats are connected to displacer arms.
5. The spares inventory should be checked along with availability of correct cross-overs.
6. The chokes should be checked for a full set and any extras that may be required (eg. 1/64th increments during
sand frac clean-ups).
7. Pressure recorders such as Foxboro or Barton should be calibration checked and recalibrated if required.
NOTE: In the field it is not practical to recalibrate the temperature probe, due to the complicated nature of this
process, but it should be checked with cold and hot sources to verify it's accuracy. Use a stick thermometer in
the thermowell if the temperature probe is out of calibration.
8. Barton differential recorders should be calibration checked (both static and differential) and recalibrated if
required. The correct plumbing of the Barton should also be checked (flange taps and upstream static
pressure).
9. The Data Logger / Edge system pressure transducers should be calibration checked and the correct functioning
of the system confirmed. The operator of the DAS must be made aware of the expected well parameters,
threshold values, etc.
10. The heat exchanger if used (should be pre-heated to the required temperature, and the operation of the
temperature controller checked.
11. The supervisor should ensure that all EXPRO crew members are aware of the rig alarm system (audible and
visual) and understand what each alarm is.
12. The supervisor should also ensure that senior crew members have a knowledge of the permit-to-work system
that work will be carried out under.
13. Where required, the supervisor should ensure that all crew members know where safety equipment eg. B.A.
sets etc. are located and ensure that all EXPRO crew know the escape routes and muster points.
14. Paperwork and stationary supplies / computer and computer supplies (if used) should be checked to ensure that
there is a plentiful supply and that the computer has not been damaged in transit.

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1.3 RIG VISITS
A rig visit should be performed if a test is to be carried out on a rig that EXPRO have not tested on before or have not
tested on for some time.
The purpose of this rig visit is to ensure that equipment can be spotted without problems, that tie in points to rig lines, etc.
and whatever crossovers required are identified. It is also a time to meet with operating and drilling company
representatives and to check out rig certification, e.g. of permanent piping, etc.
The rig visit checklist should be completed (Refer to Fig. 1.5 for an example) as much as possible. This will enable base
staff to plan equipment/flowline, etc. requirements.
NOTE: The completed rig visit checklist forms part of the planning report that is submitted for Certifying Authority
approval.

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Page 1 of 3
1.4 GAS WELL TESTING
1.4.1. PROBLEMS
1. LIQUID LOADING
This problem usually occurs when testing low producing gas wells with high liquid-gas ratios.
Indications of liquid loading are wide variations of surface pressures.
2. HYDRATE FORMATION
This problem occurs normally in a high-pressure gas well.
Flow across chokes or separator back pressure valve may also plug off causing upstream pressure to
rise.
Chemicals such as glycol and methanol can be injected (upstream of any potentially large pressure
drops) to prevent and inhibit hydrate formation.
However if a heat exchanger is used, this problem can largely be eliminated by maintaining the well
stream temperature above the hydrate formation temperature.
3. WET GAS STREAMS
Wet gas streams can cause inaccuracies when measuring the specific gravity of a gas. They also can
cause instrument lines to 'freeze' in extreme cold climates if running off separator gas instead of air,
differential recorders can 'freeze' also.
Knock-out pots, possibly filled with steel wool or with wire mesh screens to assist liquid knockout from
gas, can be used to overcome this. These pots must be blown down regularly.
4. IRREGULAR FLOW
A frequent difficulty encountered in measuring accurately, gas flow rates is the rapidly changing rate
when a well 'slugs'.
This type of flow can cause errors when reading differential recorder charts but can be partially
overcome by increasing the proportional band setting on the back pressure controller (this will cause
the BPV to stroke at less sensitive pressure changes and stop 'hunting'). Also the pulsation
dampening screw on the DPU cell can be screwed in restricting the flow of oil between either side of
the bellows. (Do not screw in more than 1 1/2 turns from fully closed or else no pen movement may
be observed).
The pulsation dampener can be found under the screw at the back of the DPU cell (model 199) and
requires a 1/8" sized Allen Key to adjust.
Clockwise adjustment reduces pulsation, anti-clockwise increases.
5. SOUR (H2S) GAS
Sour gas is extremely toxic, causing illness and death in relatively small atmospheric quantities.
H2S procedures are fully covered under Section 1.9.

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Page 2 of 3
1.4.2 OPERATING PROCEDURES
The actual course of events may differ according to conditions on the rig at the actual time of operations and the
clients Test Programme.
ASSUMPTIONS
a) SAFE and Coiled Tubing Cutting valves (if either used) installed and function tested.
b) Surface Test Tree installed with kill-wing and swab valves closed and master valve open.
c) All down hole safety valve(s) open.
d) Texteam pump function tested, and methanol available in sufficient quantity.
STABILISED CONDITIONS attained when:-
a) For closed in periods build-up <= 1 psi per 30 minutes.
b) For flowing periods:-
c) BS&W < 7% (or < 5% if mud present).
d) Pressure does not vary more than 0.1% of C/I pressure during 15 minute period.
e) Gas and liquid rates are constant.
1. Pressure test well test equipment as per client's programme.
2. Function test ESD system remote stations and high pressure pilot.
3. Check calibration of Barton / Foxboro recorders with poddy meter.
4. Function Test burner water injection screen and ignition systems. Function test burners with diesel if
environmentally acceptable.
5. Open choke manifold downstream valve.
6. Line up gas diverter manifold to boom with favourable wind conditions and ensure standby boom is
isolated at diverter manifold.
7. Ensure system is set up via separator bypass to flow to flare, this will prevent damage or plugging of
liquid meters and settling of solids or mud in separator during clean-up.
8. Ignite propane / diesel pilot burner in readiness for gas returns.
9. Apply radiation water screen to burner head.
10. Open well to overboard on suitable adjustable choke.
NOTE: On dual train systems, secondary train should be opened early in the flow period to clear
system of any trapped liquids while gas velocities are still relatively low. This will reduce
reactive forces caused should a slug of water be introduced into a high velocity gas stream.
11. Monitor surface pressures / temperatures and nature of produced fluids.
Take Draeger tests for H2S, CO2 and N2 when first gas at surface (test for mercaptans can also be
carried out). Continue testing every 3 hours or as required.

SECTION 1
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Page 3 of 3
12. Gradually bean up in required choke increments and flow until well clean and desired drawdown /
flowrate is achieved under stable conditions.
a) Estimate gas flow rates on each choke setting prior to beaning up.
b) During Clean-Up, as a minimum, it is necessary to produce a volume of fluids at least

equal to the volume of the well bore.
c) Generally the well will be cleaned up to a rate equal to or greater than the highest rate that
the well will be tested to.
NOTE: At end of clean-up period it may be required to flow via test separator to obtain accurate
flow data. Liquid levels may be established if separator used at this stage.
13. Close in at choke manifold or downhole tester valve for pressure build-up to record initial reservoir
pressure and temperature. This pressure is necessary to calculate the A.O.F. or deliverability plots.
14. Once stable C/I conditions reached open well at choke manifold and flow well for one or more
successive flow rates.
These flow rates will generally be of sequence smallest choke bean to largest.
a) The minimum flow rate should produce a pressure drop approximately 5% of shut-in
pressure, or at least to the size required to lift liquids, if any, from the well.
b) The maximum flow rate should produce a pressure drop of approximately 25% of shut-in
pressure.
c) Any other flow rates should fall equally between these constraints.
NOTE: Drawdown of the well should not > 50% of shut-in pressure to prevent possible damage to
the well-bore.
15. Flow via separator for required flow period, collecting desired samples (PVT, bulk etc.) as required for
each flow rate.
Each rate must be flowed to stabilisation in order to obtain correct data to calculate A.O.F. or
deliverability plots and prevent need for a retest.
If flowing for several flow rates work out, during initial shut-in, if one orifice plate can cover all flow
rates (while maintaining > 20% and < 80% of differential range). If not, use minimum orifice plate
changes as possible.
16. Close in well at choke manifold (or down-hole tester valve) and observe pressure build-up until initial
reservoir pressure achieved.

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Page 1 of 1
1.5 OIL WELL TESTING
1.5.1 PROBLEMS
1. EMULSIONS
If the fluid from a well consists of both oil and water, there is a possibility that they will not separate.
The resulting fluid is commonly called an emulsion. If this emulsion is measured as oil, the test will be
in error by the amount of water in the emulsion.
2. FOAMING OIL
When the pressure is reduced on certain types of crude oils, foam (or froth) can be caused by the
liberation of a large amount of micro bubbles in the oil, as the gas comes out of solution, where these
bubbles are encased in a thin film of oil. In other types of crude oil the viscosity and surface tension of
the oil may mechanically lock gas in the oil and cause an effect similar to foam.
The presence of foaming oil can lead to a number of problems if not treated such as: -
a) Prevent good separation and reduce separator capacity.
b) Disrupt liquid and gas metering
c) Disrupt pumping operations
d) Cause potential burning problems
Foaming oil procedures are fully covered under section 1.8.
3. PARAFFINS
Paraffin deposition in separators reduces their efficiency and may render them inoperable by partially
filling the vessel and / or blocking the mist extractor and fluid passages.
These deposits can be effectively removed from separators through the use of steam or chemicals.
4. SAND, MUD, SALT ETC.
If sand or other solids are continuously produced in appreciable quantities with well fluids, they must
be removed as soon as possible from the well stream. If not, deposits may build-up on vessel
interiors, reducing capacity and operating efficiency.
Where well pressures allow, the EXPRO twin pot sandfilter assembly can be used to remove these
solids, (for further information on sandfilters refer to Section 3.11).
5. SOUR (H2S) OIL WELLS
Sour oil wells cause the same problems as a sour gas well as the H2S gas produced with the oil is
extremely toxic, causing illness and death in relatively small atmospheric quantities
H2S procedures are fully covered under Section 1.9.

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Page 1 of 12
1.6 SOLIDS MANAGEMENT
1.6.1 General / Solids Production
Solids production is becoming more and more of a problem for the oil industry with depleting reservoirs and rising solids
production. Solids handling equipment is therefore becoming increasingly important due to financial, environmental and
safety consequences.
Solids can be produced either:
In a controlled manner using specially designed dedicated equipment.
1. Sand Filters/Wellhead Desander
For more details refer to the following operational guideline sections;
chapter 1 General operating guidelines

Section 1.6 Sand frac clean ups
chapter 3 Section 3.11 Sand filters
2. Sand Monitoring Equipment
These instruments basically monitor sand production accurately and if sand production is getting above an
acceptable level the flow has to be reduced, causing the solids production to decrease simultaneously.
There is a whole range of detection devices available however we can divide them into two different systems.
2.1 Non Intrusive Detectors
They work on the principle of detecting the acoustic noise of sand particle impacts on the outside of pipe
bends. The three main suppliers of this technology are:
Fluenta
Clampon
Stress wave
Devices
2.2 The intrusive probes work on the principle of measuring the increase in electrical resistance of a
metallic element exposed to erosion by the sand flow. Intrusive type probes are not used anymore
within The Expro Group.
3. Uncontrolled sand production
With no sand control equipment available sand production can only be detected with:
BSW measurements
Choke erosion
Malfunctioning instrumentation
Sudden leaks due to erosion
BSW
BSW = Basic Sediment and Water
BSW measurements should be taken at regular intervals and normally give the first indication of solids being
produced. After the spin out the solids are collected at the bottom of the sample tube where the amount can be
measured.
Reference the following operational guideline sections;
Chapter 4 Surface sampling guidelines

Section 4.4 measuring BS&W

SECTION 1
GENERAL
Page 2 of 12
4 Choke Erosion
Reference the following operational guideline sections;
Chapter 6 Contingency guidelines

Section 6.9 Choke manifold
5 Malfunctioning Instrumentation
The first signals of having solids produced and accumulating in the system is normally the performance of the
separator. With the bottom part of the interface sight glass plugged off it will be impossible to find a true interface.
Other sensitive areas for solids production are;
Plugged liners from DWT, BARTON, FOXBORO and EDGE sensors.

Plugged gauges reflecting a wrong pressure.
Faulty readings from the level controllers.
Plugged sight glasses.
Bad separation due to reduced volume in separator.
In general the process would not be under full control due to wrong information given by the instrumentation.
Eventually this could lead to an ESD signal, carry over or gas blow-by to the tanks.
If one of the above happens be aware of solids production.
6 Sudden Leaks
If solids are produced without being detected unexpected leaks could occur In general at places where a pressure
drop takes place or where turbulence is created.
In or just after elbows or bents

After X-covers
Near swages
In general after a pressure drop
Other notorious places for sudden leaks due to solids erosion are;
Liquid control valves (dump valves of the separator)

Back pressure valves (due to the pressure drop)
On threaded unions (due to turbulence)
Despite wall thickness measurements being taken at regular intervals a sudden leakage could occur at any time.
This leak could be potentially dangerous for well test personnel, high velocity escaping gas containing solids could
be experienced causing severe injuries.
If a sudden leak occurs close in the well as quick as possible using the Emergency Shut Down system. The ESD
buttons are located at strategic places around the test facility and in safe areas.
Leaks caused by erosion are known to increase very rapidly and could be completely out of control in minutes.
After the complete package is bled off start with inspection of the most sensitive points,
- Pipework downstream choke manifold
- heater inlet elbow
- heater outlet elbow
- heater coil elbows
- separator inlet spool piece
- downstream back pressure valves
- All sensor lines and instrumentation.
- DWT
- Foxboro
- All EDGE sensors
- Separator BARTON
- All instrumentation manifolds and gauges
- Vessels and tanks
- All liquid drains
- External float chambers

SECTION 1
GENERAL
Page 3 of 12
- Floats
- Level switches
The minimum inspection should consist out of a wall thickness survey and where possible a visual inspection. List
the equipment used accurately for later traceability.
Produced solids normally accumulate in the following places.
In the sand filter or well head desander

In pressurised vessels
In tanks
In dead ends of the process system
a Sand filters or Well head desander
This equipment is specially designed to remove the solids from the well stream.
For detailed description refer chapter 3, section 3.11 Sand filters, of the well test operational guidelines.
b Vessels
This could be any vessel in the test package;

First stage separator
Second stage separator
Knockout vessel
c Tanks
This could be any tank used in the process system;

Of course the solids accumulate at the bottom but could also in certain circumstances accumulate on the wall of a
tank causing serious mis-readings.
Surge tank
Gauge tank
Storage tank
d Dead ends in the process system
This could be in the following cases
Heater bypass valve and inlet valve open and the outlet valve closed.
This is bad practice and should not be done. However if this is the case
solids could accumulate in the heater coil.
With complicated rig ups sometimes solids accumulate near bypass valves where there is no flow. Obviously
these situations must be avoided at all times.
Reference the next chapters in the well test operational guidelines;
chapter 1 General operating guidelines

section 1.6 sand frac clean ups
section 1.10 acid clean up procedures
chapter 3 Equipment operating guidelines
section 3.27 proppant knockout vessel
chapter 4 Surface sampling guidelines
section 4.4 measuring BS&W
chapter 5 Safety guidelines
section 5.6 corrosive and hazardous substances

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Page 4 of 12
7. Solids Handling
Solids are considered to be:
Any slurry / sludge / solids, consisting out of and a combination of
Any type of formation sand in any size.

Artificial made proppant in any size.
Pipe dope.
Scale from tubing/casing.
Metal parts from perforating guns.
Metal parts from milling operations.
Rubber parts from previous well intervention work.
Rocks or stones from the formation.
Spent acid slurry.
Lost circulation materials like;
Carbonates
Coconut chips
Chicken grid
Cement parts
Basically any combination which can be produced by the formation or what can be pumped into the well.
Depending on the specific situation solids are contaminated and therefore be very dangerous for the health of the
operator coming in contact with the solids. Appropriate safety measurements have to be taken in order to perform
the work safely. Refer Health and Safety Manual System No. 0701 and the operational guidelines section 5 sub
section 5.6.
Solids could be contaminated with;
ACID / SPENT ACID

BENZENE / TOLUENE VAPOURS
INJECTED INHIBITOR
LSA
H2S VAPOURS
MERCURY VAPOURS
METAL DEBRIS
OTHER TOXIC MATERIAL INJECTED
OXY SCAVENGER
BIOCIDE
TOXIC POLYMER
RADIOACTIVE TRACER
SCALES
a. ACID / SPENT ACID
For stimulation purposes a whole variety of acid is pumped into the well either bull-headed or using coiled tubing.
After the acid operations the well should flow again. At this time acid either pure or spent is produced back to
surface again.
The required precautions are mentioned in the well test operational guidelines
chapter 1 section 1.10 Acid clean up procedures.
After the job the solids and or sludge/slurry can be found in the vessels and the tanks.
All safety measures must be taken as per Health and Safety Manual System No. 0803
b. BENZENE / TOLUENE VAPOURS
Oil residue normally contains benzene and or toluene vapours, particular gas wells are notorious for this. These
vapours are very toxic and even once the vessels and tanks are completely bled off slurry/sludge will produce the
vapours for a long time.
All safety measurements must be taken as per Health and Safety Manual System No. 0701 and System No. 0801
/ 0802

SECTION 1
GENERAL
Page 5 of 12
c. INHIBITOR INJECTED INTO THE TUBING
Inhibitor is normally injected into the tubing through an injection valve down hole and is meant to extend the
lifetime of the tubing drastically. In general these liquids are very abrasive and should never be touched with bare
hands and without BA. The chemical data sheets of the used inhibitor must be available at all times.
All safety measurements must be taken as per Health and Safety Manual System No. 0801
d. LSA FORMATION SAND
Especially older gas fields start producing LSA contaminated formation solids.
LSA stands for
Light
Super
Altitude
Great care should be taken since you wont notice a direct effect but the long term effects are severe.
On locations known to produce LSA solids a level 3 inspector should be available at all times. Accumulation of
LSA material in your body does finally cause death. For the correct safety procedure see the attached manual.
e. H2S VAPOURS
From an oil residue H2S could escape for a long time. H2S is also known to penetrate metal and slowly escape
from within the metal after it is taken out of the H2S environment. This process, depending on the concentration,
could last for weeks. The vapours are very toxic and have a very low MAC value. Once the vessels and tanks
are completely bled off, slurry/sludge remaining at the bottom will also produce the vapours for a long time.
f. MERCURY VAPOURS
Some gas and oil fields are known to produce mercury. Initially the amounts are small but after accumulation
pure mercury will be present in vessels and tanks.
For the correct safety procedure see the attached manual.
g. METAL DEBRIS
After perforating a well guns debris is normally produced to surface.

Depending on the type of gun used, sharp metal pieces will come to surface and will cause damage to the valves
and instrumentation. Normally the debris will plug up the adjustable choke causing interrupting the initial clean up
period due to choke changes and other complications. Because the debris is from metal the damage to valves
and instrumentation could be severe and must be avoided whenever possible.
h. OTHER TOXIC MATERIAL INJECTED
OXY SCAVENGER`
BIOCIDE
TOXIC POLYMER
Water injection wells are sometimes injected with the mentioned liquids and therefore whenever working on water
injection well be aware of this and have the chemical data cards available on site.

SECTION 1
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Page 6 of 12
i. RADIOACTIVE TRACER
In the past wells have been stimulated with radioactive proppant to measure the performance of the hydraulic
sand frac. Nowadays for obvious reasons this is not performed anymore.
However producing a well which is fracced with radioactive proppant in the past still could produce, even after
years radioactive proppant.
The same safety precautions should be taken as with an LSA contaminated well.
For the correct safety procedure see the attached manual.
j. SCALES
Throughout the well lifetime scales could accumulate on the inside of the tubing wall and finally either block the
tubing or be produced to surface causing complications in the process.

SECTION 1
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Page 7 of 12
1.6.2 SAND FRAC-CLEAN UPS

INTRODUCTION
1. Sand Fracturing is a well established and proven method of increasing production from both oil and gas
reservoirs. In recent years these operations have been particularly active in the gas fields of the Southern North
Sea.
2. There are number of inherent problems associated with 'sand frac' operations, erosion being of a particular
concern. During post-frac clean-up operations sand or proppant not retained in the fracture, along with spent
gel, have to be removed prior to producing the well. The effect of this highly abrasive fluid on surface
equipment is dramatic, causing extreme erosion within piping systems, especially downstream of chokes.
3. The EXPRO clean up package is a system designed to safely dispose of well effluents after massive sand
fracturing operations and minimise the damage to Well Test equipment. Clean up involving handling of frac.
sands and broken gels is achieved using a custom designed overboard clean up line, whilst removal of solids is
achieved in a highly specialised sand filtration package (ref OSP 4.09). This approach to clean up operations
alleviates the need for large capacity gravity separation devices and their associated control and material
handling problems and reduces the risk of gas escape due to washed out and cut out lines.
4. A major factor influencing system design relates to the control of velocities at all times in order to minimise
erosion.
5. Hence, during clean up, well control is achieved by choking primarily at the choke manifold and secondly, at the
burner booms thereby minimising velocity through all major flowlines. Due to the extremely erosive nature of this
process, special care regarding piping design has been imperative. All efforts to minimise directional flow
changes have been made, but as and when required the fittings used are of a design where risk of cut out is
low, ie, flanged 90 targets, lateral tees. All pipe sizes have been kept to a maximum within practical limits.
6. On completion of the clean up period when production of frac. fluids/proppant is significantly reduced, filtered
gas can be directed to the production loop and test separator.
NOTE: The liquid capacity of the sand filter package is limited and is dependant on the sizing of the filter
carriage viscosity of the liquid being handled.
7. The following recommendations have been obtained through several years of experience of Post Fracture
Stimulation Clean Up Operations. These procedures have been accepted and adopted by most major oil
companies. They provide the safest approach to a hazardous operation and for that reason should be given full
consideration when preparing well test programmes.
OPERATING GUIDELINE
The following is indicative of the sequence of events and operating procedures to achieve a safe and effective
clean up programme.
A fracture stimulated well must be flowed clean of fracturing fluids and proppant via sand filter equipment to
minimise any damage to the clean up system. This should be undertaken in such a way as to achieve
acceptable maximum gas flow rates in as short a period as possible without causing erosion of surface facilities
or damaging the proppant pack in the near well bore vicinity.
Prior to starting clean up operations the fracture must be closed and the fracture fluids (gels) broken down and
'leaked off'. The proppant pack will have started developing as the fracture closes. However, during the early
stages of clean up the proppant particles are adjusting and packing as a result of the closure stress exerted on
the proppant.
It is recommended that initial clean up starts on, no bigger than, a 16/64ths fixed choke. (Coiled tubing/nitrogen
lifting is normally required to bring the well into production by lifting fluids gradually whilst running in hole).
Fluid production should be kept to a minimum as broken gel exerts drag on the proppant pack, therefore, if a
small choke size is used back pressure against the formation will be maximised. It should be noted that
pressure drop and velocity of the fluid, would both increase near the wellbore. As the well slowly starts

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SAND FRAC-CLEAN UPS

clean up the well head pressure will obviously increase, hence beaning up should not be undertaken until some
sort of stability has been achieved.
It should be noted that proppant does not always come to surface straight away. Tubing size, deviation &
flowing parameters, all need to be taken into account. Therefore, it is inadvisable to attempt to speed things up
during the early stages as damage in the fracture will also effect the well's long term deliverability. By following
a set procedure the proppant production can be controlled and handled safely by the filters and other
equipment. Damaged or crushed proppant is a result of large pressure drawdown and, therefore, high closure
stress exerted on the proppant.
The actual course of events may differ according to conditions on the rig at the actual time of operations.
ASSUMPTIONS
a) At the end of the fracture stimulation the test string was displaced to seawater (dependant
on stimulation programme).
b) Kill wing on tree closed.
c) Master valve and down hole safety valves open.
d) A datum has been established with respect to pipe wall thicknesses.
1. Close swab valve.
2. Bleed down pressure in frac. line and rig down frac lines.
3. Close sand filter bypass and ensure filters installed of range suitable for coiled tubing operations.
4. Open choke manifold downstream valves (clean up line side).
5. Ensure heater inlet valve - test line side - closed and test system vented via oil line (see Note b.)
6. Line up gas diverter manifold to boom with favourable wind direction.
7. Ensure standby boom is isolated at gas manifold.
8. Ignite propane pilot burner.
9. Apply radiation water screen to burner head.
10. Open well to overboard flare via fixed choke (12/64ths to 16/64ths) at choke manifold and at
adjustable choke box at boom.
11. Continually monitor surface pressures/temperatures and nature of produced fluids.
12. Bring on well slowly on 12/64ths to 16/64ths fixed choke.
13. Establish well production and retrieve coiled tubing when well is flowing satisfactorily, without nitrogen
lift. S.G. of gas can be monitored from samples taken from top of sand filters.
14. (It should be noted that a pump rate of 500 scf/minute of nitrogen maximum should be pumped whilst
running in hole to prevent the well being 'held' back due to excessive wellhead pressure (on the small
choke size).
15. Liquid production should be controlled and observed (rough guideline: maximum 1 bbl/minute) and
the rate estimated from the flare. Proppant production should be observed and an accurate proppant
rate established.
THE TEST SEPARATOR AND PRODUCTION FACILITIES SHOULD NOT BE CONSIDERED

DURING THE EARLY STAGES OF CLEAN UP (SEE SEPARATE GUIDELINES).

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SAND FRAC-CLEAN UPS

16. When the well head pressure shows signs of stability and measured proppant production (if any) over
the last 3 hours is 50 lbs/hour or less bean up 1/64ths.
17. Continue bean up in this way until proppant is produced to surface or if proppant production exceeds
500 lbs/hour then bean back, unless a downward trend is obvious.
18. Monitor sand filter efficiency via optional sand probe and/or by checking choke box after choke
changes.
19. Monitor pipe wall thicknesses regularly using an ultrasonic thickness meter (ref. OSP section 9.3.1).
20. If problems are encountered in maintaining a lighted flare (due to slugging or nature of produced
fluids, e.g. spent gel) leave pilot system running continuously or light a `lance' and place near end gas
overboard line.
21. Once 28/64ths choke is reached consideration can be given to beaning up 2/64ths when proppant
production is less than 50 lbs/hour over a 3 hour period.
22. Once 40/64ths choke is reached consideration can be given to beaning up 4/64ths when proppant
production is less thank 50 lbs/hour over a 3 hour period.
a) When opening and closing gate valves, the number of turns achieved should be noted, so as to
ascertain if a valve is 'sanding up', and therefore, not fully closing.
b) While flowing via the clean up line with test line isolated, ensure that the test line is open to
atmosphere via the oil line to the burner not in use. This will ensure there is no pressure build up in
the test lines if an isolation valve begins to pass.
c) Constantly observe both upstream and downstream choke pressures to ensure choke erosion does
not go undetected. Visual choke / adaptor inspection should take place at least every 3 hours unless
proppant production is insignificant.
d) Before attempting to flow via the test separator / production loop proppant production should be
observed and a proppant rate established.
e) If a quick gas/water rate is required during the clean up the proppant production should be less than
30 lbs/hour over a 3 hour period with a downward trend.
Wellhead pressure should be stable (well not slugging). If two sets of filters are available use two in
series in case of filter rupture. Flow via separator for 1 to 2 hours to obtain flow rate information then
continue clean up via clean up system (check separator drain for proppant).
f) At the end of the clean up proppant production needs to be 2 lbs/hour or less with a downward trend
over a 3 hour period before flowing for extended periods via the production loop. To achieve this
bean back the well until flowing conditions are satisfactory. (4/64ths is usually enough). Use the
smallest filter size possible without effecting the well performance and check the separator drain
regularly for unfiltered proppant/fines.
Velocity through the test system should be considered at all times.
g) If for any reason the well is closed in during clean up it should be reopened with care. Bean up slowly
from 16/64ths to give a maximum of 100 psi/hour drop in flowing tubing head pressure until close to
previous flowing pressure / choke size. Check proppant production prior to final bean up to original
choke size as well performance / characteristics may have changed due to shut in.

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SAND FRAC-CLEAN UPS

USE OF A SAND FILTER BYPASS LINE
1. A bypass line can be included in the clean up system to handle large volumes of proppant safely and
efficiently during initial clean up and reversing out procedures.
2. However, once the well is flowing independently, it is advisable to bean back the well to reduce proppant
production to a manageable level and divert the flow through the Sand Filters where the clean up can continue
in a controlled manner. This also reduces the risk of erosion downstream of the boom choke.
3. The bypass line will consist of an 'L' shaped dual isolation manifold installed upstream of the Sand Filters and a
separate line running to a boom with favourable wind direction. The line will include chemical injection / pressure
tapping points and a choke box installed at the base of the boom to control flow back during coiled tubing
nitrogen lift operations.
NOTE: a) The line will have been pressure tested to 5,000 psig prior to flowback.
b) The Boom choke operator is to maintain radio contact with the coiled tubing operator.

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1.6.3 SAND SEPARATOR

Quite often older wells produce solids. The velocity of the hydrocarbon stream in the tubing slowly will decrease with a
depleting reservoir. At a certain moment the velocity of the well stream is getting too low to lift the produced solids to
surface. The solids will gradually fill the rat hole and the perforated sections. This results in less and less production and
could finally kill the well. A coiled tubing sand clean operation is then needed.
For this special situation we will use the sand separator since sand filters are not suitable to handle slugs of liquid with
solids. Furthermore the solids could be contaminated and therefore producing directly overboard is not an option.
This also counts for onshore locations.
Due to its volume and drain capabilities the sand separator is the most suitable equipment for this kind of jobs.
However it is of vital importance that the well stream is not interrupted during this kind of operation. The coiled tubing
could easily be stuck in a situation where lots of solids are on the way up, and drop down again due to a shut in of the
well.
PRINCIPLE OF OPERATION
The well is lined up through an ESD valve, choke manifold, and sand separator where after the gas is normally directed to
atmosphere in order to reduce the back pressure although back into a production facility is also possible. However this is
only recommended if the process pressure is low (not more than 300 psi). Once the coiled tubing operations have started
all the returns go through the sand separator. Liquid is automatically drained from the second compartment to the low
pressure liquid handling process facility. It could also be drained into a tank of the closed liquid circuit.
With regular checks and raw calculations first bottoms could be estimated. From that time onwards the sand separator is
regularly drained, using the 2 drain chokes into the sand skips. Sand is separated from the liquid in the sand skip.
The liquid is then pumped out of the skip through a knockout vessel either to the production process or to the closed liquid
circuit. The volume of the returned solids can be measured, and indicates how much is recovered.
Extra attention is needed during the preparation phase, rig up and execution of the job since it is not a standard job.

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1.6.3 SAND SEPARATOR
1. Have the ESD valve rigged up directly onto the flow wing side of the production tree.
2. Prior to the start of the operation check the liquid pumps and pump through the system.
3. Tape off the area around the sand separator. Only allow relevant persons near the separator.
4. Do not run the separator at a high pressure, normally 150 to 200 psi is more than sufficient to push the solids
through the adjustable drain chokes.
5. Choke the returns only at the sand separator inlet. Higher velocities will be created, but feeding into the separator
tank will less hazardous.
6. Check the returns continuously when you expect the first solids to arrive at surface.
7. Have triple isolation valves upstream the drain chokes to ensure continuation of the process in case a valve
needs to be changed out.
8. If the drain line is getting plugged gradually increase the adjustable choke.
9. Since the draining operation is done manually be aware of gas blow-by.
10. If suddenly gas blow-by occurs close the valve upstream the drain choke rather than closing the choke since this
takes more time.
11. Make sure that the suction pump does not suck any solids this is very important if you work with a closed liquid
circuit.
12. Drain the pump knockout vessel regularly in the sand skip to avoid pumping solids back into the system.
13. Inform client rep and coiled tubing operator about the solids is at surface.
14. Whenever possible measure the amount of produced solids.
15. Avoid elbows or chicksans in the drain lines.
16. Secure the drain lines to the sand skips with chains.
17. Only use hard pipe for the solid drains.
18. Line up at least two sand skids for sufficient storage.
19. In addition to the PPE have face mask available.
20. Do not overload the sand skip remember 1m solids ~ 2.5 tons.
21. Make sure all lines are secured with tie-down cables.
22. Hold toolbox meeting prior to operations.
23. Avoid unnecessary shut in of the well with the coiled tubing in the hole.
24. Be aware of the fumes/vapours when draining in open sand skip.

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Page 1 of 4
1.7 HIGH PRESSURE / TEMPERATURE WELL TESTING
INTRODUCTION
1. Recent trends in offshore activity have highlighted a significant increase in the drilling of deep, hot and high-
pressure wells.
This type of well test provides greater challenges than normal due to the fact that surface pressures may
approach 15,000 psi and temperatures of 300F, often present with concentrations of H2S and CO2.
Accordingly EXPRO have developed a High Pressure Testing capability, with equipment rated to 15,000 psi
W.P. This equipment has been designed with regard to: -
a) Expected working pressures and temperatures.

b) Anticipated well flow rates.
c) Pressure relief lines.
d) Emergency shut down systems.
2. The expected well conditions of a high pressure / temperature well could be represented by the following:-
Total Depth 17,500 ft

Bottom Hole Temperature +/- 400F
Bottom Hole Pressure +/- 16,500 psi
Shut-in Pressure +/- 13,500 psi
Flowing Surface Temperature +/- 300F
Maximum Flow Rates
- Oil +/- 10,000 BOPD
- Gas +/- 40 MMSCF/D
- Condensate +/- 5,000 BOPD
Presence of H2S +/- 5 - 200 PPM
It is important to note that the limitations imposed by high temperatures may be greater than those of
pressure and careful consideration must be given to the problem of restricting high surface
temperatures.
3. EXPRO's 15,000 psi surface equipment includes the following: -
a) surface tree
b) coflexip hoses
c) choke manifold
d) pipe-work
e) heater
Equipment placed downstream of the heater is as our standard well test equipment and is sized and arranged
according to the oil, gas or water flow rate.
EQUIPMENT SAFETY ASPECTS
Relief lines are sized to each individual well test and are provided to relieve over-pressure and prevent
catastrophic rupture of lines or vessels.
Emergency shutdown systems are also provided, both linked to automatic and manual pilots to secure the well
in the event of equipment failure.

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Page 2 of 4
1.7.1 PROBLEMS
High temperature is possibly the greatest problem to overcome during high pressure/temperature well testing. If
using a Coflexip hose from the surface test tree to the choke manifold then the flowing temperature must be
limited to below 250F, this is achieved by choking back the well.
One way of choking back the well is to fit a hydraulically controlled choke (Masterflo) onto the flow-wing outlet of
the test tree, this would have a cooling affect on the fluids immediately downstream. Alternatively the well can
be choked back at the choke manifold.
The Coflexip hose could also have water hoses directed on it eg. from fire monitors, which would also have a
cooling effect on the Coflexip.
To overcome the possible problem of elastomeric seal failure through the breakdown of the rubber, EXPRO use
Grayloc clamp connectors providing a metal-to-metal seal on all pipework upstream of the heater. The choke
on the heater will provide a cooling affect further reducing the temperature.
NOTE: For gas wells where high temperatures are encountered the main problem is in the 'flashing off' of
condensate to a gas phase meaning that no P.V.T. samples can be collected for recombination from
the separator.
1. EXPLOSIVE DECOMPRESSION
One of the major problems encountered in testing high-pressure wells, is the problem of explosive
decompression. This phenomenon causes problems in that when seals are compressed under high
pressure some gaseous elements diffuse into the seal. If a rapid pressure drop occurs or after
frequent pressure cycling, materials not resistant may suffer extensive damage, usually in the form of
splits and/or blisters. This is because the entrained gas expands against the elasticity of the rubber
causing severe internal damage that may split or rupture the elastomer.
This problem is especially prevalent where there is a high CO2 content in the well gas stream and if
this is the case then explosive decompression may occur at relatively low pressures. This is due to
the ability of the CO2 to permeate the elastomers.
NOTE: The CO2 has no chemical affect on the elastomer it is a purely physical phenomenon.
The critical parameters most likely to affect Explosive Decompression performance are:-
a) gas type
b) pressure and decompression rate
c) temperature
d) soak time at pressure
e) seal volume and exposed seal surface area
f) initial squeeze (strain exerted on seal while rigging up hammer union).
One type of rubber seal designed to overcome this problem is the Anson Superseal which is based
on Viton B (a high fluorine content fluoroelastomer) which is given the compound name FR 58/90 (the
90 refers to the hardness of the rubber).
The level of fluorine in the elastomer is thought to have a major effect on the solubility of gas in the
seal and thus resistance to ED as does the hardness of the elastomer.
NOTE: Materials above 85 IRHD generally give greater resistance to ED.
ie. The harder the elastomer seal the greater the resistance to gases permeating into it.
The downside of this is that the harder the seal, the worse the sealing properties.
If possible, bleeding down systems slowly will help prevent explosive decompression occurring.
For High Pressure Well Testing, to avoid any possibility of ED failure of elastomers, EXPRO use
metal-to-metal seals (in form of clamp connectors) for all pipework upstream of the heater inlet ie. the
high pressure process equipment. This avoids totally the possibility of explosive decompression.

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Page 3 of 4
2. UNLOADING HEAVYWEIGHT CUSHIONS
When unloading a heavyweight brine cushion or similar there exists a possibility that with a needle and stem
type adjustable choke, that the seat may "back-out", even though a copper gasket has been fitted.
This is due to the nature of the "heavy" fluids passing through the choke at high pressure, where turbulence is
set up as the flow passes the adjustable stem and cone. As this fluid passes through the choke seat, the drag it
exerts may be large enough to cause the seat to "back- out", even though it may have been torqued tight.
The recommended torque for this type of adjustable choke is in the nature of 1500 ft/lbs and to achieve this by
using an ordinary choke spanner may prove difficult. If this is the case then a "cheater" bar should be used.
NOTE: It may be desirable to use a torque wrench to achieve the correct torque rates.
Refer to Section 3.26.3 for further information.
It is also possible for the adjustable choke cone to shear off the stem. This is also due to the forces created by
the turbulence created by the "heavy" fluid passing through the choke.
If there is any doubt as to whether a choke seat (or bean) has worked loose, then flow should be diverted to a
similar sized choke on the other side of the manifold and the suspect choke inspected.
NOTE: a) Flowing through a choke where the seat/bean is not properly installed can cause damage to the
internal threads for the seat/bean in the choke body and/or erosion of the body itself.
b) This will not only be a safety hazard but will also result in a major refit of the choke assembly.
1.7.2 SUB-SURFACE CAPABILITY
In addition to the surface equipment EXPRO have a range of annular controlled sub-surface DST tools (EXACT
range). These tools have been developed with 15,000 psi and 400F capability. By combining new design
concepts with advanced metallurgy and elastomer technology, these EXACT tools are compact, robust and
combine operational safety with ease of use.
1.7.3 DATA ACQUISITION
To complement our high pressure well test equipment and increase overall safety, an upgraded Data
Acquisition system is provided to acquire Bottom Hole Data, via memory gauges, Ameradas and carriers), and
Surface Data, via the Surface data Logger. This Data Logger will play an important part in the central
monitoring and control of testing operations and temperatures can be monitored easily at any point in the
process train.
1.7.4 15,000 PSI EQUIPMENT
1. A 3" 15,000 psig Sub Sea Test Tree allows the landing string to be unlatched in the event of anchor
failure or as a precaution in the case of bad weather. The well is sealed by a proven twin ball fail safe
valve assembly that also provides an injection point for chemicals should there be a risk of hydrates.
2. A 3" 15,000 psig Retainer Valve is available and will act in conjunction with the SSTT and when
closed prevents the escape of hydrocarbons into the annulus when the landing string is unlatched at
the SSTT. Entry of wireline tools is simplified by a 3" 15,000 psig Lubricator Valve that is placed
below the rotary table thereby reducing the need for long lengths of surface lubricator above the
flowhead.
3. A 3" 15,000 psi Temperature Sub is placed below the temporary flow head and allows the
temperature of the well fluid to be monitored prior to entering the flowhead and coflexip hose.
Alternatively a tapped spool-piece can be inserted on the flow-wing outlet of the flowhead prior to the
coflexip hose.
4. It is critical to maintain the flowing temperature to 250F or less because the coflexip hose is rated to
266F only. A temperature transducer placed in the temperature sub can either give a digital display at
the rig floor or be combined with the Surface Data Acquisition system to give either a digital or
analogue read-out with alarm functions.

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GENERAL
Page 4 of 4
5. A 2-9/16" 15,000 psig Lower Master Valve is placed below the temperature sub and swivel and can
be either manually or hydraulically actuated.
6. A 2-9/16" 15,000 psig Temporary Flowhead is placed on top of the landing string above the rotary
table and is equipped with a swivel that is immediately below the chemical injection sub to allow
rotation of the flowhead or tubing prior to, and during testing operations. The surface flowhead is
equipped with a failsafe actuated shutdown valve on the flow side which is operated by hi-lo pilots or
remotely placed shutdown buttons. It can also have an hydraulically actuated kill-wing valve.
7. From the flow wing of the flowhead, the well effluent is conveyed by a 3 15,000 psig Coflexip
Flowline. The 15K production hose is suitable for H2S service and can handle Zinc Bromide and is
also suitable for continuous use over a temperature range of -4F to 266F. A 2 15,000 psig Coflexip
Kill Line is placed between the rig manifold and a non-return valve on the kill side of the flowhead.
8. 3", 15,000 psig High Pressure Pipe with either Dynator or Grayloc C25 metal-to-metal seals is used to
connect the coflexip hose to the Data Header.
9. The 3" 15,000 psig Data Header allows upstream pressures and temperatures to be acquired and has
sufficient ports for both manual and automatic data acquisition. A Data Header can also be placed
downstream of the choke manifold, where reduced pressures make it easier to collect samples, etc.
10. The 2-9/16", 15,000 psig Choke Manifold is placed downstream of the data header and comprises a
four-valve assembly with an adjustable choke and a fixed choke complete with a full range of fixed
chokes. A junk trap assembly can be placed on the inlet to remove any debris from the well stream.
11. 3", 10,000 psig Temporary Flowline fitted with Grayloc C25 metal-to-metal seals is used to take the
effluent to the steam exchanger. A Relief Valve and Relief Line is recommended to protect the
flowline between the Choke Manifold and the Steam Exchanger in the event that the well flow
becomes obstructed at the heater. Relief line sizing will have to be established once the flowing well
conditions can be predicted.
12. The Heat Exchanger is provided with a 3", 10,000/10,000 coil or 10,000/5,000 psig split coil, a bypass
to permit bypass of the heater coils and an adjustable choke should choking at the heater be required
during the earlier part of the well test. For direct steam heat exchangers, a high-pressure pilot can be
placed on the shell as an additional safety device. This will activate the ESD system in the event of a
coil rupture or leak within the vessel.
13. A diesel fired Steam Generator is used to provide the steam for the heat exchanger and is a zone 2
unit. A zone I unit is also available, which can be tied into the ESD system to shut down in the event
of an activation of the ESD system.
14. From the heater 3" fig. 602 5,000 psig Temporary Flowline is used to convey the heated fluid to the
separator inlet. The pipework is fitted with 602 Weco connections with CO2 resistant elastomeric
seals (Anson Superseals). A Relief Valve may be used to protect this leg of the process line in the
event that a blockage occurs downstream, while flowing on Separator bypass.
15. At this point the surface equipment layout reverts to a normal 10K set-up, however careful
consideration is given to the placing of Hi-Lo Pilots and shutdown valves so that the reaction times for
the ESD System are as short as possible.

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Page 1 of 3
1.8 FOAMING OIL WELL TESTING
1. When the pressure is reduced on certain types of crude oils, foam (or froth) can be caused by the liberation of
a large amount of micro bubbles in the oil as the gas comes out of solution, where these bubbles are encased
in a thin film of oil. In other types of crude oil the viscosity and surface tension of the oil may mechanically lock
gas in the oil and cause an effect similar to foam.
2. Where possible, sufficient information should have been made available from the operating company to allow
for identification of a foaming problem before equipment mobilisation. This would allow equipment to be
selected that best suits the needs of a foaming oil well and for chemical additives etc. to be chosen to help
"break" the foam. However, it is essential that a close monitoring of well effluent behaviour, through the
collection of samples, is carried out during the initial clean-up period of crude oil wells in order to ensure that
there will be no problems with foaming oil during a test.
Presence of foam during a Well Test, if not treated can cause the following:-
a) Prevent good separation and reduce separator capacity.
b) Disrupt liquid and gas metering.
c) Disrupt pumping operations.
d) Cause potential burning problems.
The main factors that increase foam volume and cause problems are :-
a) High pressure drops.
b) Pressure drops occurring at low pressures.
c) High volumes of produced gases.
The main factors that assist in "breaking" foaming oil are :-
a) Settling
b) Agitation
c) Heat
d) Chemical additives

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Page 2 of 3
1.8.1 PROBLEMS IN HANDLING FOAMING OIL
The presence of foam during a well test, if not treated, can cause the following:-
1. Prevent good separation and reduce separator capacity.
2. Disrupt liquid and gas metering.
3. Disrupt pumping operations.
4. Cause potential burning problems.
PREVENTING GOOD SEPARATION AND REDUCING SEPARATOR CAPACITY
Foam creates a problem during well testing as it greatly reduces the capacity of the separator.
This is due to the fact that the liquid level, with foaming oil, will be higher than normal for a given quantity of oil (due to
area filled by the bubbles causing the frothing effect).
This in turn lowers the retention time in the separator and reduces it's efficiency to separate foaming oil, resulting in gas
entrained oil travelling down the oil line and through the liquid meters.
LIQUID AND GAS METERING
Due to the gas entrained in the oil travelling down the oil line and through positive displacement or volumetric liquid
meters, this obviously greatly increases the oil rates due to the volume occupied by the gas. This results in high meter
factors (due to the shrinkage allowance for the gas in solution).
Another problem with metering foaming oil, is that gas is continuously "breaking out" as the oil travels through the process
equipment and into two phase flow. Gas that "breaks out" in the oil line can cause damage to the oil meter, eg damaged
paddle assemblies, due to over spinning etc.
Foaming oil will also affect the gas rates as possibly not all of the liquid droplets will be separated from the gas phase by
the mist extractor and some may "carry down" the separator gas line. This liquid droplets passing through the orifice plate
will result in higher than normal differential readings across the orifice plate. The liquid droplets may also enter and collect
in the differential recorder lines upstream and downstream of the plate, this again will affect the recorded gas rate.
CAVITATION
Foaming oil can cause problems with cavitation when pumping with centrifugal type pump.
Cavitation can also occur at the separator oil dump valve, in the form of the dump valve 'hunting' as it tries to hold a
constant liquid level in the separator.
Special 'Cavitrol' plugs are available to help overcome this.
BURNING PROBLEMS
Burning problems can occur on foaming oil wells, any liquid droplets that are carried over from the separator body through
the gas line may not be atomised & burnt. The consequence of this could be an oil slick in the sea that is unacceptable.

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Page 3 of 3
1.8.2 OPERATIONAL GUIDELINES
The main factors in "breaking" foaming oil are:-
1. SETTLING
Increasing the retention time of the oil as it passes through a separator allows more time for the foam
to "break" out of the oil.
This solution may not be practical in all cases due to the oil flow rates. One answer to this is through
the use of stage separation, whereby the two or more separators are used in series, with the
operating pressure of each separator being dropped at each stage. This allows more gas to break out
at each stage and thus reduce the foaming problem. Oil flow rate measurements are not made until
the final stage at which point there should be no problem with foam giving false flow rates.
NOTE: It may be necessary to have an additional separator tied into the gas line(s) from the upstream
separator(s) in order to collect and measure any oil that has carried over with the foam before
allowing the gas to flare (ie, acting as a gas scrubber). Gas rates should be measured at this point to
obtain accurate flow data.
2. AGITATION
Agitation is helpful in "breaking" foaming oil where the foam bubbles are mechanically locked by the
surface tension and viscosity of the oil. It does this by causing the gas bubbles to coalesce and
separate from the oil in less time than would be required were agitation not employed.
Agitation can be obtained by stirring, vibrating of through the use of baffle plates (within the separator
vessel).
3. HEAT
Heat is one of the best methods of "breaking" foaming oil, as it reduces the oil viscosity and the
surface tension of oil assisting in the release of gas that is mechanically retained in the oil. The heat
is normally applied to the oil through the use of a heat exchanger (direct/indirect).
The heated oil will flow into the separator(s) where the normal separation process will take place.
This process coupled with the use of the separator internal baffle plates to agitate and coalesce the
gas bubbles, provides a very effective method of removing foam bubbles from foaming oil.
4. CHEMICALS
Any chemical that reduces the surface tension of crude oil will assist in "breaking" foaming oil.
Silicon defoamers are currently considered the most effective chemicals to use for this purpose. The
appreciably reduce the foaming tendency of the oil by destabilising the surface of a foaming oil to
such an extent that the foam bubbles can no longer support themselves, ie, the thin film that exists
between pockets of gas either ruptures or is not permitted to form. This allows entrained gases to
escape easily, leaving a clear interface.
The defoaming chemicals should be injected at the lowest point in the test string as possible, eg Sub-
sea tree, etc.
5. ADDITIONAL METHODS
Additional methods that may assist in the reduction of foaming problems are to:-
a) Avoid large pressure drops, especially at low pressure areas of the system. This can be done
through the use of stepped pressure reductions across more than one choking device, eg step
down the well pressure at the choke manifold and again at the heat exchanger.
b) Keep the separator back pressure as high as practicable (if not using stage separation) this
will prevent the liberation of gas bubbles.

SECTION 1
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Page 1 of 8
1.9 SOUR GAS WELL TESTING
Hydrogen Sulphide (H2S) can be found at any work site or at any process plant. It may also be found in the yard when
breaking down equipment, even if the equipment has come from a 'sweet' field, due to the effects of sulphate reducing
bacteria.
CHARACTERISTICS
1. It is extremely toxic (poisonous).
2. It is heavier than air, and colourless (S.G. 1.1895).
3. It has the odour of rotten eggs, in small amounts.
4. It burns with a blue flame and produces sulphur dioxide (SO2) gas, which is very irritating to the eyes and lungs.
The SO2 is five times more toxic than H2S and can cause serious injury.
5. H2S forms an explosive mixture, with air, between 4.3% and 46% by volume.
6. H2S is almost as toxic as hydrogen cyanide and is between 5 and 6 times as toxic as carbon monoxide.
7. Produces irritation to eyes, throat, and respiratory tract.
8. H2S dangerously corrodes equipment not designed for H2S (sour) service.
POISONING BY INHALATION
1. The sense of smell cannot be depended upon to detect H2S because:-
a) The sense of smell can be lost in 2 to 15 minutes of exposure to low concentrations, due to paralysis
of the olfactory nerve.
b) The sense of smell is lost in 60 seconds or less, at higher concentrations.
2. Susceptibility to H2S poisoning varies according to the number of exposures by an individual. A second
exposure is more dangerous and so on.
3. The results of inhalation are :-
a) Asphyxiation may occur after a few seconds of exposure to high H2S concentrations. This produces
such symptoms as panting, pallor, cramps, paralysis of the pupil, and loss of speech. This generally
is followed by immediate loss of consciousness.
b) Death may occur quickly from respiratory and cardiac (heart) paralysis. One deep sniff of high
concentration can cause death.
c) Coughing, eye burning and pains, throat irritation, and sleepiness come from exposure to low
concentrations.
TREATMENT
H2S acts so quickly that there is often no time to call the medic before beginning to revive the victim.
1. Remove the victim to fresh air IMMEDIATELY.
NOTE: Remember to protect oneself before entering a suspected area with H2S present in the atmosphere.
2. Keep the victim warm and at rest.
3. If the victim is not breathing, begin applying artificial respiration at once . Exercise due care due to possible lung
congestion. Although breathing is paralysed, the heart may continue beating for a few minutes after the attack.
It is of the utmost importance that artificial respiration be given as quickly as possible and continued until
medical aid is available or until the victim resumes natural breathing.
NOTE: Do not wait the arrival of a resuscitator, when available someone else can set it up, while you
continue to apply artificial respiration. In acute poisoning, continuous use of oxygen is of great value.

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Page 2 of 8
Figures 1.3 and 1.4 on artificial respiration methods can be photocopied and placed around the test
area in pre-determined safe areas, to aid personnel should an incident occur where artificial
respiration is required.
As with other hazardous substances, safe working with H2S is controlled by the COSHH regulations.
Within EXPRO the Company Health and Safety System No. 2 - Hydrogen Sulphide, details the
procedures that have to be followed to control exposure to H2S. An uncontrolled copy of this
document can be made available for reference if required.
TABLE 1-1 TOXICITY OF HYDROGEN SULPHIDE GAS
TOXICITY OF HYDROGEN SULPHIDE GAS

10 ppm Can smell. Safe for 8 hours exposure
(1/1000 of 1%)
100 ppm Kills smell in 3 to 15 minutes. May sting eyes and throat.
(1/100 of 1%)
200 ppm Kills smell rapidly. Stings eyes and throat
(2/100 of 1%)
500 ppm Loses sense of reasoning and balance. Respiratory
(5/100 of 1%) paralysis in 2 to 15 minutes. Needs prompt artificial
resuscitation.
700 ppm Breathing will stop and death result if not rescued promptly.
(7/100 of 1%) Requires immediate artificial resuscitation.
1,000 ppm Unconscious at once. PERMANENT BRAIN DAMAGE
(1/10 of 1%) MAY RESULT UNLESS RESCUED PROMPTLY.
1.9.1 EFFECT OF H2S ON EQUIPMENT
Exposure of stressed steel to H2S and water may result in failure because of sulphide Stress Corrosion
Cracking (SSC). This can be defined by the following:-
1. The brittle failure by cracking under the combined action of tensile stress and corrosion in the presence of water
and hydrogen sulphide.
This may occur in carbon and low alloy steels, severely cold-worked austenitic stainless steels, some
precipitation hardened stainless steels and some high nickel alloys under severe conditions.
Susceptibility to attack of most carbon and alloy steels is approximately proportional to the steel strength with
the resistance to stress cracking decreasing with temperature. This means that the maximum danger occurs
under low temperature operations, particularly when testing gas wells.
It is important to be aware that embrittlement can occur at very low H2S concentrations as Figures 1 and 2
show.
Refer to Fig. 1.1 SOUR GAS SYSTEMS and Fig. 1.2 SOUR MULTIPHASE SYSTEMS.
Fig 1.1 Sour Gas Systems
Materials shall be selected to be resistant to SSC or the environment should be controlled if the gas being
handled is at a total pressure of 65psia or greater and if the partial pressure of H2S in the gas is greater than
0.05 psia. The partial pressure is determined by multiplying the mole fraction (mol% / 100) of H2S in the gas by
the total system pressure.
Fig 1.1 provides a method for determining whether the partial pressure of H2S in a sour environment exceeds
0.05psia. The following examples explain how to use the chart.
1. A partial pressure of H2S in a system containing 0.01 mol% H2S (100 ppm or 6.7 grains per 100
standard cubic feet) at a total pressure of 1,000 psia exceeds 0.05 psia (point A on Fig 1.)
2. A partial pressure of H2S in a system containing 0.005 mol% H2S (50 ppm or 3.3 grains per 100
SCF) at a total pressure of 200 psia does not exceed 0.05 psia (point B on Fig. 1).

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Page 3 of 8
Fig 1.2 Sour Oil and Multiphase Systems
Sour crude oil systems require the selection of sour service equipment when the fluids being handled are either
oil or oil, water and gas when the following limitations are exceeded.
a) Maximum gas oil ratio is 5000 SCF/bbl

b) Gas phase contains a maximum of 15% H2S
c) The partial pressure of H2S in the gas phase is a maximum of 10psia
d) The surface operating pressure is a maximum of 265psia and when the pressure exceeds 265psia and
0.05psia
NOTE: Partial Pressure can be defined as follows:
In a mixture of gases, each component exerts the pressure which it would exert if present alone at the
same temperature in the total volume occupied by the mixture. The partial pressure of each
component is equal to the total pressure multiplied by its mol fraction in the mixture. For most gases,
the mol fraction is equal to the volume fraction of the component.
1.9.2 STRESS CRACKING
Stress cracking can be avoided by the following:-
a) Controlling the environment of susceptible materials by the use of inhibitors etc.
b) Isolating the components from the sour environment.
c) The use of H2S resistant materials.
Generally the latter method is preferred.
1.9.3 EQUIPMENT FABRICATION
NACE Standard MR-01-75 covers metallic material requirements for resistance to sulphide stress cracking for
petroleum, drilling gathering and flowline equipment, and field processing facilities to be used bearing
hydrocarbon service.
All EXPRO equipment supplied for the testing of sour wells is rated to MR-01-75 (latest revision).
NOTE: A copy of which is available at EXPRO facilities onshore.
To ensure that equipment does not suffer embrittlement over a long period of time it is periodically checked
through the means of hardness testing. For the materials used by EXPRO generally, the hardness should not
be above HRC = 22 for the equipment to remain serviceable.
1.9.4 PYROPHORIC IGNITION
While pyrophoric iron sulphide is a widely recognised ignition source in shore based operations, it has rarely
been cited as the cause of a marine ignition and in those few cases the hydrogen sulphide levels were very
high.
In an oxygen-free atmosphere or where the concentration of hydrogen sulphide exceeds that of oxygen,
hydrogen sulphide can convert iron oxide (rust) into iron sulphide.
Fe2O3 + 3H2S Fe2S3 + 3H2O
When the iron sulphide formed is subsequently exposed to air, it is oxidised back to iron oxide and either free
sulphur or sulphur dioxide gas is formed. This oxidation can be accompanied by the generation of considerable
heat so that individual particles may become incandescent. Rapid exothermic oxidation with incandescence is
called pyrophoric oxidation. The heat evolved from this pyrophoric oxidation is capable of igniting flammable
hydrocarbon gas/air, petroleum/ air and oil/ air mixtures.
The industry-wide conversion to the use of inert gas systems on crude carriers has probably increased the
possibility of forming pyrophoric deposits, but as long as the cargo tanks remain inert there is no danger of

SECTION 1
GENERAL
Page 4 of 8
ignition from pyrophoric exothermic reaction. However it is imperative that the atmosphere in the tank is not
allowed to become flammable. Flammable atmospheres would inevitably arise if the tanks are discharged while
the inert gas plant is inoperable.
This does not mean that the probability of ignition is high if discharge without atmospheric control takes place.
Various factors may inhibit pyrophor formation or a pyrophoric reaction. These factors include:
a) The lack of sufficiently thick deposits of iron oxide.

b) The inclusion of elemental sulphur and crude oil in tank deposits.
c) The introduction of some oxygen by repressurising.
1.9.5 TRAINING FOR PERSONNEL PRIOR TO TEST
It is imperative that all personnel receive proper H2S training prior to commencing a well test on an H2S
producing well. Any training received onshore should be complemented by training on the particular installation
that the test will be taking place on, with the relevant safety equipment to ensure familiarity with the type of
equipment, safety procedures that will be used on that installation.
1. At EXPRO, H2S training commences when new starts join the company. Each new start is given an
EXPRO 'filofax' which contains a section on H2S along with other relevant safety information. The
new starts should study this and be aware from the outset of the job what hazards/dangers they will
be working amongst.
2. Training continues during courses run at the EXPRO training school at Livingston. Specific H2S
instruction covers the following:-
a) The characteristics of H2S and it's dangers.
b) Safety procedures to be adhered to when working where H2S is suspected or known to be

present.
c) The effects of metal embrittlement in equipment due to the presence of H2S.
3. When EXPRO is involved in the testing of a well with suspected H2S, it is the operating company
responsibility to provide a specialist H2S company to provide all the relevant safety equipment,
together with all the training of all personnel prior to commencing any testing operations. This training
should cover the use of breathing apparatus, resuscitation equipment and safety procedures.
4. EXPRO can also provide additional specialised H2S training, eg. S.T.O.P. course. However,
personnel who have had previous H2S training should still be additionally trained at the offshore
location, to ensure familiarity with the equipment being utilised.

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Page 5 of 8
1.9.6 OPERATIONAL GUIDELINES
1.9.6.1 PRECAUTIONS TO BE TAKEN WHEN H2S IS KNOWN OR IS SUSPECTED TO BE PRESENT
Where H2S is known, suspected or found to be present, an atmospheric tank (ie. a gauge tank) SHOULD NOT
be used. Flow should be directed to a surge tank, with the subsequent gas produced piped to a designated
area.
1. Prior to commencing the test, all personnel should have received the training laid out under Section
1.9.2.
2. Warning signs should be posted and testing area roped off.
NOTE: Where high concentrations of H2S are present, only essential personnel should be out on deck, the
remainder should remain within the accommodation, with doors sealed, etc.
3. If an H2S leak is suspected or confirmed and cannot be contained immediately, then persons in areas
of risk must withdraw to a safe area, generally upwind and in an elevated position of the hazardous
area and follow the emergency procedures as per Section 1.9.6.4.
4. Never enter an enclosed space or area where H2S may have accumulated without wearing B.A. sets.
If the worker is over an arms length away, a safety belt should be secured to a life line and held by a
responsible person in a safe area.
1.9.6.2 OPERATIONAL SAFETY PROCEDURES
1. EXPRO personnel will generally be required to follow the rig operators procedures and use their
safety equipment.
2. The testing area and other areas where a potential danger of free H2S is present should have
continuous gas monitoring taking place using either fixed or portable monitors, with audible and
visual alarms. The set point of these alarms should be whenever the concentration of H2S in air
exceeds 10 ppm. Well test operators should also wear personal H2S monitors (eg. Compur).
3. All testing equipment will be rated to NACE MR-01-75 and all safety relief lines will be routed to an
area where there discharge will present no hazard.
WHERE EQUIPMENT CANNOT BE POSITIVELY IDENTIFIED AS H2S RESISTANT, IT MUST BE

CONSIDERED AS NON H2S RESISTANT.
4. Prior to the well test commencing, a meeting with all parties concerned with any operations during
the test must be held to establish hazardous areas, safe areas, escape routes, etc. This meeting
should also decide the area of responsibilities between EXPRO and the operating/drilling company
particulary at which point the test should be terminated.
5. First hydrocarbons should be produced to surface in daylight hours only.
6. As soon as first reservoir returns to surface (ie. the tubing contents have been displaced) are
observed, checks should be made for the presence of H2S. These checks should continue
periodically throughout the duration of the well test (ref. Section 4.9 for information on the use of a
Draeger tester).
NOTE: There should be an adequate supply of detector tubes (various ranges) readily at hand, to measure
the H2S concentration should a leak occur. Should H2S be detected in the wellstream, the test
supervisor must be informed so that action can be taken to control the risk.

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Page 6 of 8
TABLE 1-2 EXPRO'S RECOMMENDED H2S POLICY
10-50 ppm in well stream Mask up with BA set for an operations that vent
gas
> 50ppm in well stream BA sets to be masked up and worn continuously.
100-10,000 ppm in well stream Well to be flowed in daylight hours only
> 10,000 ppm in well stream Test should be terminated
> 50 ppm in air Test should be suspended/terminated
8. Where the H2S levels are greater than 50 ppm, then during the course of a test, a "buddy" system
should be implemented, ie. where every operator must constantly be in sight of another person who
can raise the alarm in case of emergency.
Arrangements with the operating / drilling company must be made to provide sufficient help in
watching personnel and to define how the alarm will be triggered.
9. A communication network (eg. radio) between all crew members is recommended.
NOTE: This may prove in-operable where personnel are masked up with B.A. sets and also due to noise
levels when testing.
1.9.6.3 SPECIFIC SAFETY RECOMMENDATIONS
1. No H2S should be allowed to escape to atmosphere in a place where it can accumulate and be
dangerous. Wind direction should be monitored constantly.
2. If a leak develops, every effort should be made to stop the leak at once.
3. While flowing, all effluent should be sent to the burners.
NOTE: Flow periods should be limited to when the wind direction is suitable for carrying the gasses away
from the selected burner and the installation, eg. if there is no wind, then flaring should not be
considered. If in doubt as to whether the well should be shut in, checks should be made of the H2S
concentration around the boom and if it rises above 10 ppm (concentration in air) the well should be
shut in.
4. Every effort should be made to keep the flare alight at all times during flow periods. This can be
done by leaving the propane/diesel pilot system running continuously or by using a propane lance.
NOTE: If using a propane lance, this should be lit only when the well is shut-in, personnel should not go on
the boom to light the lance while flaring.
5. It is desirable not to use a gauge tank on H2S tests, if it is required to measure tank rates, then a
surge tank should be used as an atmospheric vessel and the vent line run to an area where the
vented gas will not prove hazardous.
6. Any shrinkage measurements must be performed with the shrinkage tester in a well ventilated
position.
NOTE: B.A. sets should be used.
7. B.A. sets must be used in all operations where personnel might be in contact with effluent eg.
sampling, changing orifice plates, changing chokes, etc.

SECTION 1
GENERAL
Page 7 of 8
1.9.6.4 EMERGENCY PROCEDURES
When an H2S alarm is activated, the following procedures should be followed by EXPRO personnel.
1. Obtain a B.A. set/escape mask and mask up immediately.
NOTE: B.A. sets may already be worn by the test crew, dependant on H2S levels for the test in progress. If
it is obvious that an equipment failure to atmosphere has occurred, the well should be closed in
immediately via the safety shut down system and surface process equipment vented to zero
pressure via the flare boom.
2. Warn other crew members/personnel in the area and leave immediately.
3. The rig floor/control room/radio room should be informed of the situation.
4. Two testers with air masks and B.A. sets (properly fitted and checked with air sufficient for 30
minutes) should return to the area and investigate the source of the leak.
NOTE: One of these testers should be of senior status.

Life lines should be worn and held by a responsible person in a safe area.
5. The H2S levels should be checked by Draeger tester while the investigation is ongoing.
6. Once the source of the leak has been found then the appropriate remedial action should be taken
(shutting in the well if required).
7. If the source of the leak cannot be identified, and the H2S concentration remains at a level which is
considered unsafe for testing operations to continue, the test should be terminated and surface
process equipment bled down to zero pressure via the flare. The system should be flushed then
filled with water and rechecked for the source of the leak.
NOTE: B.A. sets should still be worn and masked up while this operation is continuing, especially if
breaking out equipment etc.
1.9.7 SUPERVISORY RESPONSIBILITY
The supervisor has prime responsibility for accident prevention. It is most important to:-
1. Know the company policy on H2S.
2. Know safe working practices and include them in instructions when teaching job methods. Every
new employee must clearly understand the hazards of H2S gas and the safe practices, which will
be necessary to prevent accidents.
3. Be alert to unsafe conditions and actions.
4. Take immediate and appropriate action when H2S is suspected or detected.
5. Know the workers under your control well enough to notice quickly any changes in attitudes or
physical or mental conditions.
6. Set a good example. Attention to safety must be consistent and employee's interest in safety must
be maintained. Initiate and direct regular on-the-spot meetings to discuss accident prevention
matters and allow employees to make safety suggestions.
7. See that safety meetings are held for employees. These meetings will be used to instruct, review or
discuss the safe working practices, or to discuss and take action on unsafe conditions or actions
that have been observed. Employees should be encouraged to take an active part in these
meetings, since their constructive suggestions are an aid in keeping safe practices up-to-date.
8. Conduct training sessions regularly for employees, in the use and maintenance of breathing
apparatus.
Training sessions are a MUST.

SECTION 1
GENERAL
Page 8 of 8
1.9.8 ARTIFICIAL RESUSCITATION METHODS
ALL PERSONNEL SHOULD BE AWARE THAT BY APPLYING MOUTH-TO-MOUTH RESUSCITATION TO A

VICTIM TO REVIVE HIM, MAY ENDANGER THE RESCUER (DUE TO THE INTAKE OF H2S GAS INTO THE
VICTIMS LUNGS) AND IT'S EXTREME TOXICITY.
Refer to Fig. 1.3 and 1.4 ARTIFICIAL RESUSCITATION METHODS

SECTION 1
GENERAL
Page 1 of 2
1.10 ACID CLEAN UP PROCEDURES
If in the planning phase an acid job is anticipated certain points should be addressed with regards to:
1. Equipment Suitability.
2. Personal Safety.
3. Environmental Impact.
4. Neutralising acid returns.
All four points need to be satisfactorily addressed to safely execute the job.
1. EQUIPMENT SUITABILITY
As acid is a very corrosive substance the pressurised equipment should be checked for its suitability from the well
head down to the surge tank.
a) MAIN EQUIPMENT ITEMS:

All main items: Flow head, choke manifold, heater, separator and surge tank are capable of handling
acid.
However due to the corrosive properties of the fluid it is recommended that the exposure time is
minimised eg.
- Drain separator immediately after use.
- Try to avoid flowing through the liquid meters in the separator.
- Drain surge tank as soon as possible and neutralise returns in the gauge tank as soon as possible.
b) PIPEWORK
All the pipework from the tree to the surge tank is capable of handling the acid.
Not recommended to leave any residual acid in the lines.
Preferably flush the lines with water.
c) COFLEXIP HOSE
In some instances coflexip hoses are preferred over hard pipe. Not all coflexip hoses are suitable for
acid. Two types of coflexip hoses are in use within the Expro Group: Hoses with Rilsan or Coflon inner
lining. Only Coflon hoses are suitable for acid. This has to be checked in the planning phase, Because a
Rilsan coflexip hose could be severely damaged if exposed to acid.
d) SEALS
By far the most common seals in the system are WECO seals. The standard seal used within the Expro
Group are "Superseals". These elastomers are acid proof. All other flanged connections are acid proof.
2. PERSONAL SAFETY
Although there are many different acids used for well treatment they all have one thing in common They
are very dangerous to people:
- For skin contact
- Eye contact
- Internal contact
To minimise the risk, all non-essential personnel should be denied access. For the people who are working in the
process area, optimum personal protection measures should be taken.
a) All personnel working in the process area must wear their personal protective clothing equipment,
consisting of:
- An acid resistant overall/ boiler suit
- Rubber acid resistant boots
- Safety goggles
- Rubber acid resistant gloves
- For certain jobs where acid is drained from the equipment e.g. draining sight glasses or sampling, full
face visors must be worn.
b) In the safety meeting held prior to the acid clean up, personnel involved must be briefed about the
specific properties and safety measures of the acid.

SECTION 1
GENERAL
Page 2 of 2
1.10 ACID CLEAN UP PROCEDURES
c) An emergency shower must be available at an easily accessible spot on the deck.
d) Escape routes should be free of obstacles.
e) A chemical identification chart (gevaren kaart) must be available to the medic to ensure adequate
recommended action is taken for the specific chemical being used.
3. ENVIRONMENTAL IMPACT
As an 'A' contractor Expro are liable for deliberately polluting the sea. No acid is to be drained "over the side". All
liquid returns are collected in storage tanks, neutralised, and shipped to shore to be disposed of in an
environmentally responsible manner.
4. NEUTRALISING ACID RETURNS
Neutralising acid requires the use of equally harmful chemicals but with alkaline qualities. Expro recommend that
neutralising should be carried out by the contractor executing the acid job. Expert knowledge of the chemicals,
handling the chemicals and calculations for quantities of alkaline chemicals to neutralise, are available in that
company. If all safety measures are taken, the acid can be flowed back.
5. OPERATION
The technical side of flowing back acid is no different than flowing back any other liquids.
- Controlling the well at the choke manifold is no different from unloading water from the well.
- The separator is set up as normal with the exception that only two phase separation is required.
- The surge tank is run the same as under normal conditions.
The difference is the acidic properties of the liquid drained for sampling, venting or leaks. Personnel must be
constantly aware of the extreme caution that has to be taken once the liquid is no longer contained in the
equipment.

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GENERAL
Page 1 of 1
1.11 POST TEST GUIDELINES
EXPRO's commitment to quality continues after a particular job has finished. This is in the form of post job procedures
that take place once equipment has been returned to the base from offshore.
All equipment returned to base has routine maintenance carried out on it, as laid out in the maintenance procedures
manuals. The actual maintenance required is laid out on "job cards" which details the maintenance procedures, any
special maintenance requirements to follow and allows for the work completed to be signed off by the person carrying out
the maintenance. This allows any problems, and the person who carried out the work, to be traced in order that the actual
steps taken in carrying out the maintenance can be identified to allow flexibility of response to ensure the problems do not
occur again.
DAMAGED EQUIPMENT
If equipment has been returned damaged, photographs are taken of the damage, and if the costs or re-chargeable to the
customer then they are invited to view the equipment within three days after which time the necessary repairs are carried
out. If the repair costs are not re-chargeable then an insurance claim will be made.
RETURN OF EQUIPMENT FROM H2S CONTAMINATED WELL TESTS
All equipment returned from a well test involving H2S, involves the need for extra care in performing even routine
maintenance.
Special maintenance procedures have been laid out for equipment that has returned from well tests on H2S wells which
include the following :-
1. All equipment will be quarantined until deemed H2S free. This quarantine takes the form of a label attached to the
actual equipment and also a note on the job card. This forbids any maintenance to be carried out on equipment or
for that equipment to be brought into a building until it has been deemed H2S free.
2. The equipment report will be checked to see if equipment has been flushed offshore prior to backloading.
3. Sniffer checks will then be carried out to ensure the equipment is H2S free. Once equipment has been deemed H2S
free, the quarantine labels are removed and normal maintenance procedures can be carried out.
4. Where sniffer checks indicate the presence of H2S the equipment will be flushed / purged as required until
subsequent sniffer checks allow the equipment to be deemed H2S free.
NOTE: Special attention should be paid to tanks, and the possibility that sludge may remain in the bottom of the
tank that has not been flushed away. This may require the tank to be filled with water and the sludge
skimmed off. The tank should then be filled with water and left for several days, to allow the water to
absorb any H2S, and then drained away. This should be repeated as required.
Personal safety of the maintenance staff should be considered at all times when working on
equipment returned from H2S well tests. If in doubt seek advice.

SECTION 1
APPENDIX 1
Page 1 of 9

FIG 1.1 SOUR GAS SYSTEMS

SECTION 1
APPENDIX 1
Page 2 of 9
FIG 1.2 SOUR MULTIPHASE SYSTEMS

SECTION 1
APPENDIX 1
Page 3 of 9
FIG 1.3 ARTIFICIAL RESUSCITATION METHODS

ARTIFICIAL RESPIRATION
MOUTH-TO-MOUTH RESUSCITATION METHOD
1. 2.
Place victim on his back, loosen clothing Insert thumb in the mouth. Grasp lower jaw
around neck and waist. Turn victims head to and lift it forcibly upwards and forwards.
the side, wipe out the mouth quickly, using
your fingers to get rid of any foreign matter.
3. 4.
Hold the lower jaw up and with the other hand Take a deep breath, place your mouth firmly
close the victims nostrils. over the victims mouth and breathe out.
5. 6.
While breathing into victim, watch chest rise Remove your mouth from the victims to allow
to indicate air passage is clear. breath to exhale. Count to three and repeat.
NOTE: Every moment lost before beginning artificial resuscitation reduces chances for success. Artificial respiration
should be continued until the patient recovers or rigor mortis sets in.

SECTION 1
APPENDIX 1
Page 4 of 9
FIG 1.4 ARTIFICIAL RESUSCITATION METHODS

ARTIFICIAL RESPIRATION
LAY VICTIM IN PRONE POSITION
Elbows bent, one hand on the other. Head on

hands, face to one side. Kneel at victims head
on either or both sides.
Fingers spread, thumbs touching, heels of Rock forward slowly until arms are
hands just below a line between armpits. vertical.
Keep elbows straight.
Rock back slowly. Grasp victims arms just Raise arms until tension is felt for maximum
above elbows. Continue backward. chest expansion. Lower arms to complete
cycle.
REPEAT CYCLE 12 TIMES PER MINUTE

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APPENDIX 1
Page 5 of 9
1.3 RIG VISITS
FIG 1.5 RIG VISIT CHECKLIST (example)
RIG SURVEY REPORT

CLIENT DRILLING CONT.
RIG NAME SURVEYOR
DATE
GENERAL
Observation Comments
Company mans name
Toolpushers name
Info. on proposed drilling programme
Info. on proposed testing programme
RIG FLOOR
Flowline
Flowline connection
Pipework required
Possibility of connecting kill line to flowline
Photographs/Sketches
MAIN DECK
Maximum depth loading to test area
Flowline connection from rig floor
Gas line connection
Oil line connection
Vent line connection
Gas manifold required
Steam supply connection
Steam return connection
How much steam available?
Electricity supply available
2 steam hoses required

SECTION 1
APPENDIX 1
Page 6 of 9
1.3 RIG VISITS
FIG 1.5 RIG VISIT CHECKLIST (example) contd
RIG SURVEY REPORT Contd

Main Deck Observation Contd Comments
Pipework required to connect test equipment,
also separator relief line
Availability and type air connections
Photographs of test area
2 air hoses if own compressors used
Any extra pipework required for sacrificial lines
Any extra pipework required for diesel line from
oil manifold to burners
Any extra pipework required for diesel supply line
to tank
Sight all well test equipment, including
compressors and steam generator
Draw schematic, include wet weights and
dimensions
BOOMS
Oil line connections
Water line connections
Gas line connections
Vent line connections
Electricity supply available
Pipework required
King post and base plate layout
Measure end of booms for installation of burners
Measure length of booms
Maximum weight loading
When king post last approved

SECTION 1
APPENDIX 1
Page 7 of 9
1.3 RIG VISITS

Burners Observation Comments
Condition of propane hoses and connections
Air line connection
Oil line connection
Water line connection
Diesel line connection
How much air available
Condition of equipment already onboard
Amount of pipework required
Any crossovers required
STACK
Drawings
Make
Type
Pressure Rating
Size
Type of rams
Thickness and position of rubbers
Distance from mid point of rubbers to datum point
WELL HEAD
Drawings
Make

SECTION 1
APPENDIX 1
Page 8 of 9
1.3 RIG VISITS

Well Head Observation contd Comments
Type
Casing
Size
Position of wear bushing to datum point
ADDITIONAL NOTES
Additional notes Comments

SECTION 1
APPENDIX 1
Page 9 of 9
1.3 RIG VISITS
FIG 1.6 RISK ASSESSMENT FORM
TASK ASSESSED: ASSESSMENT No.:
ACTIVITY:
HAZARDS IDENTIFIED: CONTROLLED BY: REF No.:
REV: DATE: BY:
APPROVED: DATE:
RISKS: POTENTIAL SEVERITY

F
R 6 5 4 3 2 1
E 5 30 25 20 15 10 5
Q 4 24 20 16 12 8 4
U 3 18 15 12 9 6 3
E 2 12 10 8 6 4 2
N 1 6 5 4 3 2 1
C
(* Denotes most significant risk - see matrix ) Y
RISK RATING HIGH MEDIUM LOW
16 - 30 7 - 15 0-6
PREVENTIVE MEASURES:
MODIFIED RISK RATING: HIGH/MEDIUM/LOW

ACTIONS REQUIRED: DATE: REFERENCE DOCUMENTS:
The Expro Group Health and Safety Manual

Please tick/shade if applicable
Re-assess Manual Handling Assessment
once Nos.
complete COSHH Assessments for
See Health & Safety System Number 0103 for guidance when completing this form.

SECTION 2
PRESSURE TESTING
Page 1 of 1
2.0 PRESSURE TESTING
INTRODUCTION
1. Pressure testing should be carried out on all equipment, with reference to the diagrams (examples of which can
be found in Appendix 2) to the maximum pressure specified by company personnel / program, before any well
effluent is allowed to enter the Well Test package. It is carried out in order to ascertain the integrity of all flowlines,
vessels etc.
NOTE: These diagrams are for specific equipment layouts and may vary from job to job dependent on the equipment
shipped from base and hook-up.
2. It should be noted that, although a pressure test may have been completed satisfactorily, once a valve has been
operated or the well flowed through equipment then the future integrity of the equipment is not guaranteed eg.
erosion etc.
3. A record of all pressure tests carried out should be included on the well test report, indicating sequence of testing,
test pressures and testing medium.

SECTION 2
PRESSURE TESTING
Page 1 of 1
2.1 PRESSURE FOR FIELD PRESSURE TESTING
Refer also to the Health and Safety System No. 5 - Pressure Testing
1. All pipework to be pressure tested shall be in current certification and have a steel test band indicating:
- Maximum Working Pressure (MWP)

- Test date
- Test pressure
- Test certificate number
- Service:Standard or Sour
- Inspection authority stamp of authenticity
NOTE: Pipework shall be not used if this band is missing
2. The MWP of the well test equipment shall be the limited to being equal to MWP of the lowest rated component
in that section of the rig-up.
3. Full pressure testing (1.5 times the MWP) is a base workshop operation, requiring the use of a test bay or
similar protected place. This operation should not be conducted offshore unless a test bay facility is available.
4. The equipment shall only be used in a sweet or sour environment if all the components in the rig-up are
certified, in accordance with SI 289 and NACE MR-01-75 regulations, as being fit for service in the environment.
5. During pressure testing, unless the client requires testing to the MWP, then the equipment should be tested to a
pressure greater than the maximum expected pressure to be found during the test plus a safety margin of at
least 10%.
6. Sand filter, Subsea and Test Separator Assemblies will have been pressure tested at EXPRO facilities onshore
and certification will be supplied. Therefore it is not necessary to test these vessels unless the client's testing
program calls for this.
NOTE:
a) In the Northern North Sea all vessels whether supplied with onshore pressure test charts or not will
always be tested prior to use offshore. This is a certifying authority requirement which has to be
witnessed either by a certifying authority representative or a rig designated rep. ie. OIM, Barge
Engineer etc.
b) Normally separator relief valves will be set to the MWP of the vessel. There may be orifice plates
fitted upstream of the relief valve to restrict flow to maintain within the relief line pipe specification.
c) The test pressure of the separator should lie between the maximum expected operating pressure
during a test and the set pressure of the relief valve minus a safety margin of 10%.
7. Any relief valve setting will be the rated working pressure for that part of the system of the system it is
protecting.
8. If a relief valve lifts during a pressure test then that valve should be changed out prior to continuing with the well
test.

SECTION 2
PRESSURE TESTING
Page 1 of 1
2.2 DURATION OF PRESSURE TESTS AND MEDIUMS USED
1. All pressure tests will continue until a straight line has been held for 15 minutes to the specified pressure, using
cement pumps, and a Martin Decker Chart Recorder or equivalent.
2. This chart should be seen by a company representative (eg. the P.E.) to witness the completion of a satisfactory
pressure test and should contain the following information:-
a) Sequence that pressure test was carried out against relevant section of chart.
b) Client name.
c) Field.
d) Well No.
e) Date
NOTE: All charts must be kept onboard the rig for the duration of the equipment rental period.
3. The different mediums commonly used while pressure testing are as follows:-
a) Water
b) Water/Glycol mix
c) Well gas (not recommended for safety reasons)
d) Nitrogen
NOTE: a) Well Gas and Nitrogen will not be used for pressure testing in the Northern North Sea.
b) Great care should be taken when pressure testing with nitrogen due to the nature of the gas
ie. it's expansion rate (1 cu ft liquid = 696.10 SCF gas) and the fact that it can cause
asphyxiation.
c) (If an uncontrolled leak of nitrogen occurs, the gaseous nitrogen displaces the air and
suffocation can occur).
4. It is not recommended to pressure test with diesel or base oil due to the possibility of explosion if all the air has
not been flushed out of equipment prior to applying pressure.

SECTION 2
PRESSURE TESTING
Page 1 of 5
2.3 PRESSURE TEST GUIDELINES FOR INDIVIDUAL ITEMS OF EQUIPMENT
2.3.1 SURFACE TEST TREE (ON DECK)
1. Make up surface tree, as required, on pipedeck. Flush through tree from below.
2. Shut swab, kill and hydraulic wing valves. Test to required pressure.
3. Shut manual master, bleed off pressure above valve. Test to required pressure.
4. Flush through tree from swab valve. Shut kill, hydraulic and master valves. Test to required pressure.
5. Shut swab valve, bleed off pressure below valve. Test to required pressure.
6. Flush through tree from hydraulic wing valve. Shut kill and swab valve. Test to required pressure.
7. Shut hydraulic wing valve, bleed off pressure below valve. Test to required pressure.
8. Flush through tree from kill valve. Shut swab and hydraulic wing valve. Test to required pressure.
9. Shut kill valve, bleed off pressure below. Test to required pressure.
NOTE: These tests should be carried out with tubing swivel and lifting sub in place, along with the required
cross-over.
2.3.2 SAND FILTERS
Single Block
1. Close in a valve downstream of the sandfilter (that is the same pressure rating as the filter) or blank
off the filter assembly outlet.
2. Open all valves on both pots and bypass.
3. Flush through pots venting at high spot.
4. Carry out body test to required pressure.
5. Close inlet and outlet valves on both pots and bleed off pressure in pots. Test inlet and outlet valves
to required pressure.
6. Open both pot outlet valves and bypass valve and bleed off downstream. Test to required pressure
(inlet and bypass valves).
7. Bleed off pressure, open all valves and drain both pots of liquid.
Double Block
1 Close in a valve downstream of the sandfilter (that is the same pressure rating as the filter) or blank
off the filter assembly outlet.
2. Open all valves on both pots and bypass.
3. Flush through pots venting at high spot.
5. Close inlet and outlet valves on both pots and bleed off pressure in pots. Test inlet and outlet valves
to required pressure.
6. Repeat step 5 for outer valves on same pot.
7. Repeat steps 5 and 6 for other pot.
8. Close both pots upstream inlet valves and bypass valve. Bleed off downstream and test to required
pressure.

SECTION 2
PRESSURE TESTING
Page 2 of 5
9. Bleed off pressure, open all valves and drain both pots of liquid.
2.3.3 CHOKE MANIFOLDS
Four Valve Manifolds
1. Open all valves and adjustable choke.
2. Close a suitably rated valve downstream or fit bull plug to choke manifold outlet.
3. Flush manifold with water, venting through taps downstream of chokes.
4. Pressure test body to required pressure.
5. Close front and back valves on one side, bleed off between. Test to required pressure.
6. Open valves and repeat step 5. for other side.
7 Close both back valves, bleed off downstream and test to required pressure.
Five Valve Manifolds
2. Close a suitably rated valve downstream or fit bull plug to choke outlet.
3. Flush manifold with water, venting through taps downstream of chokes.
4. Pressure test body to required pressure.
5. Close front and back valves on one side, bleed off between. Test to required pressure.
6. Open valves and repeat step 5. for other side.
7. Close both back valves, bleed off downstream and test to required pressure.
2.3.4 HEAT EXCHANGERS
1. Close a suitably rated valve downstream or blank off heater outlet.
3. Flush through coils venting at high spot.
4. Carry out coil test to required pressure.
NOTE: Where the heat exchanger has split coils, ie. the downstream choke coils are of a lower pressure
rating than the upstream, then the coils must be tested only to the lower pressure rating, UNLESS a
blank choke can be installed in the choke box to pressure test the upstream coils against.
5. Close outlet and bypass valves, bleed off downstream and test to required pressure.
6. Close inlet valve and bleed off downstream. Test to required pressure.
2.3.5 SEPARATORS
Prior to pressure testing the separator ensure that the separator relief is correctly installed and that the vent line
runs to a safe area, this will prevent injury if the rupture disk blows or relief valve lifts.
1. Ensure downstream of water, oil and Gas outlets are closed in (for body test).

SECTION 2
PRESSURE TESTING
Page 3 of 5
2. Close sight glass drain valves
3. Close isolating valves on Barton Recorder and sensing line to Fisher 4150 (Wizard) controller.
4. Raise Orifice Plate Carrier.
5. Connect air supply to oil and water control valves and maintain in an open position.
6. Open all isolating valves.
7. Fill separator with water through fluid inlet making sure all air is expelled by venting at high points.
8. Pressure test body to required pressure examining for leakage.
9. Pressure test valves so that following valves are tested:-
a) Inlet valve
b) Bypass valves
c) Gas outlet valve
d) Oil outlet valve
e) Water outlet valve
NOTE: These are the major valves to test. Dependent on the operating companies requirements, it may be
necessary to test isolation valves eg. the liquid meter isolation valves in order to change the meter
while flowing through the separator. These additional tests should be completed as required.
10. All tests through vessel to include shrinkage tester (if fitted), Daniel Senior Orifice Fitting and sight
glasses.
Daniels Senior should be body tested and also tested with the slide valve closed and upper chamber
vented.
11. During the pressure testing of separators, this provides an ideal opportunity to observe correct
functioning of the liquid level controllers and sight glasses. Liquid meters can also be flow proved to
check the accuracy of the meter factors on the calibration certificate.
This should be carried out by pumping water from the cement unit to the gauge / surge tank (surge tank
should have B.P.V. open to remain at atmospheric pressure) and checking against the meter reading for
that volume (bench meter factor). Calculate the meter factor for the meter as follows:-
VOLUME IN TANK
VOLUME THROUGH METER
NOTE: This will be an uncorrected meter factor and if used then shrinkages will have to be calculated and
used in the oil calculation.
FOR MORE INFORMATION ON METER FACTORS REFER TO SECTION 3.16.9
2.3.6 GAS DIVERTERS
1. Flush through manifold with water
2. Close both valves. Test to required pressure.
3. Bleed off pressure and open both valves.
2.3.7 OIL DIVERTERS
1. Open all valves.
2. Flush through manifold from separator inlet line.

SECTION 2
PRESSURE TESTING
Page 4 of 5
3. Close valves 4 and 5 to booms, valve 2 outlet to gauge tank and valve 3 return line from transfer pump.
Test to required pressure.
4. Bleed off pressure and open valves 3, 4 and 5.
5. Close valve 1 inlet from separator. Test to required pressure.
6. Bleed off pressure and ensure all valves open.
2.3.8 SURGE TANKS
1. Close outlet valves.
2. Close sight glass drain points (if applicable).
3. Fill vessel with water, venting at high spots.
4. Close all vent valves and pressure test to required pressure, examining for leakage.
5. Close inlet valves to both compartments, bleed off downstream and test to required pressure.
2.3.9 GAUGE TANKS
1. Close outlet valves.
2. Close sight glass drain points (if applicable).
3. Fill vessel with water, venting at high spots.
4. Examine for leakage.
5. Close inlet valves to both compartments, test to required pressure.
2.3.10 FREESTANDING VALVES
1. Close suitably rated valve downstream or blank off valve outlet.
2. Open valve.
3. Flush through valve venting where possible.
5. Close valve and test to required pressure.
6. Bleed off pressure and connect to outlet end of valve.
7. Test to required pressure.
8. Bleed off pressure, open valve and drain.
2.3.11 SCREWED PRESSURE FITTINGS
All pressure test fittings used shall have a pressure rating stamped on it. No fittings shall be used above there
pressure rating.
The use of PTFE tape is not permitted on many installations, in such cases a liquid thread sealant is preferred
eg. Liquid 'O' ring.
NOTE: All fittings without pressure ratings stamped on them should not be used.
If it is required to change a fitting then follow the procedure below.

SECTION 2
PRESSURE TESTING
Page 5 of 5
1. Remove all previous PTFE thread tape or thread sealant.
2. Visually inspect the male and female threads before assembly to ensure there is no misalignment or
previous cross threading.
3. Use the correct size wrench on the connection when tightening.
4. Check for adequate thread engagement when the connection is tight as follows:
NOTE: Although not all male NPT threads can be assumed to be of standard length per ANSI B1-20-1, the
number of male threads visible is a good indication.
(a) From ANSI B1-20-1, the correct wrench tight thread exposure is 3 1/2 threads for 1/2" and 3/4". NPT, if
significant thread exposure is discovered the connection should be broken and inspected.
(b) An excess of PTFE tape extruding out of the thread may indicate too much tape has been used, which
will reduce thread engagement and pressure rating.
5. Multiple thread assemblies and reducing bushings should be kept to a minimum in the make up of any
pressure test manifold.
6. All bleed off manifolds shall have a double needle valve block.
7. All check valves, where required, shall be fitted to retain the MAWP pressure in the section of the well
test equipment that they are fitted.
2.3.12 EROSION PROBES " NPT
These units are utilised to monitor potential erosion within the containing pipework and are normally installed
upstream of the choke manifold. Each probe is installed between the manifold and any intrusive device which
may deflect particles around the erosion probe and have a detrimental effect on the efficiency of the probe.
Each probe has three notches cut into each apex of the hexagonal head to permit easy identification from
thermowells.
The probe should only be installed in the flowline once a block and bleed isolation valve has been fitted to the
" NPT female thread of the device. During pressure testing the valve should remain open with an appropriately
selected pressure gauge installed on the assembly. Once testing is completed and the flowing parameters
established it may be necessary to replace the gauge with another of a more suitable range. This operation
must always be conducted in the following manner.
1. Ensure that gauge is indicating 0 p.s.i. (if well is flowing it is possible that a slight pressure increase may
be observed due to thermal expansion).
2. Close isolation valve.
3. Open vent valve and bleed pressure from below pressure gauge.
4. Remove pressure gauge.
5. Install replacement gauge of appropriate range.
6. Close vent valve
7. Open isolation valve.
8. Continue monitoring gauge at periodic intervals for pressure increase, indicative of erosion.

SECTION 2
PRESSURE TESTING
Page 1 of 1
2.4 EXAMPLE PRESSURE TEST DIAGRAMS
Drawing number index as follows:-
Fig. 2.1 Line up for Flushing System
Fig. 2.2 Starboard and Port Oil and Gas Lines to Burner, Surge Tank Inlet Valves
Fig. 2.3 Function Test High Pilot (PSH) between Heat Exchanger and Separator and Actuated Surface Safety Valve
Fig. 2.4 Starboard and Port Oil and Gas Diverter Lines
Fig. 2.5 Oil Manifold Inlet Valves
Fig. 2.6 Surge Tank Body
Fig. 2.7 Separator Vessel and Outlet Valves
Fig. 2.8 Separator Inlet and Bypass Valves
Fig. 2.9 Heater Coils and Bypass Valves
Fig. 2.10 Heater Inlet and Bypass Valves
Fig. 2.12 Surface Safety Valve
Fig. 2.13 Choke Manifold and Downstream Valves
Fig. 2.14 Choke Manifold Upstream Valves
Fig. 2.16 Hydraulically Actuated Flow-wing Valve and Flow Head Master Valve
Fig. 2.17 Remote ESD Stations

SECTION 2
PRESSURE TESTING
Page 1 of 1
2.5 POST PRESSURE TESTING GUIDELINES
1. On completion of pressure testing all the relevant valves shall be shut to isolate the test unit. The test lines shall
be bled down to zero.
2. On completion of pressure testing an announcement should be made over the rig tannoy system stating that
pressure testing has been completed.
3. All vessels should be drained of liquids.
NOTE: To purge the separator and tank with nitrogen (if required) reference OSP 7.16.
4. If an individual component has been pressure tested the following procedures shall be followed:
a) Repeat steps (1) and (2) above. Depressurise the component and drain all the test fluid from the vessel.
b) The test equipment shall be rigged down and tidied away.
5. The barrier tape used to cordon off the pressure testing area should be removed.
6. Key personnel (ie. Driller, Crane operator etc.) should be notified stating that pressure testing has been
completed.
7. Sign off cold working permit.
DATE: MARCH 1999 ISSUE 2 REVISION O

SECTION 2
WELL TEST OPERATIONAL GUIDELINES APPENDIX 2
Page 1 of 17
FIG 2.1 LINE UP FOR FLUSHING SYSTEM

SECTION 2
Page 2 of 17
FIG 2.2 STARBOARD AND PORT OIL AND GAS LINES TO BURNER, SURGE TANK INLET
VALVES

SECTION 2
Page 3 of 17
FIG 2.3 FUNCTION TEST HIGH PILOT (PSH) BETWEEN HEAT EXCHANGER AND SEPARATOR
AND ACTUATED SURFACE SAFETY VALVE

SECTION 2
Page 4 of 17
FIG 2.4 STARBOARD AND PORT OIL AND GAS DIVERTER LINES

SECTION 2
Page 5 of 17
FIG 2.5 OIL MANIFOLD INLET VALVES

SECTION 2
Page 6 of 17
FIG 2.6 SURGE TANK BODY

SECTION 2
Page 7 of 17
FIG 2.7 SEPARATOR VESSEL AND OUTLET VALVES

SECTION 2
Page 8 of 17
FIG 2.8 SEPARATOR INLET AND BYPASS VALVES

SECTION 2
Page 9 of 17
FIG 2.9 HEATER COILS AND BYPASS VALVES

SECTION 2
Page 10 of 17
FIG 2.10 HEATER INLET AND BYPASS VALVES

SECTION 2
Page 11 of 17
FIG 2.11 LOW PRESSURE PILOT (PSL2)

SECTION 2
Page 12 of 17
FIG 2.12 SURFACE SAFETY VALVE

SECTION 2
Page 13 of 17
FIG 2.13 CHOKE MANIFOLD AND DOWNSTREAM VALVES

SECTION 2
Page 14 of 17
FIG 2.14 CHOKE MANIFOLD UPSTREAM VALVES

SECTION 2
Page 15 of 17
FIG 2.15 LOW PRESSURE PILOT (PSL1)

SECTION 2
Page 16 of 17
FIG 2.16 HYDRAULICALLY ACTUATED FLOW-WING VALVE AND FLOWHEAD

MASTER VALVE

SECTION 2
Page 17 of 17
FIG 2.17 REMOTE ESD STATIONS

SECTION 3
EQUIPMENT
Page 1 of 20
3.1 EQUIPMENT HOOK-UP
Prior to hooking-up the swivel the following checks should be taken:-
1. Verify smooth rotation of swivel.
2. If swivel not rotating then inject Shell Alvania grease through grease nipple.
3. If rotation still not possible then a replacement swivel is required or the swivel must be redressed.
3.1.1 TUBING HEAD SWIVEL
1. Install Tubing Head Swivel in test string directly below Surface Test Tree and torque connection to
required torque.
To torque connections using the rig tongs, remember that the line pull shown on the drillers console is not
the ft.lbs applied to the connection. To work out the true torque this figure must be multiplied by the
length of the tongs e.g.
Tong length 4'

Drillers console line pull reads 1,000 ft.lbs
True torque applied to connection is 4 X 1000 = 4,000 ft.lbs
Mark the breaking point between other connections e.g. on the surface test tree to indicate if any
connections are backing out as the swivel is torqued up.
2. Observe for connections backing out when using rig tongs.
3.1.2 SURFACE TEST TREE
Prior to hooking-up the Surface Test Tree, the following steps should be taken:-
1. Check that actuated valve(s) are in the correct fail safe positions prior to the application of hydraulic
pressure.
2. Verify operation of manual valve(s) by cycling from fully closed to full open positions.
3. If required, install tubing head swivel on bottom of tree (if not already fitted).
4. Install correct cross-over onto bottom of tree/swivel with thread protector fitted.
5. If required, install lifting sub top of tree (if not already fitted).
6. Install correct cross-over for wireline etc. on top of lifting sub, or install suitably rated pressure cap if no
cross-over required.
NOTE: Never install an aluminum thread protector on top of tree to prevent debris from entering on top of swab
valve, always use a suitably rated pressure cap (in case swab valve leaks).
7. For Baker Model 'C' Actuators, ensure the lock-open cap and disk is fitted, to avoid damage to the
actuator stem during hook-up.
Refer to Fig. 3.1 ACTUATOR LOCK-OPEN CAP AND DISC
8. Remove thread protector from bottom of tree assembly.
9. Install surface test tree into test string and torque connections to required torque.
NOTE: If possible install the tree with the actuator and valve handles facing away from the 'Vee' doors to avoid
damage when rigging up wireline or coiled tubing.
Rigging up coiled tubing wireline while producing through the tree is not recommended, as there is no
double block isolation between well pressure and the open connection while stabbing on the injector
head/lubricator.

SECTION 3
EQUIPMENT
Page 2 of 20
10. Connect hydraulically actuated valve(s) to emergency shut down system.
11. Remove lifting bridle if required.
12. Check positions of all manual valves, (Should be open at this point).
13. During operations, valve handles should be removed from valve(s) not normally operated or safety pins
must be installed.
3.1.3 CONTROL PANEL
1. Connect air supply to control panel and turn on air.
2. Check air supply pressure to panel is at least +/- 100 psi.
3. Spot ESD remote stations and tie into control panel ESD loop using 6mm polythene liner.
NOTE: a) This polythene liner must be the coloured black variety and not the see-through type as this is
biodegradable.
b) In Holland 1/4" low pressure hose with JIC fittings may be used.
Refer to Fig. 3.2 PRESSURE PILOT AND REMOTE ESD TIE-IN
4. Tie in high pressure pilot valve (if applicable) to ESD loop as per Fig. 3.2.
5. Check that there is sufficient oil in the oil reservoir, if not, top up with a suitable hydraulic oil.
6. Loosely connect hydraulic line from panel to quick exhaust (if fitted) on actuator, else connect line directly
to actuator.
7. Purge line from control panel to quick exhaust/actuator and secure.
8. For Baker model 'C' actuators:-
Apply +/- 2000 psi hydraulic pressure to actuator and remove cap and disk that holds the stem down to
prevent damage during transit.
9. Verify operation of hydraulic valve(s) by cycling from fully open to fully closed using the control panel and
then re-open.
10. Verify operation of safety valve(s) by using a remote ESD station.
11. Open safety valve and maintain control pressure in accordance with the charts for the type of actuator.
NOTE: Sometimes, at low control line pressures, when opening the actuated safety valve with a quick exhaust
fitted, a small amount of hydraulic oil weeps past the dump on the quick exhaust preventing pressure
from building up inside the actuator and the valve opening. If this is the case a 1/2" ball valve should be
fitted to the quick exhaust dump and closed while pumping open the safety valve.
REMEMBER TO RE-OPEN OR REMOVE ANY VALVE CLOSED ON THE QUICK EXHAUST DUMP
AFTER THE SAFETY VALVE HAS BEEN OPENED.
3.1.4 COFLEXIP HOSES HOOK-UP
COFLEXIP HOSES MUST ALWAYS BE FITTED WITH THREAD PROTECTORS WHEN NOT IN USE.
The type of coflexip used is critical and this must be checked before hook-up. The two types are DST or PTL
refer to Section 3.9 for a list of all coflexip hoses in service with EXPRO.
DST lines are designed only for temporary exposure to sour service, which for each individual test should not
exceed 72 hours.

SECTION 3
EQUIPMENT
Page 3 of 20
PTL lines are designed for a permanent exposure to sour service and should be used where the test period will be
longer than 72 hours.
1. Perform visual inspection throughout the entire length of the coflexip hose.
Points to look for are:-
a) Carcass is properly attached at both end fittings.
b) The entire surface of the polymeric sheath is protected.
c) Any damage on the carcass e.g. creases, collapse and general deterioration, that is likely to
be detrimental to the inner tube.
2. Inspect by removal the seals for condition from the end connection (hammer unions only).
3. Inspect end connections for damage and pitting (including seal-ring recess).
NOTE: End connections may be either hammer union or clamp connection.
4. Check threads of coupling for damage visually and by screwing a mating half of coupling together
(hammer unions only).
5. Using the crane lift the hose and install the upstream end to the flow-wing of surface test tree or required
connection.
NOTE: When handling the Coflexip avoid bending the hose to a distance of 2 to 3 feet behind the connection.
6. The coflexip must never be bent below the Minimum Bend Radius, whether under pressure or not.
As a rule of thumb M.B.R. = 12 X I.D. in inches
Therefore the M.B.R. in feet will equal the I.D. in inches of the line.
7. At no time must the hose be lifted with a 2 legged sling attached at either end. This would result in the
hose exceeding the minimum bending radius. The hose is to be lifted at one end using the collar provided
at the hammer union.
Refer to Fig. 3.3 HANDLING COFLEXIP HOSES
8. Prevent abrasion of the coflexip against the deck: use wooden supports or planks.
9. On semi-submersibles where the coflexip is hooked up to the surface test tree, the preferred hook-up is
with the hose in a J configuration with the end fittings pointing in a vertical position utilising the derrick
standpipe (if applicable).
Refer to Fig. 3.4 PREFERRED HOOK-UP ON SEMI-SUBMERSIBLE RIGS
3.1.5 PIPEWORK
1. When rigging up pipework, personnel safety is of prime importance:-
a) Safety glasses should always be worn.
b) If working at heights, a safety harness should be worn.
c) The proper tools should be used for the correct job, i.e. a Stillson is not a hammer and
should not be used as such.
2. Pipework pressure ratings will have been selected to allow for the maximum expected pressure plus a
safety margin, and it is imperative that when rigging up the correctly rated pipework is placed in the
correct section of the well test system, i.e. low pressure pipework MUST never be used upstream of the
heater.
3. When rigging up, if unsure of a pressure rating, the metal banding around the pipework should be
checked, from where the necessary MAWP can be found.

SECTION 3
EQUIPMENT
Page 4 of 20
Refer to Fig. 3.5 PIPEWORK METAL BAND
4. Use the proper height pipe supports to support the pipe, be careful if using piles of wood, they may fall
over.
5. Tie down the pipework using 11mm tie down-cable, fitted through pipe clamps and bound round pipework
in a half-hitch.
3.1.6 TWIN POT SAND FILTERS
1. Chain blocks should be fitted and davits raised.
2. Filters with an appropriate mesh size suitable to the sand size expected should be installed in each filter
pot prior to start-up.
3. Hook-up Barton recorder or Barton differential gauge.
Refer to Fig. 3.6 BARTON RECORDER HOOK-UP
4. Drain Barton purge pots and assure that all lines to recorder are clear of any pressure testing fluid.
5. Ensure pressure tappings to differential pressure unit to each filter pot are open and all vents/drains on
each filter pot are closed.
6. Fit gauges of suitable range to each pot for observing pressure in pot. Ensure gauges are protected by
suitable isolating valves.
7. Bypass Barton recorder manifold. Wind instrument clock and install chart. Check pens functioning
properly.
8. Check operation of valves by cycling from fully closed to fully open position. Close bypass valve. Close
inlet valve and outlet valve on one pot (standby pot), leaving the other pot ready for service (duty pot), if
required, else open bypass and close all pot valves.
9. Sand hopper should be fitted and drain hose run overboard.
NOTE: In Holland the drain will be ran to a dedicated tank or to the mud pits as no liquids are dumped overboard.
10. A water line should be hooked up to enable filters to be flushed.
11. Rig up flexible vent lines or "Boyer tubes" as applicable.
12. Filters should be earthed to rig structure using appropriate earthing strap.
3.1.7 DATA HEADERS
1. Ensure that all pressure, sampling and injection points are fitted with suitable double block isolating
valves.
2. The data header should be mounted with the temperature, pressure and injection points vertical and
the sampling point horizontal.
3. Ensure that a suitable thermo-well is fitted in the 3/4" tap angled downstream.
4. Ensure that the instrument manifold is fitted to the 1/2" tapping furthest upstream.
5. Ensure that the chemical injection point is fitted to the 1/2" tapping furthest downstream and has a
check valve installed downstream of the liner to prevent an uncontrolled emission of well pressures in
the event of the injection liner parting.
NOTE: The instrument manifold should be made up in such a way as to allow the fitting of a suitable
pressure gauge, a dead weight tester and a Barton/Foxboro pressure recorder to it. The legs of the
instrument manifold should be marked to allow quick recognition of which leg the dead weight tester
or pressure recorder is connected to.

SECTION 3
EQUIPMENT
Page 5 of 20
For high pressure/temperature wells there should never be more than one instrument/
recorder/pump connected to a single tapping. There should also be double check valves
fitted to the chemical injection point, as an extra safety procedure.
6. Connect temperature probe from recorder to thermo-well.
7. Connect sampling hose.
8. Connect liner from chemical injection pump to injection point.
9. Connect pressure recorder, dead weight tester and a suitable pressure gauge to instrument manifold
or individual tapping.
For high pressure testing, the sampling point should be downstream of the choke as to take samples
upstream causes valve cut-outs and compromises safety. The sample point should also be fitted with
a 90 block pointing downward to help reduce damage.
Refer to Fig. 3.7 SAMPLE POINTS
3.1.8 CHOKE MANIFOLD HOOK-UP
1. Spot choke manifold(s) as per specific layout diagram for current job.
2. Hook-up flowlines (or data header) to choke inlet connection.
NOTE: Inlet connections on choke manifold will be either:-
- 2" Fig. 2202 female, 15,000 psi W.P.

- 3" Grayloc C25 clamp connection, 15,000 psi W.P.
- 3" Fig. 1502 female, 5,000 or 10,000 psig W.P.
- 6" Fig. 1002 female, 3,000 psig W.P.
3. Hook-up flowlines to outlet connection.
NOTE: If using a modified choke manifold, in conjunction with a dedicated clean-up line, the clean-up line ties
into the 4" Fig. 602 and the test system lines tie into the 3" Fig. 1502 outlet connections.
Refer to Fig. 3.8 CLEAN-UP CHOKE MANIFOLDS
4. Install earthing strap (if not fitted) and connect to earth point on deck.
ONCE THE CHOKE IS HOOKED-UP THE FOLLOWING CHECKS SHOULD TAKE PLACE
5. Check if full range of chokes available for current job.
6. Remove adjustable choke and inspect choke stem and seat, replace as required.
7. Remove blanking plug and inspect positive choke side, assure threads of choke box not damaged.
NOTE: Do not flow at any time through the positive side without a positive bean fitted.
8. Inspect blanking plug seal surface and 'o-ring' and lightly grease.
9. Clean choke body O.D. threads, seat threads and bonnet bore. Lightly apply grease to these areas
before re-installation.
10. Ensure suitable isolating valves fitted to upstream (if applicable) and downstream taps of choke box.
11. Fit pressure gauges and bleed off points to downstream of choke to monitor pressure drop across
choke.
12. Fully open and close all valves.

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EQUIPMENT
Page 6 of 20
3.1.9 HEAT EXCHANGER
1. Remove bonnet assembly from adjustable choke box.
2. Check choke and needle for size and condition.
3. Replace adjustable choke box assembly, check free rotational movement of adjustable choke stem,
tighten stem until needle engages on seat. Set choke opening indicator sleeve to zero.
4. Check operation of manual valves by cycling from fully open to fully closed position.
5. Open bypass valve and close process coil inlet and outlet valves.
6. Assure air supply (150 psi max.) to temperature control instrumentation.
7. Check operation of T.C.V. by cycling from fully open to fully closed. This temperature controller should
have been calibrated onshore before shipment.
DIRECT STEAM
8. Ensure steam supply at 200C and 125 psi.
INDIRECT STEAM
9. Fill heater body with water and ensure steam supply at 200C.
10. The temperature controller should be tested to ensure that the correct temperature can be maintained
during flowing periods.
3.1.10 RELIEF VALVE SKID
1. The relief valve skid should be spotted as per the layout diagram, normally between heat exchanger and
separator and in will be set to 1,440 psi.
2. Pipework should be rigged up correctly to both inlet and outlet connections, and tied down with 11mm tie-
down cable.
3. The vent line should be rigged up to the relief valve outlet and routed as shown on the layout diagram.
NOTE: This may be run separately or 'teed' into the separator line and then run overboard or to the flare boom.
The size of this vent line is critical to the safe relieving of pressure and must be of the same size and
pressure rating as shown on the layout diagram as this will have been calculated for the specific well test
in hand.
For high pressure testing, an additional relief valve skid may be placed between the choke manifold and
the Heat Exchanger. In this case the relief valve will be set to 5,000 psi in order to protect the low
pressure coils in the Heat Exchanger.
3.1.11 3 PHASE TEST SEPARATOR
1. Ensure air supply to instruments (and high level, high pressure alarms if applicable) via instrument air
knock-out pot at 100-125 psi.
2. Set manual valves at inlet manifold to bypass flow to gas or oil downstream lines as required.
3. Ensure that flowpath is open downstream of separator to overboard line or burner boom as required.
4. Open isolating valve in sensing line between gas B.P.V. control instrument (Fisher Wizard 4150) and
separator.
5. Check that gas B.P.V. is fully open with 6 psi at instrument set pressure output (for 3 - 15 psi ranged
Wizards this will obviously be 3 psi).
6. Check that liquid dump valves are fully closed with 6 psi at instrument set pressure output (for 3 - 15 psi
ranged controllers this will be 3 psi).

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Page 7 of 20
7. Lift orifice plate carrier and bypass gas flow meter (Barton) manifold. Wind instrument clock and install
chart. Check pens functioning properly.
Refer to Fig. 3.9 SEPARATOR BARTON HOOK-UP
8. Drain Barton knock-out pots (if fitted) and assure that all lines to meter are clear of any pressure testing
fluid.
9. Verify all needle valves, sampling points etc. which vent to atmosphere are closed.
10. Ensure all pressure gauges are protected by suitable isolating valves.
11. Where possible, ensure that displacers are in place in level-trol cages and any float retainers are
removed.
NOTE: This can be checked by operating the controllers during pressure testing, when the vessel is being filled
with water.
12. Function check oil/condensate and water dump valves by applying instrument pressure and fully stroking
the valves, (fully open at 3 / 6 psi, fully closed at 15.30 psi).
13. Set oil/condensate and interface level-trol instruments so that the respective P.C.V.'s are closed but will
react immediately to rising levels within the separators (if not already set during pressure testing
sequence.
NOTE: This can also be done during pressure testing.
14. Ensure sight glasses are clear enough to observe levels.
15. Ensure rotation of Floco 2500 liquid meters by removing blind nut from back of meter (left hand thread)
and with an adjustable spanner (looking from the back) rotate paddle assembly shaft in a clockwise
direction, this will assure free rotation of the paddle assembly.
16. Inspect orifice plates to ensure:-
a) Plate is flat as possible and not buckled.

b) Upstream edge is sharp with no nicks.
c) Plate is clean.
3.1.12 GAS DIVERTER MANIFOLD
1. The gas diverter manifold should be spotted as per the layout diagram.
Refer to Fig. 3.10 GAS DIVERTER HOOK-UP
2. The inlet connection will be run from the separator gas outlet.
3. The outlet connections should be run to the port and starboard flare booms.
3.1.13 OIL MANIFOLD
1. Check free movement of valves on oil manifold by cycling all five valves fully open to fully closed.
2. Ensure in-line choke (Teledyne Merla or B.S.T.) fitted by Weco connection onto outlet to tank (when using
gauge tank only) or a suitably sized positive choke is installed when using a surge tank.
Refer to Fig. 3.11 OIL MANIFOLD HOOK-UP
3. Ensure oil manifold is connected as follows:-
a) inlet from separator oil outlet to valve #1

b) one outlet to port burner to valve #4 or #5
c) one outlet to starboard burner to valve #4 or #5
d) one outlet to tank (with in-line choke) to valve #2
e) one inlet from discharge line of transfer pump to valve #3

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Page 8 of 20
NO LINES OTHER THAN THE LINES TO THE FLARE BOOMS SHOULD BE CONNECTED TO THE OUTLETS
FROM VALVES #4 AND #5 UNLESS WRITTEN PROCEDURES APPROVED BY THE CERTIFYING
AUTHORITIES ARE AVAILABLE.
4. Ensure any redundant manifold connections are plugged off with the bull plugs chained to the manifold.
NOTE: The purpose of the in-line choke is to limit flow to the tank to a rate below that which the gauge tank vent
and Whessoe weighted hatch can safely relieve and prevent pressure build-up in the event of failure of
valve #2. For a standard 1/2" trim the flow of gas through the choke will be in the order of 5 MMSCF.D.
The purpose of the positive choke is to limit oil flow to the surge tank to a rate below which the relief valve
can safely vent.
The line from transfer pump discharge should have a stainless steel check valve fitted to prevent backflow
to pump through oil manifold valve when pump not in use.
3.1.14 GAUGE/SURGE TANK
GENERAL
1. The tank(s) should be spotted as per the layout diagram.
2. Fit flame arrestor (gauge tank) or ensure instrument air supply to back pressure controller, if not
mechanical type (surge tank).
3. Check relief valve/flame arrestor outlet not restricted and run vent line (from flame arrestor or relief valve)
to a pre-determined safe area or tie into line to flare boom.
NOTE: Where to run this line will be shown on the layout diagram.
4. Run gas line to flare booms, tie-ing into a diverter manifold where required (for surge tanks where
required).
5. Connect inlet line/hoses from oil manifold to tank inlet.
NOTE: For low flow rate wells (eg. gas wells), it may be desirable to connect the condensate line to one
compartment and the water line (from the separator) to the other compartment.
6. Connect line from tank drain/liquid outlet to transfer pump.
7. Ensure drain valve(s) closed.
8. Close bypass valve (if fitted).
9. Ensure all sampling/pressure gauge points are protected by suitable isolating valves.
10. Ensure pressure gauge of suitable range fitted and open to vessel pressure (surge tank).
11. Ensure sight glasses are clear and gauge cocks open.
12. Ensure inlet valve closed.
13. Where required blowdown air regulator to back pressure controller to clear any condensation or liquids.
14. Check operation of B.P.V. and set for minimum back pressure.
NOTE: Where a high or low level alarms are fitted to the tank ensure these are hooked-up in accordance with the
manufacturers procedures.

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EQUIPMENT
Page 9 of 20
3.1.15 TRANSFER PUMP
1. ELECTRICAL
a) Assure correct electrical power supply to pump and unit is earthed properly.
b) Connect suction line from tank drain/liquid outlet to pump.
c) Connect discharge line from pump to oil manifold.
d) Check switch gear is operating properly.
e) Check for correct direction of pump rotation
f) Check installation of pressure relief valve between pump feed and discharge lines (if applicable).
2. AIR DRIVEN
a) Connect air supply to pump.
b) Connect suction line from tank drain/liquid outlet to pump.
NOTE: The suction line should be as short as possible.
c) Connect discharge line to oil manifold to pump.
d) Check for correct operation of pump.
NOTE: Check all external gasketed fasteners for looseness caused by gasket creep. Tighten loose
fittings securely to prevent leakage.
For both types of pump, a stainless steel check valve should be fitted to the discharge line from
the pump to the oil manifold. (This may be hooked directly onto the diverter manifold).
3.1.16 BURNER BOOMS
PLANNING
When planning the installation of a burner boom on a clients rig or platform, a meeting must be held with the client
to discuss rigging procedure.
A rig visit will also be required to discuss the hanging procedure with the O.I.M. or barge engineer. It will also be
necessary to check the following points with specific detail being added as necessary.
1. Determine the measurements of king posts or pad eyes, sling lengths and side slew wire points.
2. Determine if the base plate swivel point is vertically below the supporting pad eye. Measure any
deviation.
3. Check certification of king posts, boom, slings, and base plate mounting points to ensure they are
adequate to support the loads imposed on by the boom. (Certification is normally undertaken by a third
party, on behalf of the rig owners).
NOTE: The rig certification authority must be supplied with details of the intended boom installation to confirm
that the rig mounting points are adequate.
BOOM INSTALLATIONS MUST NOT COMMENCE UNTIL APPROVAL HAS BEEN OBTAINED FROM THE
CERTIFYING AUTHORITY.
4. Check to see if the crane is able to jib out over the point of installation of the boom. If this is not
possible for any particular installation, then special installation procedures have to be made to prevent
overloading the boom structure.
5. Check that access is available to the mounting point for boom slings.

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EQUIPMENT
Page 10 of 20
6. The effects of radiant heat are unpredictable depending very much on weather conditions. It is
essential that provision is made for adequate water screening. This should be discussed during the rig
visit.
THE CLIENT WILL DETERMINE THE MAXIMUM ACCEPTABLE HEAT LEVELS ON THE RIG.
7. Continuity of walkway and handrails from deck to boom must be maintained.
NOTE: This may require the fabrication of extra linking pieces for the handrails and possibly steps or a bridge
piece for the walkway.
This should be thought of at the planning stage.
8. A safe location with a clear view of the burner must be available on deck for the pilot light propane
cylinders or diesel pump.
Ease of access to the location is required to allow for the spotting of propane cylinders or diesel tank.
WHEN PLANNING BOOM RIGGING INSTALLATIONS, PARTICULAR ATTENTION MUST BE PAID

TO THE MINIMUM DIMENSIONS DETAILING SUPPORT SLINGS AND SLEW WIRES, WHICH ARE
DETAILED IN THE DESIGN VERIFICATION REPORT HELD BY THE ENGINEERING DEPARTMENT
AT READING.
FAILURE OF THE ABOVE CAN LEAD TO BOOM COLLAPSE
HANGING THE BURNER BOOM
1. Before hanging the boom, the following inspections should be made:-
a) Inspect all the securing bolts on connected sections to ensure they are tensioned properly.
b) Inspect the structure of the boom for any damage during transit.
c) Inspect the turnbuckles, spreader plate, shackle, pennant line(s) (box & U frame booms
have only one pennant line) used to hang the boom from the king post pad eye, ensuring that
they are correctly installed.
Refer to Fig. 3.12 CORRECT INSTALLATION OF DOGS ON LINES
d) Inspect the lifting brothers, ensuring that the leg lengths are connected to the correct lifting
pad eyes and that they will not foul on the boom structure when lifting with the crane.
e) Grease the base plate swivel pin.
f) Fit a tag line to the boom for control during maneuvering the boom onto the swivel pin.
2. Once all inspections have been made the crane can be attached to the boom ready for lifting.
EXPRO have identified two ways of hanging booms, were there is NORMAL ACCESS and
RESTRICTED ACCESS
NORMAL ACCESS
Normal Access hanging procedure is where the crane can position the boom unaided in its final
position. Typically semi - submersible floating rigs.
RESTRICTED ACCESS
Restricted Access hanging procedure is where the crane is unable to position the boom unaided in its
final position. Reference, types of jack-up drilling rigs.
NOTE: For restricted hanging procedures, it is permissible to use standard transportation slings, but an
additional pulling point extension arm (side arm extension) is required to enable the boom to be pulled
safely into position.

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EQUIPMENT
Page 11 of 20
NORMAL HANGING GUIDELINES
1. Pick the boom up with the crane and position the swivel plate to the base plate pin and lock with washer
and bolt.
NOTE: It may be that the swivel plate and base plate are fitted and that the boom will be positioned with the
end pad eyes to line up with the swivel plate. These should be pinned and secured once lined up. The
base & swivel plates should always be installed on the rig side prior to installation of the boom.
2. Connect the pennant line(s) to the King Post.
NOTE: These may require the use of a "Tirfor" to raise to the King Post.
In some cases it may be required to install a "Tirfor" to the mounting point on the King Post.
Care must be taken to ensure that no part of the boom pipework fouls the support base-plate or
the rig structure when the boom is lifted.
FOR BOX AND U FRAME BOOMS
3. Once the pennant line has been secured the boom should be in a horizontal or slightly elevated
position, with the complete boom weight taken by the hanging pennant(s). On no account should the
boom hang below the horizontal level.
NOTE: It may be necessary to raise the boom slightly with the crane to allow sufficient slack to be obtained to
allow the pennant line to be connected to the King Post.
FOR 90ft BOOMS
4. It is important that when installing 90ft booms, that the main outer pennant line is connected to the king
post prior to the inner to provide major boom support.
5. Release the side slew wires from both handrails and attach to the rig pad eyes. Use a "Tirfor" mounted
on the rig to take the slack out of the side wires.
6. Double check that all support slings are secure and correctly positioned, and tension the side slew
wires.
7. Release the crane.
NOTE: The crane must not be disconnected from the boom until both pennant lines are connected and taking
the load.
8. Once the crane has been removed, inspect the hanging brothers to ensure that the boom walkway is
not obstructed. Inspect the connecting pins on the swivel plate for correct installation. (not applicable to
90ft booms)
9. Clear up any extra lengths of side wire (tie to handrail etc.).
10. Fit extra handrail/steps etc. as required to permit safe access and egress to/from boom.
11. Connected all flowlines/pilot lines etc. to boom
NOTE: Attempt to leave the access to the boom as clear as possible.
12. Hook-up and function test the ignition system.
RESTRICTED HANGING GUIDELINES
1. Use the crane to lower the boom swivel plate as near as possible to the base plate pin.
2. Pull the boom swivel plate onto the base plate pin, using a tag line or like where necessary, and secure
with washer and bolt.
3. Connect the pennant line(s) to the King Post as under Normal Access guidelines, steps 2 - 4.

SECTION 3
EQUIPMENT
Page 12 of 20
4. Release the side slew wires and attach to the rig pad eyes. With the aid of the side arm extension and
the "Tirfor", pull the boom into position.
NOTE: On some installations it may be possible to use a line from an air winch, ran through a suitable point to
pull the boom around.
The crane should be used only as a back-up and must not take any load. It will have to pay out line as
the boom moves if a load is placed on the boom by the crane not paying out enough line, THIS CAN
CAUSE BOOM FAILURE. The horizontal movement of the boom should be controlled between the
"Tirfor" and the tag line
5. Follow the Normal Access hook-up guidelines from step 6 onwards.
REMOVAL OF BOOMS FROM INSTALLATION
Removal of the booms from the rig should be performed in a reverse process.
1. Attach the crane so the weight of the boom is supported.
2. Restrain the sideways movement of the boom by a suitably long tag line, then release the side slew
lines from the rig padeyes.
3. Elevate the boom slightly and disconnect three main pennant and support lines from the booms.
4. The side slew lines should be gathered and tied of into the boom.
5. Next step is to disconnect the boom from the rig base plate. This should only be performed when the
crane has been aligned vertically and balanced to prevent inward and outward swinging.
NOTE: No personnel should be on the boom when removal of the base plate pins is being performed.
Only person removing the pins should be close at this stage.
RIGGING ARRANGMENT WIRE SIZES
The following wire sizes applies to all Expro booms. Refer to the following diagrams for the rigging
arrangement (pages 14 & 15)
1. Main top wire (Pennant wire): Normally 36mm dia. 6 x 36 TWRC construction, galvanised right hand
ordinary lay (RHOL). Tensile strength approx. 180kgf/mm2 pre-formed, safe working load 16.7 tonne,
minimum safety factor x 5.
2. Fish/Monkey Plate wires: Normally 32mm dia. 6 x 36 TWRC construction, galvanised R.H.O.L. tensile
strength approx. 180kgf/mm2 preformed, safe working load 13 tonne, minimum safety Factor x 5.
3. Side/ Slew wires: Normally 16mm dia. 6 x 36 fibre cor (f/c) galv. R.H.O.L. wire rope tensile strength
approx. 180 kgf/mm2 pre-formed, safe working load 3 tonne, minimum safety factor x 5.
In certain cases the main (Pennant) wire will be increased to 44mm dia. with a safe working load of 25 tonne.
For typical Fish/Monkey plate design see dwg. no. TED080501.

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EQUIPMENT
Page 13 of 20
CLAMPS & SHACKLES
The table below shows a typical clamp & shackle arrangement for one TX 600 series boom.
TYPICAL GUY LINES, CLAMPS & SHACKLES TYPE No. S.W.L.

DESCRIPTION LENGTH OFF (TONNES)
(FT)
Main Guy Line, (Pennant wire):

44mm dia. Wire rope talurit clamped thimble eye each 30ft 1 17
end.
Wires from Fish Plate to Boom:

end
Side/Slew Wires:
end.
Fish/Monkey Plate 1 25
Safety Bow Shackles 2 17
Safety Bow Shackles 4 12
Safety Bow Shackles 4 8.5
1 Eye & Jaw Bottlescrew 1 3
NOTE: a) Wires mfg to BS 1290

b) Shackles mfg to federal specn RR-C-271D.
c) Lengths shown are for example only, and are dependant on rig lay-out. This must be calculated prior
to each load out and installation. Should be confirmed against boom loading and verified by approved
third party independent lifting company.
d) The main/pennant guy line is either 44mm or 36mm, depending on loading.
e) Number & rating of shackles is dependent on the individual requirements.
f) Does not include shackles & clamps for loadlifting test.

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EQUIPMENT
Page 14 of 20
GUY LINE LENGTHS & ANGLES
BOOM GUY LINE WIRES HEIGHTS AND ANGLES
BOOM TX No 2 OR 4 ALLOWABLE MINIMUM MINIMUM

SERIES WIRE HANGING KING SIDE
SYSTEM LENGTHS (ft) POST SLEW
HEIGHT ANGLE
(M)
44 Box frame 2 52 ft only 5.0m 30
600/670 U frame 2 52 ft & 72 ft 5.0m 22
1659 U frame 2 60 ft & 72 ft 5.0m 22
1896 Triangular 4 61ft & 90 ft 8.5m 20

frame
The following diagrams illustrate the typical hanging arrangement for all boom types.
TX 44 SERIES BOOMS 52FT LENGTH ONLY (2 WIRE SYSTEM)

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EQUIPMENT
Page 15 of 20
TX 600 SERIES BOOMS 52FT & 72FT LENGTH (2 WIRE SYSTEM)
TX 1896 SERIES BOOMS 61FT & 90FT LENGTH (4 WIRE SYSTEM)

SECTION 3
EQUIPMENT
Page 16 of 20
NOTE: For all the above diagrams:

A. King Post
B. Fish/Monkey Plate
1. Main/Pennant Wire.
2. Plate to Boom Support Wires.
3&4 Side/Slew Wires.
Prior to testing the burners out, the ignition system will have to be hooked up, depending which system is used
this can be carried out as follows:-
PROCEDURE TO PROOF LOAD TEST ALL EXPRO BOOMS
The following procedure is based on using one boom as the test load for its opposite pair.
Carry out full visual examination of the boom to be tested, paying particular attention to the general condition of
the structure.
The following procedure is based on using one boom as the test load for its opposite pair.
1. Carry out full visual examination of the boom to be tested, paying particular attention to the general
condition of the structure.
2. Remove existing paint around padeyes and carry out full M.P.I. (See following procedure).
3. Fit slings to one of the booms and place the master-link to the crane hook. Lift and slew the boom over
the top of the other identical boom and connect both via wire rope slings evenly along the length of the
booms. Raise both booms with the aid of the crane so that the under-slung boom is just clear of the
ground. Hold for 5 (five) minutes. Whilst under load carry out a visual examination of both booms. If
satisfactory lower the booms and disconnect the lower one, swop around the pair and repeat the
operation as above.
4. Carry out full M.P.I. on each of the padeyes.
5. If satisfactory, fit test and examination plates and date stamp test and I.D. number of the unit.
6. Proof load the lifting slings and shackles via the test bed. Connect each of the 4 (four) legs in turn to
the pulling points of the test bed and apply a test load of twice the safe working load of each leg,
examine the lifting sling after proof loading. If satisfactory date stamp one of the alloy ferrules.
7. Connect each of the 4 (four) shackles to the test bed and apply a proof load of twice the safe working
load stamped on the shackles, carry out full examination of the shackles.
8. Re-fit the slings and shackles to the padeyes on the boom.
9. Issue certification on the boom and lifting equipment.
PROCEDURE TO PROOF LOAD TEST & M.P.I. PADEYES
1. Carry out full visual examination of the boom to be tested, paying particular attention to the general
condition of the structure.
2. Remove existing paint around padeyes and carry out full M.P.I.
3. Load the boom with solid test weights evenly distributed along the full length of the boom. Total weight
required is equal to the weight of the boom, which equates to a 100% proof load.
4. Fit lifting slings and attach.
5. After 5 (five) minutes under load, lower the boom to the ground and remove the lifting slings, carry out
full M.P.I. again on the padeyes, remove solid test weights and carry out visual examination of the
boom.
6. If satisfactory, fit test and examination plates and date stamp test and I.D number of the unit.
7. Proof load the lifting slings and shackles via the test bed. Connect each of the 4 (four) legs in turn to
the pulling points of the test bed and apply a test load of twice the safe working load of each leg,
examine the lifting sling after proof loading, if satisfactory date stamp one of the alloy ferrules.

SECTION 3
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Page 17 of 20
8. Connect each of the 4 (four) shackles to the test bed and apply a proof load of twice the safe working
load stamped on the shackles, carry out full examination of the shackles.
9. Re-fit the slings and shackles to the padeyes on the boom.
10. Issue certification on the boom and lifting equipment.
3.1.17 BURNER/IGNITION SYSTEM
MAGNITER IGNITION SYSTEM
1. Before attempting to start the 'MAGNITER' a physical inspection should be made of the following.
a) That the chassis earth is correctly and securely fitted through to the spark plug in the pilot light
assembly.
b) That the chassis is firmly mounted either to the flare boom direct or in it's chosen enclosure.
c) All air pipes, valves and air management units are gas tight and operational.
d) That there is adequate oil (AD 220) in the oil mister.
e) Ensure all valves and regulator are closed and shut down.
f) Ensure all site safety regulations are being observed.
g) Air supply of at least 100 psi is connected to air in port.
2. Connect HT leads to spark plug in pilot assembly.
DIESEL IGNITION SYSTEM
1. Before attempting to start the ignition system a physical inspection should be made of the following:-
a) That the control panel earth is correctly and securely fitted through to the spark plug in the
pilot light assembly.
b) All air pipes, valves and air management units are gas tight and operational.
c) Ensure all site safety regulations are being observed.
2. Plug in 240 Volt AC mains input cable (blue 3 pin socket).
3. Plug in remote control cable if required (yellow 5 pin plug).
4. Plug in HT cable/probe rod assembly.
5. Switch pump control switch to off.
Refer to Fig. 3.13 ENCLOSURE LAYOUT
3.1.18 BURNER HEADS
1. Assure adequate supply of air to burner heads (approx 600 c.f.m at 100 psi per 5000 BOPD) and water
to cooling screens.
2. Assure sufficient supplies of bottled propane for pilot flame.

3. Check function of pilot light ignition system by operating Ignition system so spark is delivered in flow
path of propane.
4. Open Propane regulator valve and observe pilot flame.
5. Once established that ignition systems will ignite pilot gas then the pilot system can be shut down.
6. Check operation of water screens, clear/replace nozzles as necessary.

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7. Check free movement of burner chokes (if applicable) by cycling from fully closed to fully open.
NOTE: Burner chokes should be left +/- 1/2 way open for start of test and adjusted according to well conditions.
3.1.19 PRESSURISED LABORATORIES
1. Laboratory should be spotted as per layout diagram.
2. Spot fan in safe area as shown on the layout diagram.
3. Run air intake conductor from fan to laboratory air intake.
4. Connect air supply to laboratory.
5. Hook-up correct power supply.
NOTE: a) When offshore the rig electrician should do this.
b) In Holland on some land locations, a generator supplied by EXPRO may form part of the well test
equipment, and will be serviced by well test personnel.
6. Ensure fire dampeners are open.
7. Ensure there are no restrictions over the air in or out ducts.
8. Check door seals are in good condition.
9. Ensure all M.C.T. blocks are in place.
10. Check direction of fan in laboratory.
NOTE: With a centrifugal fan the air output will be vastly reduced when the impeller is revolving in reverse. The
impeller should always revolve towards the outlet as shown below.
Refer to Fig. 3.14 ROTATIONAL DIRECTION OF IMPELLER
3.1.20 DEAD WEIGHT TESTER
1. The Dead Weight Tester must be on a level area, sufficient in size to accommodate weights "at the
ready" when needed. (Offshore care should be taken to avoid working over grating, or grills so that if
small weights are dropped, they can be recovered readily).
2. Remove the Knurled nuts, cover and weight rods and the 50 lb., 100lb., and 500 lb. weights.
3. Connect tubing from DWT pressure chamber to point of pressure to be investigated.
4. Do not tighten fitting at the pressure point.
5. Fill the lucite oil reservoir with proper oil (in winter SAE 10 or 10W; in summer use SAE 20).
NOTE: Using lighter oils will increase the leakage rate between piston and cylinder. This does not create a
problem except for the mess of oil. Accuracy of the DWT is constant through the life of the piston and
cylinder regardless of the leakage rate.
6. Close pressure valve and open reservoir valve.
7. Turn screw type pump to the left, backing out the plunger, all the way.
8. Close reservoir valve and open pressure valve.
9. Turn screw type pump to the right, discharging oil in the pump chamber to purge pressure chamber and
tubing.

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10. Repeat action as necessary until oil is observed leaking at well pressure connection. Tighten tubing
fitting at pressure point.
The system is now charged with oil.
3.1.21 SURFACE PRESSURE/TEMPERATURE RECORDER
1. Mount the recorder onto a suitable stand or place box on a flat surface.
2. Perform a zero check of the pressure element with no applied pressure.
3. Connect a D.W.T. to the pressure element and check linearity and range of instrument. If the
instrument appears to be out of calibration, a complete calibration should be performed as per OSP.
4. Connect suitable liner from data header or required pressure sensing point, to recorder static pressure
connection.
NOTE: a) Where there are two different static ranges, ensure the correct range is used.
b) Ensure suitable isolating valves are used at data header etc.
5. Insert temperature bulb in thermowell to its full depth.
NOTE: Fill the thermowell up with hydraulic oil before inserting the temperature bulb.
6. Secure the gland nut into the thermowell.
NOTE: Because of the extensive procedure and elaborate test stand requirements needed to stimulate
operating conditions, it is recommended that only a zero check can be performed. If the instrument
appears to be out of calibration, a complete calibration should be performed.
3.1.22 TEXSTEAM CHEMICAL INJECTION PUMP
1. Connect air line to pump.
2. Connect pump fluid discharge to downstream tap on data header with 1/4" stainless steel liner or a
suitable high pressure chemical resistant hose.
NOTE: A check valve should be fitted in this line to prevent an uncontrolled leak of process pressure if the liner
should rupture, where required. On high pressure wells dual check valves should be used.
3. Ensure regulator is set to supply air at correct pressure to avoid damaging the pump diaphragm.
4. To start the pump, slowly open the air inlet valve on the master valve assembly.
5. Prime the pump head by opening the priming valve on the fluid discharge end. After the pump
discharges liquid (eg. methanol glycol, anti-foam) without bubbles, close the priming valve to ready the
pump for normal operations.
6. Perform a visual check of the plunger drip, by removing the plunger cover and if necessary slowly
tighten the gland nut, using a flat bladed screwdriver.
DO NOT ADJUST UNDER PRESSURE
7. Close the valve isolating the injection point and function test pump for output pressure.
NOTE: Observe liner for leaks during this operation.
8. Ensure an adequate supply of methanol/glycol is on board the rig/platform for the duration of the well
test.

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3.1.23 STEAM GENERATOR
EQUIPMENT
1. Steam Generator should be rigged up as per certified equipment layout. (This may include "tie-ing" into
the well test ESD system).
2. Routing of steam outlet and return lines must be as per equipment layout and particular emphasis must
be given to the avoidance of trip hazards.
3. Boiler blowdown line should be piped preferably to overboard. If this is impractical then it should be
routed away from walkways and barriered off when the boiler is in use.
4. Before rigging up Operator should liaise with Well Test Supervisor or his deputy to ensure a valid permit
is in place.
5. Access to top of Generator structure should be in accordance with rig procedures.
6. If required then the ESD system should be connected to Steam Generator and function tested in
presence of Well Test Supervisor or his deputy.
7. Prior to 'firing up' Steam Generator the pipework should be checked for conformity with 1, 2 and 3
above by Well Test Supervisor or his deputy and Heat Exchanger valves should be arranged so that the
heater coil is not 'closed in', i.e. heater outlet valve should be open to gas overboard line.
8. Steam Generator and associated pipework should be barriered off during normal operations.
9. PA announcements to be made prior to and on completion of any venting from the Steam Exchanger.
3.1.24 AIR LINES
Air lines should be of sufficient size to allow the required air levels to pass for equipment requirements (generally
1/2").
1. Air lines should be run so that they do not cause a tripping hazard.
2. Crows foot connection should be pinned.
NOTE: As added protection it is recommended that whip-checks are used at each connection.

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3.2 LOWER MASTER VALVE
3.2.1 MANUAL VALVE
The manual version of this valve is based on the McEvoy model 'E-2'. To operate the valve follow the guidelines
below.
OPEN VALVE
1. Slowly turn the valve handle fully counter clockwise until the valve 'butts' open.
2. Back off the valve a quarter turn. This leaves the stem in a "relaxed" position, which lengthens the life
of the stem. It also provides a position indicator, enabling you to determine whether the valve is open
or closed by simply turning the handwheel slightly over a quarter turn in one direction.
CLOSE VALVE
1. Slowly turn the valve handle fully clockwise until the valve 'butts' closed.
2. Back off the valve a quarter turn.
As above this leaves the stem in a "relaxed" position, which lengthens the life of the stem. It also
provides a position indicator, enabling you to determine whether the valve is open or closed by simply
turning the handwheel slightly over a quarter turn in one direction.
NOTE: It is important to count the number of turns when operating a valve to ascertain whether it is fully open
or fully closed this is especially so during wireline operations.
Refer to Table 3-15 Required Number of Turns to Fully Open/Close a McEvoy Valve
3.2.2 HYDRAULICALLY ACTUATED VALVE
The hydraulic version of this valve is based on the EXPRO 'SAFE' valve, details of which can be found under
the Subsea Manual for the relevant operating guidelines, maintenance, etc.
TO OPEN
1. Pressure up control line to 3000 psig.
NOTE: In order for the valve to remain open, control line pressure must be held, ie. the valve is fail-safe
closed unless the mechanical lock-open device is engaged. (This lock open device is to prevent the
valve accidentally closing, eg. when wireline is in the hole.
TO CLOSE
1. Bleed off control line pressure.
EMERGENCY CLOSURE
1. Bleed off Control Line pressure.
2. Apply 3,000 psi to the assist line, in order to shear the lock-open pins and close the valve. (If the lock-
open device is not in operation, this assist pressure will aid ball closure and reduce the closure time).
ANY EMERGENCY OPERATION OF THE VALVE WHERE WIRELINE IS IN HOLE WILL

SUBSEQUENTLY REQUIRE THE VALVE TO BE STRIPPED AND INSPECTED FOR DAMAGE.

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3.3 TEMPERATURE SUB
Early warning of potentially hazardous temperature levels is essential as it is critical to maintain the flowing temperature to
below 250F due to the rating of the coflexip hose.
The temperature sub was primarily designed for high pressure/ high temperature well testing to monitor the well
temperature before it enters the surface test tree and the associated coflexip / flowlines of the well test package.
This is achieved by the Temperature Sub being placed below the surface test tree.
The temperature sub is designed with a mandrel fitted with a collar, through which is drilled a port (1/2 NPT tapped) for a
temperature transducer or other measuring device to be fitted. The temperature measuring device does not come into
direct contact with the wellstream, thus reducing the possibility of a leak occurring.
The temperature sub allows the placing of a temperature transducer to give either a digital display at the rig floor or be
combined with the Surface Data Acquisition system to give either a digital or analog read-out with alarm functions by the
use of a pre-determined temperature that once this limit is exceeded will set off the alarm.
The temperature sub has a 1/2" NPT port in the top of the collar. A temperature transducer or other temperature
measuring device should be placed in here. This port leads inside the collar alongside the mandrel that forms the basis of
the temperature sub, allowing for the well temperature to be transferred to the measuring device.

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3.4 CHEMICAL INJECTION SUB
The Chemical Injection Sub is used to inject methanol/glycol at a point below the surface test tree, normally during high
pressure well testing. It is normally hooked up above the lower master valve and has 5" Stub Acme threads top and
bottom (box and pin respectively).
As a safety feature the sub is fitted with integral dual check valves to prevent leaks in the event of the chemical injection
liner parting.

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3.5 TUBING HEAD SWIVEL
For 5,000 and 10,000 psi well testing, some Drill Stem Testing Tools are operated by rotating the drill pipe from surface
(eg. packers) and may require the capability of rotating the test string without breaking surface connections. This is done
by means of a tubing head swivel which is run below the surface test tree.
A typical 10,000 psi swivel assembly comprises an upper inner mandrel rotating inside a lower outer mandrel with
elastomers providing the sealing mechanism.
For 15,000 psi well testing the specifications for these swivels had to be upgraded to cope with the demands of testing
high pressure, high temperature wells. The elastomer seals by themselves were insufficient to withstand the adverse
operating conditions therefore the high pressure swivel assembly, in addition to the normal elastomeric seals utilises
metal-to-metal sealing when under pressure.
This is achieved by combining two sets of seals, a set of elastomer seals retaining tubing pressure when the tool is in
neutral point condition. These seals are located below the bearings and allow the tool to swivel under low pressure. When
tension is applied to the tool during normal testing operations, sealing is transferred to a metal-to-metal seal above the
bearings. Tubing pressure will also act to energise the seal so that a greater sealing force is provided when high tubing
pressures are present. This will prevent the swivel turning but will maintain metal-to-metal sealing integrity.
NOTE: For high pressure well testing, it is very rare to use a retrievable packer eg. RTTS. The packers used would
normally be permanent and thus it would not be necessary to turn the tubing to set it.
1. If it is required to break the swivel assembly out from the Surface Test Tree then this should be done on the rig
floor using the rig tongs.
2. Place thread protector on exposed box or pin ends prior to moving off rig floor.
NOTE: If the assembly is to be further utilised the swivel will be left on the Surface Test Tree and not broken out.

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3.6 SURFACE TEST TREE
3.6.1 HYDRAULICALLY ACTUATED VALVES
OPERATING
It is recommended that the well is never opened up on an actuated valve, and should be opened on a manual
valve eg. the master valve, if possible.
1. Ensure actuator hooked-up to control panel.
2. As certain necessary control line pressure using the relevant chart for the type of actuator.
NOTE: A quick calculation for the Baker model 'C' actuator control pressure is:
control pressure = 0.65 x WHP + 150 psig
3. Apply hydraulic pressure on actuator as per control panel procedures.
NOTE: Ensure ESD loop is pressurised etc. beforehand.
4. If debris eg. proppant enters the sump or migrates between seats and gates on the actuated valve,
this valve may not open fully. A possible solution to this is to increase the hydraulic pressure to exert
more pressure on the actuator piston and force the valve to open. GREAT CARE must be taken
during this operation that the maximum hydraulic pressure for the type of actuator in use is not
exceeded ie. 5,000 psi for McEvoy Willis and 7,500 psi for Baker Model 'C'.
It is possible that where the valve may not open fully due to packed proppant and the actuator
hydraulic pressure is increased, this could result in the retaining bolts shearing causing the actuator to
spring off, possibly causing injury.
5. The actuated valve can be closed either by remote shutdown or manually at the control panel.
3.6.2 MANUAL VALVES
OPEN VALVE
It is recommended that when opening the master valve the lines downstream of the flowhead are open no
further that the choke manifold.
This leaves the stem in a "relaxed" position, which lengthens the life of the stem. It also provides a
position indicator, enabling you to determine whether the valve is open or closed by simply turning the
handwheel slightly over a quarter turn in one direction.

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3.6 SURFACE TEST TREE
CLOSE VALVE
1. Slowly turn the valve handle fully clockwise until the valve 'butts' close.
2. Back off the valve a quarter turn. As above this leaves the stem in a "relaxed" position, which lengthens the life
of the stem. It also provides a position indicator, enabling you to determine whether the valve is open or closed
by simply turning the handwheel slightly over a quarter turn in one direction.
NOTE: It is important to count the number of turns when operating a valve to as certain whether it is fully open or fully
closed this is especially so during wireline operations.
TABLE 3-1 REQUIRED NUMBER OF TURNS TO FULLY OPEN/CLOSE A McEVOY VALVE
SIZES
1-13/16 2-1/16 2-9/16 3-1/16 4-1/16 5-1/8
MODEL C --- 13 16 18 17 22
MODEL E-2 7 9 10 12 17 --

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3.7 CONTROL PANELS
CONTROL LINE PRESSURE
The hydraulic control pressure is supplied by an air driven pump, which has a manual over-ride in the event of loss of air
supply pressure. Hydraulic control line pressure is dumped when the pilot line pressure falls below 40 psi, to close the
safety valve. It can also be dumped directly from the control panel by pressing an "Emergency Stop Button" on the panel
front.
The ESD unit has a self contained reservoir and is constructed of stainless steel.
SAFETY FEATURES
1. The pumps are fitted with a relief valve on the pump output line to limit hydraulic pressure to 6,000 psi.
2. An air pressure relief valve situated in the air line prior to the air driven pump. This valve prevents the pump from
generating output pressure in excess of 7,000 psi.
ESD SYSTEM CHECK
The ESD control panel must be checked before use offshore/onshore and at regular intervals throughout the well test. To
ensure the safety system is operable in an emergency. Refer to sections 3.7.1 and 3.7.2 below, for closing and opening
procedures of the two types of ESD circuits.
3.7.1 RESATO SPP-10 CONTROL PANEL
TO CLOSE THE HYDRAULICALLY ACTUATED SAFETY VALVE
1. Push in on the handle of the three-way pneumatic relay valve on the control panel. This exhausts gas
from the diaphragm of the three-way hydraulic valve, which is designed to block pump output pressure
and release hydraulic pressure on the safety valves back to the reservoir.
NOTE: The activation of any pilot or remote ESD device connected to the pilot line of the manifold is designed
to cause the same reaction as the above and cause the safety valve to close. Loss of hydraulic
pressure or loss of supply gas pressure should also cause the safety valve to close.
OPEN HYDRAULICALLY ACTUATED VALVES
1. Turn on air supply to manifold and check air supply pressure.
2. Turn pump regulator clockwise to build supply pressure on the pump supply gauge. Increase supply
pressure to build up the desired hydraulic output pressure for the safety valve. This is read on the pump
output pressure gauge.
3. Turn pilot line regulator clockwise to build pressure on the pilot system. This pressure may be monitored
on a gauge located above the regulator marked "Pilot Supply Pressure". The pressure must be set from
45 PSI to 100 PSI.
NOTE: At this point, hydraulic pressure is available to the three- way control valve, and control pressure is
available to the three-way pneumatic relay valve on the control panel. The manifold is ready to open
the safety valves.
4. Pull the handle of the pneumatic relay valve marked "Push to Close-Pull to Reset". This must be held
until at least 40 PSI is shown on the Pilot line gauge. If desired, The pump handle may be inserted
under the handle of the pneumatic relay valve to hold it open. Pilot line pressure cannot build up until all
pilots are in service and all remote ESD devices in the closed position. When the handle of the
pneumatic relay is pulled to the out position, pneumatic pressure is supplied to the diaphragm of the
hydraulic control valve causing it to admit hydraulic pressure to the safety valves, and the pumps should
start cycling to open the safety valves.
5. Once the safety valve is open and pilots go into service, pressure should build on the pilot line gauge.
When this pressure is above 40 PSI, the handle of the pneumatic relay valve may be released, and it
will stay in the out position.

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Page 2 of 2
3.7 CONTROL PANELS
NOTE: The safety system is not in service with the manual over-ride engaged. When pilots got into service and
pilot pressure is available, pull the handle of the pneumatic relay valve to the OUT position and pull the
over-ride handle out. Now the safety system should be in service.
3.7.2 HYDRATRON SINGLE CIRCUIT ESD UNIT
TO CLOSE THE HYDRAULICALLY ACTUATED VALVES
1. Push the RED 'Emergency Shut Down Button' on panel front.
OPEN HYDRAULICALLY ACTUATED VALVES
1. Release the 'Emergency Shut Down' on panel front by twisting.
2. Press and hold in 'System Start/Reset Button' on the panel until the pilot line is charged enough to
maintain the main air control valve in open position and close hydraulic dump valve.
NOTE: This pressure is pre-set at the manufacturers factory and is 5 psi higher than pressure
required to open main air control valve to ensure system start up.
If pressure on pilot line gauge falls repeat step 2.
3. Wind pump air pressure regulating valve slowly clockwise until desired hydraulic system pressure is
achieved (indicated on 'Pump output Pressure Gauge').
NOTE: The pump will stall out, but should the hydraulic system pressure fall it will stroke and attempt to
maintain hydraulic set pressure.
4. To restart the pump after an ESD activated shutdown, ensure the emergency stop button is twisted until
released (if button was used to initiate shutdown), or remote ESD station is reset to closed position.
The valve can now be opened following steps from 1 onwards.

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Page 1 of 1
3.8 SURFACE SAFETY VALVES
The Surface Safety Valve is designed as an additional safety device to the actuated flow-wing on the tree. It is a hydraulic
pressure controlled valve similar to the actuated flow-wing and is normally controlled by a control panel situated near the
Well Test Equipment or a pressure pilot. Shut-down will be initiated manually from this panel by a member of the Well
Test crew or by well parameters going outside of the preset pilot pressure.
The Surface Safety Valve is normally situated upstream of the choke manifold and tied into a low pressure pilot, but can
also be used downstream of the choke manifold, upstream of the heater to protect from pressure surges.
This valve is intended purely as a safety device and it is not recommended to be used in the pressure testing of
surface equipment.
1. The actuated surface safety valve can be operated in the same way as an actuated valve on the surface test tree,
i.e. it can be closed in manually at the control panel or by remote shutdown.
NOTE: In the case of a remote shutdown, the type of shutdown will depend on well conditions ie. on over-pressure
situation or an under-pressure situation.

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Page 1 of 5
3.9 COFLEXIP HOSES
Coflexip hoses have many advantages over conventional pipework in that they can come in longer sections, give better
resistance to corrosion and low restrictions to fluids passing through them, eg. no elbows in-line, they also offer a wider range
of physical and mechanical characteristics. They do, however, also have many disadvantages due to the nature of the
restrictive space often found offshore and the fact that they can be hard to handle during hook-up.
Coflexip hoses are basically composed of steel and thermoplastic materials. The steel components act as armour and also
give the mechanical resistance required to withstand the rigours of work, ie. the resistance to pull, the high burst pressure, etc.
These components are not leakproof and it is the thermoplastic inner sheath that provides this.
A typical pipe structure comprises the following components:
1. INNER TUBE (Thermoplastic Sheath)
The functions of the internal thermoplastic sheath are:
a) to make the pipe leakproof
b) to resist abrasion and corrosion
2. PRESSURE ARMOUR (Interlocked Zeta Layer)
The main function of the interlocked Zeta wire layer is to sustain the radial loads due to the inner pressure.
3. INTERMEDIATE THERMOPLASTIC SHEATH
This component is necessary whenever the pipe structure is intended for subsea service in rigorous conditions. Its
purpose is to prevent the internal sheath from collapsing in the event of damage to the external sheath.
4. TENSILE ARMOURS
The functions of the crosswound tensile armours are:
a) to resist axial load.
b) to protect the pipe from torsional strain resulting from handling and working conditions.
5. EXTERNAL THERMOPLASTIC SHEATH
The functions of the external polyethylene sheath are:
a) To protect the metallic layers of the structure against external corrosion or abrasion.
b) To bind the underlying tensile armour.
6. OUTERWRAP CARCASS
The main function of the outerwrap carcass is to protect the thermoplastic sheath against shocks.
NOTE: Water seeping from the outerwrap carcass does not necessarily mean that the integrity of the coflexip has been
damaged due to the fact that this carcass is constructed of a non bonded material which expands under pressure
allowing any fluids eg. rain, between this layer and the thermoplastic sheath to escape.
If, however, continuous seepage is observed, and a leak is suspected, then the hose should be isolated and the
pressure bled off. The hose should then be picked up, filled with water and any seeping water should be allowed to
drain away. It should then be observed if the water level drops.
If doubts still remain then the hose should be pressure tested with eg the chemical injection pump (taking extreme
caution) to ascertain it's integrity. (By testing with the chemical injection pump, liquid volumes are kept to a minimum
and any other possibly leaking valves are removed from the test. Any broken pipework connections during these
operations should be re-pressure tested also before re-opening the well flow.

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Page 2 of 5
3.9 COFLEXIP HOSES
7. END COUPLINGS
These are designed to retain all the mechanical characteristics of the COFLEXIP hoses with a substantial safety
margin. They are internally flush and can be fitted with any type of standard connection such as flanges, hubs,
unibolts, etc.
They consist of 2 sections:-
a) The termination which ensures the seal and the mechanical attachment of the end-fitting to the flexible pipe.
b) The connector to allow the connection of the end fitting to other pipework, etc.
HIGH PRESSURE/TEMPERATURE COFLEXIP HOSES
The coflexip hoses used for high pressure / temperature applications differ from the standard in that the INNER TUBE is
constructed of COFLON and not RISLAN.
As in all high pressure / temperature pipework used by EXPRO, the end connections of the coflexip are fitted with clamp
connectors to provide a metal-to-metal sealing face.
There are two types of coflexip in use (DST and PTL) and it is critical that this must be checked before hook-up. (refer to
Section 3.9 for a list of all coflexip hoses in service with EXPRO.)
DST lines are designed only for temporary exposure to sour service, which for each individual test should not exceed 72
hours.
PTL lines are designed for a permanent exposure to sour service and should be used where the test period will be longer
than 72 hours.
Refer to Fig. 3.15 TYPICAL COFLEXIP HOSE STRUCTURE

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Page 3 of 5
3.9 COFLEXIP HOSES
TABLE 3-2 RISLAN HOSES
CHARACTERISTICS
I.D.
O.D.
WEIGHT lbs/ft
MINIMUM BEND RADIUS (STORAGE) ft
MINIMUM BEND RADIUS (IN SERVICE) ft
NORMAL DAMAGING PULL STRAIGHT LINE lbs
PRESSURES
MAXIMUM WORKING PRESSURE psi

MAXIMUM HYDTROSTATIC TEST PRESSURE psi
NOMINAL BURSTING PRESSURE psi
DIFFERENTIAL HYDROSTATIC COLLAPSE psi
TEMPERATURES
CONTINUOUS USE TEMPERATURE RANGE - to + F

SHORT DURATION TEMPERATURE RANGE - to + F
Where hoses are expected to be in service with flowing temperatures exceeding 220F then
a COFLON hose should be used instead of the RISLAN.
CHEMICAL RESISTANCE
The hose will have resistance to the following substances throughout the temperature range.
- -
- -
- -
- -
END CONNECTIONS
Grayloc metal-to-metal connections or hammer unions are used.

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Page 4 of 5
3.9 COFLEXIP HOSES
TABLE 3-3 COFLON HOSES
CHARACTERISTICS
I.D. 2.84
O.D. 5.83
WEIGHT 39 lbs/ft
MINIMUM BEND RADIUS (STORAGE) 3 ft
MINIMUM BEND RADIUS (IN SERVICE) 5.4 ft
NORMAL DAMAGING PULL STRAIGHT LINE 430,000 lbs
PRESSURES
MAXIMUM WORKING PRESSURE 15,000 psi

MAXIMUM HYDTROSTATIC TEST PRESSURE 22,500 psi
NOMINAL BURSTING PRESSURE 36,650 psi
DIFFERENTIAL HYDROSTATIC COLLAPSE 21,750 psi
TEMPERATURES
CONTINUOUS USE TEMPERATURE RANGE - 4 to + 266F

SHORT DURATION TEMPERATURE RANGE -4 to + 293F
Where hoses have been in service when flowing temperatures have exceeded 220F then a
record will be made on the equipment status sheet and at the end of the job passed on to
the QA Department
CHEMICAL RESISTANCE
The hose will have resistance to the following substances throughout the temperature range.
- Most acids and Bases - Salts

- Oxidising Agents - Halogens
- Alchols - Chlorinated solvents
- Alphatic hydrocarbons - Crude oil
For high temperature applications the hose will, however, be non-resistant to the following
substances
- Amins - Concentrated Sulphuric

and Nitric Acids
- Sodium hydroxide - Ketones
- Esters - Dimethylacetamide
- Dimethylformamide - N-methylpyrrolidon

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3.9 COFLEXIP HOSES
TABLE 3-4 LIST OF HOSES IN SERVICE
TX-No. TYPE END PRESSURE LENGTH I.D

CONNECTION RATING
138-1 PTL 3 FIG 602 10,000 3

138-2 PTL 3 FIG 602 10,000 30 3
138-3 PTL 3 FIG 602 10,000 47 3
138-4 PTL 3 FIG 602 10,000 3
138-5 PTL 3 FIG 602 10,000 45 3
138-12 PTL 3 FIG 1502 10,000 60 3
138-13 NO LONGER
IN SERVICE
138-14 G-LOC 10,000 3
138-15 PTL 3 FIG 602 10,000 45 3
138-16 PTL 3 FIG 1502 10,000 50 3
138-17 PTL 3 FIG 1502 10,000 50 3
139-1 PTL 2 FIG 1502 10,000 30 2
191-1 DST 3 FIG 602 5,000 30 2.5

191-2 DST 3 FIG 602 5,000 30 2.5
195-1 PTL 3 FIG 602 5,000 30 3

195-3 PTL 3 FIG 602 5,000 30 3
256-1 PTL 3 FIG 2202 15,000 30 2.5
267-1 PTL 3,000 25 6

267-2 PTL 3,000 22 6
267-3 PTL 3,000 22 6
267-4 PTL 3,000 22 6
267-5 PTL 3,000 22 6
273-1 PTL 3 FIG 2202 15,000 45 2.5

273-2 PTL 3 FIG 2202 15,000 45 2.5
273-3 PTL 2F/3M 1502 15,000 40 2.5
273-4 PTL CAM HUB 15,000 40 2.5
319-1 PTL 4 FIG 1502 10,000 4
624-1 PTL G-LOC 4-GR34 5,000 100
632-1 PTL 15,000 60 2.5

632-2 PTL 15,000 60 2.5
632-3 PTL 15,000 60 2.5
633-4 PTL 15,000 60 2.5
632-9 PTL 325HD Techlok 15,000 61 3

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3.10 PIPEWORK
3.10.1 MINIMUM ALLOWABLE WALL THICKNESSES
TABLE 3-5 MINIMUM ALLOWABLE WALL THICKNESS FOR A106B STEEL
psi psi psi psi psi

Nominal 1,440 2,160 5,000 10,000 15,000
2 Inch 2.1 3.2 6.9 8.9 12.2
3 Inch 3.1 4.6 10.1 13.1 17.1
4 Inch 4 5.9 13 16.8
5Inch 4.9 7.4 16.1 20.8
6 Inch 5.9 8.8 19.1 23.6
These thicknesses are worked out for the lowest schedule pipe used for each pressure rating. This obviously gives a
greater margin for error on heavier weight pipes, eg. XXS, but lessens the risk of operators miscorrectly grading pipework
to it's correct schedule.
3.10.2 THICKNESS CHECKING
1. Prior to flowing the well a baseline survey should be completed on the pipework from the flowhead via
both primary and secondary sand trap and choke systems, the dedicated clean up and the test system
lines up to the separator inlet.
2. Experience gained from previous clean-ups has shown that the areas most at risk from cut-outs are
immediately downstream of a choke, especially the sacrificial choke on the boom, and after periods of
turbulent flow (ie after bends).
3. During a clean-up it is impractical to measure the thickness downstream of the sacrificial choke to the
formation of hydrates at this point. This should be measured after switching flare booms or during a shut-
in period.
4. To reduce turbulent flow, flowlines are run with the minimum amount of bends. Points to be measured on
the pipework are close to either wing (where turbulent flow is most likely) and for 10' lengths a point
should be chosen in the middle section of the pipe.
5. Where to take thickness checks:-
TABLE 3-6 THICKNESS CHECKING
Wing End Thread End Mid Section Bend Target
10 Flowline X X X
5 Pup X X
Target Tee X X X
Lateral Tee X X X
Elbows X
6. While measuring the baseline survey, the points should be marked and numbered on the pipework and a
log should be started for each point. This log should be updated as each survey is completed and include
the time and date that the survey was carried out.
When carrying out a new survey several points around the pipes circumference should be checked (but
not necessarily logged) to compare with the marked point.
The amount of surveys carried out will be dependent on the amount of sand returned and may vary from
hourly to twelve hourly. This will also depend on the availability of Well Test personnel from carrying out
other duties.

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3.10 PIPEWORK
7. During a clean up the pipe thickness found on each survey should be checked against the Minimum
Allowable Wall Thickness Table to ascertain if the wall thickness is nearing a critical stage for
replacement.
8. If a pipe has to be replaced then it should be clearly marked on the pipe where the thin spot is and a note
made on the equipment status report form.
3.10.3 HAMMER UNIONS
The hammer union used by EXPRO is typically a Weco Union.
The basic design of hammer unions is a ball and cone seat system with the 'male' and 'female' mating together to
provide the seal. The male section of the union has the ball and a wing nut and the female section has the cone
with Acme threads. The two halves of the union are simply screwed together and made tight, requiring only a
hammer, or in the case of the Fig.100, a bar.
Refer to Fig. 3.16 HAMMER UNION MATING PARTS
For higher pressure applications an elastomeric lip type seal ring is provided on the female (thread) union. This
helps to facilitate a seal where the flowlines are slightly misaligned.
All parts of the same size and pressure rating are interchangeable and can be made up and broken out with
minimal maintenance.
The key to identifying Weco unions is in the Figure (Fig.) that they are given.
TABLE 3-7 TYPICAL RANGE OF UNIONS USED BY EXPRO
UNION MAWP (COLD) MAWP (COLD) COLOUR

STANDARD H2S SERVICE CODE
SERVICE
Fig. 200 2,000 N/A Blue
Fig. 206 2,000 N/A Blue
Fig. 602 6,000 4,000 Yellow
Fig. 1002 10,000 7,000 Red
Fig. 1502 15,000 10,000 White
Fig. 2202 N/A 15,000 Purple
Where a union is described as having a 2 on the end of the Fig. eg. Fig. 602. The 2 is referring to the fact that the
union has a seal ring fitted and is not only a metal-to-metal seal.
The Fig. 206 union has an "O"-ring fitted to improve the sealing qualities and protect the metal-to-metal seal
against corrosion.
Care must be taken when connecting Weco union halves together as it is possible to connect two differing unions
together eg. a Fig. 1002 and a 1502, where they look as though they are properly connected but may blow apart
under pressure. Each piece of pipework has a metal band around it detailing information about the pipe.
The metal bands on pipework should be checked prior to rigging up unions where it is not known if they
are compatible.

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3.10 PIPEWORK
3.10.4 CLAMP CONNECTIONS
Clamp connectors are a self-energising, metal-to-metal seal designed to withstand the severest conditions of
working environment such as corrosive and erosive elements and high and low temperatures. They are a high
pressure, low weight alternate to flanges and once made up properly are comparable to a welded joint in sealing
integrity.
Each connector has three components:-
1. A metal seal ring.

2. Metal hubs.
3. Clamp assembly.
Refer to Fig. 3.17 CLAMP CONNECTOR COMPONENTS
ASSEMBLY
1. Hub & sealring seating surfaces must be clean & free from foreign matter. Damage to hub seats is not
acceptable, & should be rectified before assembly. Align the hubs so that the seal ring can be installed
between the hubs.
2. Usually sealrings are coated which acts as lubricant during make up. If required light oil or MoS2 can be
used. Take care that no solid particles are present in the lubrication. Install the seal ring in the sealing
surface of the hubs.
NOTE: The seal ring should 'rock' slightly (i.e. the seal ring rib should not be able to firmly contact the hub face. If
it does not 'rock' replace the seal ring).
3. Install the clamps around the hubs. Apply lubrication to the hub-clamp contact area to reduce friction.
This will aid assembly.
4. Insert the stud bolts into the clamp ear holes. Install the nuts, ensuring the spherical surfaces of the nuts
and the clamps are in proper position for mating. Lubrication of the studs and the spherical faces of the
nuts and the clamp is recommended.
5. Tighten the studs in a criss-cross pattern (i.e. bolt #1, #3, #2 and #4) to keep the spacing between the
clamp halves approximately equal.
6. To properly pre-load the connector against gasket loads, fluid pressure loading, thermal shock loading
and pipe reaction loads, the studs should be torqued to the values shown in table below.

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3.10 PIPEWORK
LUBRICATED UNLUBRICATED
Ft-Lbs Nm Ft-Lbs Nm
STANDARD CLAMP SERIES
1 17 23 26 35
1 35 47 53 71
2 55 75 83 112
3 60 81 90 122
4 90 122 135 183
5 140 190 210 285
6 200 271 300 407
8 300 407 450 610
LIGHT DUTY SERIES
L14 650 881 975 1322
L16 900 1220 1350 1830
L18 1200 1627 1800 2440
L20 1300 1762 1950 2644
L24 1850 2506 2775 3762
HEAVY DUTY
H2 90 122 135 183
H3 100 136 150 203
H4 140 190 210 285
H8 390 529 585 793
H10 600 813 900 1220
H12 900 1220 1350 1830
H14 1200 1627 1800 2440
H16/H18/H20/H22/H24/H26 2000 2711 3000 4067
NOTE: For all bolt sizes a torque wrench is recommended to ensure that the minimum pre-load values are met.
Assembly should include jarring the clamps during the bolting process, ie a sound blow to the back of the
clamp with a soft hammer (torque, jar, torque, jar etc) until bolt torque does not change after jarring.
7. At full make-up the hub faces will shoulder flush against the seal ring rib. The seal ring rib will prevent
over torqueing & seal damage.
NOTE: To prevent permanent damage from distortion to other components of the connection, maximum torque
applied should not exceed twice the values shown in the table.
The connector should not be tightened while under pressure loading or severe mechanical loads.
DISASSEMBLY
1. Ensure all pressure in process lines is bled off to zero prior to breaking out lines. (Always check! Never
take for granted that the line has been de-pressurised.)
2. Slacken nuts but do not remove from the studs then slacken clamp segments. Gradually run nuts back
along the studs until just loose. If clamp segments remain bound onto hubs, then BOTH segments must
be slackened by hitting the inner face clamp with a suitable hammer (soft headed).
3. Once certain no trapped pressure, remove studs and clamp connection.

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3.10 PIPEWORK
3.10.5 FLANGES
The most commonly used flanges are:-
1. Weld neck flange

2. Slip-On Welding flange
3. Threaded flange
4. Blind flange
5. Reducing flange
Flanges are currently sized by one of two standards, either as API or ASA this information is usually stamped on
the outer edge of the flange.
API Rated Flanges
Working pressures of equipment components were at one time referred to by an API series designation such as
series 600 - meaning a working pressure of 2000 psi. These series designations have been discontinued and
replaced with more easily remembered terms indicating the actual allowable cold- working pressures in psi.
Standard API cold working pressure ratings, test pressure ratings and the corresponding former series
designation are listed below:-
TABLE 3-8 API RATED FLANGE PRESSURE RATINGS
Pressure PSI Series Designation

960 1,440 Series 400
2,000 4,000 Series 600
3,000 6,000 Series 900
5,000 10,000 Series 1500
10,000 15,000 Series 2900*
15,000 22,500
* The series 2900 flange is now obsolete.
The maximum working pressure is the maximum operating pressure to which the equipment should be subjected.
The hydrostatic test pressure is the static body test pressure imposed by the manufacturer to prove adequacy in
design, materials and workmanship. Equipment should never be subjected to pressures above the recommended
working pressure.
ASA Rated Flanges
The ASTM (American Society of Testing Materials) define the specifications of steel used for the manufacture of
ASA flanges.
ASA flanges are manufactured in steels of varying quality:-
1. carbon steel
2. stainless steel
3. nickel steel, etc.
There are seven series of ASA flanges:-
- ASA 150, 300, 400, 600, 900, 1500 and 2500.
The values of maximum cold working pressure in the different series are as follows:-

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3.10 PIPEWORK
TABLE 3-9 ASA RATED FLANGE PRESSURE RATINGS
SERIES MAX. WP IN PSI
ASA 150 275

ASA 300 720
ASA 400 960
ASA 600 1,440
ASA 900 2,160
ASA 1500 3,600
ASA 2500 6,000
Except for ASA 150 series the MAWP in psi corresponds to the series number multiplied by a factor of 2.4.
e.g. ASA 300 series - MAWP = 2.4 x 300 = 720 psi

ASA 900 = 2.4 x 900 = 2160 psi
The hydrostatic test pressure for ASA flanges is 1.5 times the working pressure (to the nearest 25 psi).
ASA flanges of different series can be identical from the point of view of dimensions or can be assembled even if
all their dimensional characteristics are not the same. This however does not apply to small diameter flanges.
NOTE: The two different standards are interchangeable providing the MAWP is lowered to the lesser pressure
rating as detailed below.
eg. An API 2000 flange can be assembled on an ASA 600 flange but since the ASA flange is made of
steel with inferior mechanical characteristics than those of the API flange steel then the MAWP of the ASA
flange is less than that of the API flange.
An ASA 900 can match with an API 3000 but with MAWP = 2160 instead of 3000, and ASA 1500 can match with
an API 5000 to give MAWP = 3600 instead of 5000 psi.
When describing a flange the following should be indicated.
1. Nominal diameter
2. API or ASA
3. Number of series
4. Type of flange
5. Type of face or gasket
6. Bore if necessary
7. Threading if necessary
8. Steel type for ASA flange
TO AVOID MISTAKES WHEN USING FLANGES
1. Use API flanges ONLY for wellheads
2. ASA for surface connections (except when necessary to match with equipment with API flanges)
3. Use flat gaskets up to ASA 300 series
4. Use RTJ gaskets from ASA 400 series
There are two common types of sealing faces on flanges:-

1. Raised face (RF)

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3.10 PIPEWORK
2. Ring Joint (RTJ)
The raised face flange uses a flat gasket, common type spiral wound, for sealing between flange faces whereas
the RTJ uses a soft metal ring for sealing. The RTJ is less likely to leak and is often preferred in high pressure
situations or in large diameter piping.
NOTE: API flanges only use RTJ gaskets while ASA flanges may have RTJ or flat gaskets.
There are four different types of ring gasket available, identifiable by differing shapes. The types are:-
1. type R oval
2. type R octagonal
These type 'R' ring joints are bolt compression seals and rely solely on bolt torque for sealing.
3. type RX
4. type BX
The 'RX' and 'BX' ring joints are pressure energised seals ie. the process line pressure acts internally on the ring
joint via a centerline hole, in addition to bolt torques, to aid sealing and combat failures from vibrations, test-load
shocks, etc.
HOW THEY SEAL
Both type 'R' RTJ gaskets seal only by compression on them applied through the action of bolt torque on the
flange. This often caused dangers if the bolts were subject to vibration or other external loading.
When using an oval RTJ the curved surface of the soft RTJ is mated to the flat surfaces of the hard flanged
groove. As bolt torque is applied, this caused a small flat to be pressed on the curved section of the oval ring. The
size of this flat depends on the bolting make-up tightness.
When bolting up this type of RTJ in a flange, by the time all bolts have been tightened, the first is often loose and
it requires that the bolts are tightened in sequence several times to reach a stable condition.
RX RINGS
To overcome these problems the type 'RX' RTJ was developed. This gasket has large flats which mate with the
standard flange groove preparations. As the flange is made-up, the flats on the outside diameter of the RTJ come
into contact with the flange groove first. This causes the gasket to be pre-loaded against the groove's outer
surfaces as the flanges are brought together.
This preloading is stopped when the RTJ's inner surface comes into contact with the inner surface of the groove.
This ensures proper alignment and offers maximum resistance to external forces.
The self sealing comes into effect when pressure is applied to the process lines, a center-line hole allows process
pressure to act internally on the RTJ to further compress the gasket against the sealing edge of the gasket
groove.
During tests it was found that to have a self sealing effect the height to width ratio of the gasket must be 3 to 1 or
greater.
NOTE: The gasket should be installed with the large side flats towards the outside edge of the flange.
Bolts need only be tightened once to preload the gasket and start the self sealing effect.
BX RINGS
Another type of RTJ, the 'BX' has been adopted by API for high pressure applications. Like the 'RX' this is a self
sealing gasket that is pre-loaded under the action of tightening up the flange. The gasket also has a center-line
hole to allow for a self sealing effect.

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3.10 PIPEWORK
NOTE: Unlike the other flanges using 'R' and 'RX' RTJ's the API 6BX flange that uses this RTJ is designed to
make-up FACE-TO-FACE at the raised portion of the flange.
The 'BX' is not interchangeable with other types of RTJ gaskets.
The ring gasket size is stamped on each flange.
ONCE A TYPE 'RX' OR 'BX' GASKET HAS BEEN USED THEN IT SHOULD NOT BE RE-USED IF THE
CONNECTION IS BROKEN APART.
Refer to Fig. 3.19 FLANGE MAKE-UP SEQUENCE

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3.10 PIPEWORK
3.10.6 RELIEF LINE CAPACITIES
TABLE 3-10 PIPELINE CAPACITIES (mmscf/d) FROM HIGH PRESSURE RELIEF VALVES
Maximum allowable back pressure 740 psig

Temperature 200F
Bend 50 Ft 60 Ft 70 Ft 80Ft 90 Ft 100 Ft 120 Ft

s
3 4 72.93 69.42 67.98 64.68 62.63 60.81 57.46
6 70.03 67.5 65.18 63.07 61.23 59.42 56.94
8 68.03 65.7 63.52 61.62 59.82 58.16 55.9
10 66.24 70 62.03 60.22 58.51 56.98 54.94
12 64.47 62.46 60.64 58.88 57.91 55.9 53.44
14 62.89 61.06 59.27 57.67 56.21 54.89 52.61
16 61.47 59.57 58.01 56.53 55.18 53.96 51.81
4 4 135.01 130.47 126.32 122.54 119.23 116.9 110.72
6 130.39 126.24 122.47 119.17 116.25 113.94 108.24
8 126.17 122.4 119.11 116.19 113.28 110.61 105.96
10 122.93 119.04 116.14 113.22 110.56 108.16 103.67
12 118.98 116.08 113.17 110.51 108.1 105.87 101.56
14 116.03 113.11 110.46 108.07 105.82 103.58 99.6
16 113.06 110.41 108.01 105.77 103.54 101.47 97.78
6 4 338.41 328.78 320.24 312.60 305.74 299.54 288.94
6 324.08 316.04 308.83 302.54 296.45 290.97 280.97
8 312.08 305.27 299.11 293.51 287.94 282.66 279.28
10 301.89 296.04 290.54 285.07 280 275.33 266.96
12 293.13 287.54 282.3 277.46 272.97 268.8 261.09
14 284.68 279.66 275 27.69 266.68 262.94 255.26
16 277.11 272.66 268.51 264.65 260.8 256.96 249.92
8 4 621.18 608.52 597.11 585.21 573.73 563.17 544.4
6 596.75 584.81 573.36 562.84 553.12 544.12 527.97
8 573 562.5 552.8 543.83 535.49 527.72 513.68
10 552.49 543.54 535.22 527.47 520.24 513.47 499.82
12 534.96 527.22 520 513.25 506.31 499.61 487.29
14 519.77 513.03 506.08 499.39 493.07 487.10 476.07
16 505.86 499.17 492.87 486.9 481.27 475.9 465.97

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3.10 PIPEWORK
TABLE 3-11 PIPELINE CAPACITIES (mmscf/d) FROM HEAT EXCHANGER

Temperature 150F

s
3 4 11.4 11 10.6 10.2 9.9 9.6 9.1
6 11.1 10.7 10.3 10 9.7 9.4 8.9
8 10.8 10.4 10 9.7 9.5 9.2 8.7
10 10.5 10.1 9.8 9.5 9.3 9 8.6
12 10.2 9.9 9.6 9.3 9.1 8.8 8.4
14 9.9 9.7 9.4 9.1 8.9 8.7 8.3
16 9.7 9.4 9.2 8.9 8.7 8.5 8.2
4 4 21.3 20.6 20 19.4 18.8 18.4 17.5
6 20.6 20 19.4 18.8 18.4 17.9 17.1
8 19.9 19.4 18.8 18.4 17.9 17.5 16.8
10 19.3 18.8 18.4 17.9 17.5 17.1 16.4
12 18.8 18.4 17.9 17.5 17.1 16.7 16.1
14 18.3 17.9 17.5 17.1 16.7 16.4 15.7
16 17.9 17.5 17.1 16.7 16.4 16 15.5
6 4 53.4 52 50.6 49.4 48.3 47.3 45.5
6 51.2 50 48.8 47.8 46.9 46 44.3
8 49.3 48.3 47.3 46.4 45.5 4.6 43.2
10 47.7 46.8 45.9 45.1 44.3 43.5 42.2
12 46.3 45.5 44.6 43.9 43.1 42.5 41.3
14 45 44.2 43.5 42.8 42.2 41.6 40.4
16 43.8 43.1 42.4 41.8 41.2 40.6 39.5
8 4 98.2 96.2 94.4 92.5 90.7 89 86.1
6 94.3 92.5 90.6 89 87.4 86 83.5
8 90.6 88.9 87.4 86 84.7 83.4 81.2
10 87.3 85.9 84.6 83.4 82.2 81.2 79
12 84.6 83.3 82.2 81.1 80 79 77
14 82.2 82.2 980 78.9 77.9 77 75.3
16 80 78.9 77.9 77 76.1 75.2 73.7

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3.10 PIPEWORK
TABLE 3-12 PIPELINE CAPACITIES (mmscf/d) FROM SEPARATOR

Temperature 80F

s
3 4 30.7 29.5 28.4 27.4 26.6 25.8 24.4
6 29.7 28.6 27.7 26.8 26 25.2 23.9
8 28.9 27.9 27 26.2 25.4 24.7 23.5
10 28.1 17.2 26.3 25.6 24.8 24.2 23.1
12 27.4 26.5 25.7 25 24.3 23.7 22.7
14 26.7 25.9 25.2 24.5 23.9 23.3 22.3
16 26.1 25.3 24.6 24 23.4 22.9 22
4 4 57.3 55.4 53.6 52 51 49.4 47
6 55.3 53.6 52 50.6 49.3 48.1 46
8 53.5 51.9 50.5 49.3 48.1 46.9 45
10 51.9 50.5 49.3 48 46.9 45.9 44
12 50.5 49.3 48 46.9 45.9 44.9 43.1
14 49.2 48 46.9 45.9 44.9 44 42.3
16 48 46.9 45.8 44.9 43.9 43.1 41.5
6 4 143.6 139.5 135.9 132.7 129.7 127.1 122.4
6 137.5 134.10 131.10 128.3 125.8 123.5 119
8 132.4 129.5 126.9 124.6 122.2 120 116
10 128.10 125.6 123.3 121 118.8 116.8 113.3
12 124.4 122 120 117.7 115.8 114.10 110.8
14 120.1 118.7 116.7 114.9 113.2 111.6 108.3
16 117.6 115.7 113.9 112.3 110.7 109 106.1
8 4 263.6 258.2 253.4 248.4 243.5 239 231
6 253.2 248.2 243.3 238.8 234.7 230.9 224.1
8 243.2 238.7 234.6 230.8 227.3 223.9 218
10 234.5 230.7 227.10 223.8 220.8 217.9 212.1
12 227 223.7 220.7 217.8 214.9 212 206.8
14 220.6 217.7 214.8 211.9 209.3 206.7 202
16 214.7 211.8 209.2 206.6 204.2 201.9 197.7

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3.10 PIPEWORK
TABLE 3-13 PIPELINE CAPACITIES (mmscf/d) FROM SURGE TANK

Temperature 60F

s
3 4 4.8 4.6 4.5 4.3 4.2 4.1 3.8
6 4.7 4.5 4.4 4.2 4.1 4 3.8
8 4.5 4.4 4.2 4.1 4 3.9 3.7
10 4.4 4.3 4.1 4 3.9 3.8 3.6
12 4.3 4.2 4 3.9 3.8 3.7 3.6
14 4.2 4.1 3.9 3.8 3.7 3.7 3.5
16 4.1 4 3.9 3.8 3.7 3.6 3.5
4 4 9 8.7 8.4 8.2 8 7.8 7.4
6 8.7 8.4 8.2 7.9 7.8 7.6 7.2
8 8.4 8.2 7.9 7.7 7.6 7.4 7.1
10 8.2 7.9 7.7 7.5 7.4 7.2 6.9
12 7.9 7.7 7.5 7.4 7.2 7.1 6.8
14 7.7 7.5 7.4 7.2 7.1 6.9 6.6
16 7.5 7.4 7.2 7.1 6.9 6.8 6.5
6 4 22.6 21.9 21.4 20.9 20.4 20 19.2
6 21.6 21.1 20.6 20.2 19.8 19.4 18.7
8 20.8 20.4 20 19.6 19.2 18.9 18.2
10 20.1 19.7 19.4 19 18.7 18.4 17.8
12 19.6 19.2 18.8 18.5 18.2 17.9 17.4
14 19 18.7 18.3 18.1 17.8 17.5 17
16 18.5 18.2 17.9 17.7 17.4 17.1 16.7
8 4
6
8
10
12
14
16

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3.11 TWIN POT SAND FILTERS
3.11.1 EQUALISING POTS
ASSUMPTIONS:
a) A flexible hose has been run from the top of the sand filter pot to the redundant line on the oil manifold
for venting purposes while flowing via the dedicated clean-up line. This hose should be isolated when
not in use. Alternatively a "Boyer" tube has been hooked-up to the top of pot cap.
b) When Flow is diverted via the test system then this hose must be rigged down and if required to vent
the sandfilters then this should be done by means of a vent tube, i.e. a 3/8" Stainless Steel liner rising
vertically from the top of the pot.
1. Open equalising line valves in the order, valve nearest the vessel first followed by sacrificial valve.
2. Pressurise pot up to +/- 200 psi.
3. Close equalising line valves in reverse order, i.e. sacrificial valve first
4. Vent down standby filter pot to zero.
5. Open equalising line valves as step 1.
6. Pressurise standby vessel slowly to full well pressure.
7. When pressure gauge confirms balanced pressure, close the equalising valves in reverse order.
3.11.2 DIVERTING FLOW VIA DUTY STANDARD POT
each filter pot closed.
2. Slowly pressurise one filter pot to line pressure.
3. Open filter pot inlet valve.
4. Open filter pot outlet valve.
5. Slowly close bypass valve. It is not recommended to reopen this valve during clean up due to the risk of
sanding up.
6. Note differential pressure on Barton (if any) - this is initial clean up and will be dependant on gas flow
rate and liquid content.
7. An increasing differential pressure is indicative of the filter element filling with sand and it may be
necessary to switch to the standby filter pot.
NOTE: Excessive sand and fluid production will result in high D.P.'s and present a risk of filter damage. Under
these conditions time is at an essence and switching filters quickly most important.
3.11.3 SWITCHING FROM DUTY TO STANDBY POT (STANDARD) POTS
1. Slowly pressurise the standby filter pot to line pressure.
2. Open standby filter pot inlet valve.
3. Open standby filter pot outlet valve.
4. Close duty filter pot outlet valve.
5. Close duty filter pot inlet valve.
NOTE: The standby pot now becomes the duty pot and the duty pot now becomes the standby pot.
6. Pump 4 strokes of McEvoy sealant to closed valves.

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Page 2 of 7
7. Bleed off pressure in the chamber via the vent.
8. Remove cap and filter element. Remove, drain and flush body.
9. Empty proppant from used filter and weigh contents.
10. Install clean filter element and reinstall cap and drain.
11. Close vents.
12. Pressurise filter pot to line pressure.
13. If leaking, bleed off and rectify.
14. Equalisation line to be left open at all times until standby pot is utilised. Never leave filter pot isolated
under pressure.
3.11.4 DIVERTING FLOW VIA DUTY POT (DOUBLE BLOCK POT)
1. Filter with an appropriate mesh size suitable to the proppant size and liquid rate viscosity expected
should be installed in each filter pot prior to start up.
each filter pot closed.
3. Slowly pressurise one filter pot to line pressure.
4. Open filter pot upstream inlet valve.
5. Open filter pot downstream inlet valve.
6. Open filter pot downstream outlet valve.
7. Open filter pot upstream outlet valve.
8. Slowly close bypass valve. It is not recommended to reopen this valve during clean up due to the risk of
sanding up.
9. Note differential pressure on Barton (if any) - this is initial clean up and will be dependant on gas flow
rate and liquid content.
10. An increasing differential pressure is indicative of the filter element filling with sand and it may be
necessary to switch to the standby filter pot.
NOTE: Excessive sand and fluid production will result in high D.P.'s and present a risk of filter damage. Under
these conditions time is at an essence and switching filters quickly most important.
3.11.5 SWITCHING FROM DUTY TO STANDBY POT (DOUBLE BLOCK) POTS
1. Slowly pressurise the standby filter pot to line pressure.
2. Open standby filter pot upstream valve furthest from pot.
3. Open standby filter pot upstream valve closest to pot.
4. Open standby filter pot downstream valve furthest from pot.
5. Open standby filter pot downstream valve closest to pot.
6. Close duty filter pot downstream valve closest to pot.
7. Close duty filter pot downstream valve furthest from pot.
8. Close duty filter pot upstream valve closest to pot.

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9. Close duty filter pot upstream valve furthest from pot.
NOTE: The standby pot now becomes the duty pot and the duty pot now becomes the standby pot.
10. Pump 4 strokes of McEvoy sealant to closed valves.
12. Bleed off pressure in the chamber via the vent.
13. Remove cap and filter element. Remove, drain and flush body.
14. Empty proppant from used filter and weigh contents.
15. Install clean filter element and reinstall cap and drain.
16. Close vents.
17. Pressurise filter pot to line pressure.
18. If leaking, bleed off and rectify.
19. Equalisation line to be left open at all times until standby pot is utilised. Never leave filter pot isolated
under pressure.
3.11.6 DRAINING STANDBY POT
1. After vessel has been isolated (when pots have been switched), open double block vent valves in the
order upstream first, then downstream.
2. Once all pressure has been vented connect chain block line to eyelet on pot cap.
NOTE: If unable to vent the pot to a satisfactory level, due to valves leaking, then the filter assembly should be
taken out of service and changed out or have the valves serviced. The secondary system can be used,
if applicable, while the primary filter assembly is being changed out.
3. Back off pot cap nut a few turns and take strain on chain block line.
4. Tighten chain block line until cap moves upwards free of "o-ring" seal. (It may be necessary to tap the
cap to assist in working it free.)
5 Once "o-ring" seal has been broken back off the cap nut and work the nut upwards until hanging freely.
6. Swing the cap and nut over and rest on table. Remove chain block line.
7. Remove filter retainer.
8. Connect chain block line to filter carrier and hoist upwards, checking for splits or ruptures as the filter
rises.
9 A calibrated stick (or tape measure) should be lowered to find fill level of proppant in the filter. The
weight of proppant in the filter will approximately be:-
2.0lbs X the height in inches
This will depend on the density of the proppant returns and should be checked on the first filter dump
and any subsequent filters where the proppant density changes, eg. wet proppant dry proppant, by
weighing the entire filter contents.
NOTE: For low levels of proppant the contents of the filter should be dumped into a bucket and weighed.
10. Once filter clear of pot, either:-
a) Remove base plate and drop proppant in pot for removal through drain line (not recommended
for large quantities).
b) Swing filter over hopper and remove base plate to dump sand through overboard line.

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c) Remove base plate and drop contents of filter into a bucket for weighing.
The drain line bull plug of the pot should be broken out and any liquids that have collected be
dumped. Any proppant that has collected in the bottom of the pot should be retrieved and weighed prior
to dumping and this amount added to that of the proppant in the filter.
11. The empty filter should be washed outside and inside and an internal visual inspection of the filter
element should take place to check for splits etc.
12. Refit the base plate and the drain line bull plug and install the filter carrier in the pot.
13. Install filter retainer.
NOTE: Ensure retainer is installed the right way ie. with hole lined up with inlet.
14. Reconnect the chain block line to the eyelet on the cap and hoist cap and nut onto top of pot.
15. Once cap lined up, gently tap down with a hammer taking care not to 'nip' the "o-ring".
16. Turn the nut clockwise, taking care that it is not cross-threaded, and continue to tap the cap downwards
until it bottoms out.
17. Once nut home, back-off a quarter turn to make removal during the next dump.
18. Close vent valves and remove chain block line from cap. Pressure up the sand filter pot.
4-1/16" 10K DUAL ISOLATION SANDFILTERS - SINGLE POT
3.11.7 USING THE DUAL ISOLATION SYSTEM
All of the 10k psi sandfilters are fitted with dual isolation valves on the inlet and outlet of the vessel. Procedures
are slightly modified for pot changing when dual isolation is employed Referring to Fig 1.
1. Close outer isolation valves 1. then 2.
2. Bleed of pressure within the pot then close valves 3. & 4.
3. Monitor pressure gauge between the dual valves to ascertain the condition of valves 1. & 2.
4. Continue filter pot changing procedures as standard, (as long as no valve leakage is evident).
5. Prior to equalising the pot, assuming no leakage of the valves, open the inner isolation valves 3. & 4. of
the inlet and outlet.
6. Should pressure develop between 1. & 4. and 2. & 3. the inner valve must be pressure equalised prior
to opening.
7. Continue filter pot changing procedure as standard.
3.11.8 SWITCHING FROM DUTY TO STANDBY POT
1. While flow is through a pot that is required to be emptied, a secondary unit is made ready and pressure
equalised (only the inlet valve to the standby unit (second pot) is closed).
2. Open the inlet valve on standby pot (second pot), flow is now passing through both filter pots.
3.11.8 SWITCHING FROM DUTY TO STANDBY POT (CONT'D)
3. Close outlet then inlet valves on first pot.
4. Bleed of pressure from first pot, closing bleed off valves after de-pressurisation.
5. Monitor gauge pressure to ensure no pressure build-up.

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6. Disconnect hammer union blind caps (Fig 1. no. 5.) from inlet/ outlet flushing lines and attach flexible
flushing hoses.
7. Flush through the pot at 1,500 BPD (2" sandpiper output) until discharge is free of solids.
8. Open the upper valve to observe returns & close the outlet flushing line whilst pumping to fill the pot with
water. Repeat until the filter is sufficiently clean, inspecting the filter if necessary.
NOTE: It is necessary to fill the pot completely with water to ensure the filter screen is clean.
9. Once the filter screen is clean, stop flushing, disconnect flushing lines open and drain to release the
bulk of water and replace Hammer Union blind caps, then close drain.
10. Referring to fig 2. Open bleed off valve 3. and first pot isolation valves 4. on equalising line, ensuring
equalisation isolation valves on duty pot are closed.
NOTE: This operation will allow any water trapped in the vessel to drain via the equalisation line bleed off
valves.
11. Close equalising line bleed off and equalising valves.
12. Open secondary pot (currently in use) equalising line valves (first pot bleed off valve still open) briefly to
purge the first pot of trapped air.
13. Close first pot bleed off valves.
14. Open second pot equalisation line valves (first pot equalisation valves still open).
15. Pressurise first pot, ensuring pressure gauge of equalisation line is same as downstream filter pot
pressure.
16. Close equalisation line valves and bleed off trapped pressure.
17. Bleed off 20% of pressure in equalisation line.
18. Monitor equalisation line for any increase in pressure to ensure no leaks in equalisation valves.
19. Open equalisation valves of first pot, ensuring pressure returns to value obtained when pot was first
pressurised. This also ensures no blockage in equalisation line.
20. Close equalisation line valves and bleed off trapped pressure.
21. Open outlet valve of first pot, first pot is now clean and ready for duty.

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FIG 1. 4-1/16" 10K SAND FILTER (DUAL ISOLATION VALVES)
5.
3.
2.
INTLET OUTLET
4. 1.

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FIG 2. 4-1/16" 10K SAND FILTER (EQUALISATION VALVES)
3.
1. 2. 2. 1. DUTY
POT
4. ENSURE
STANDBY
VALVES ARE
POT ENSURE VALVE CLOSED FOR
IS CLOSED FOR DRAINING
EQUALISATION
BUT OPEN FOR
DRAINING

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Page 1 of 1
3.12 DATA HEADERS
Refer to Fig. 3.18 DATA HEADERS
NOTE: 15,000 psig data headers are fitted with Grayloc C-25 clamp connections and not hammer unions as shown
above and may have up to eight tappings on them.
During a well test it is necessary to accurately measure and record the pressure and temperature of the fluids produced
before they pass through the choke manifold by both manual and electronic means.
It is also desirable to have the ability to inject chemicals, such as hydrate inhibitors, demulsifiers, anti-foam agents etc.,
into the flowline and have a point for sampling from which the well effluents can be drawn for analysis.
The data header / flowline manifold, which is rigged up between the flowhead and the choke manifold provides the means
to accomplish these features.
5,000 and 10,000 psi data headers are normally constructed of line pipe tapped and fitted with 1/2" NPT half-couplings. A
3/4" NPT half-coupling is provided to tie in a temperature probe.
The end connections for the 5,000 psi data headers are 3" Fig. 602 hammer unions with the 10,000 psi data headers
being 3" Fig. 1502 hammer unions.
The common means of tying in the required pressure gauge / recorder / DWT is to make-up an instrument manifold in the
form of a 'T' (with suitable isolation valves) and to connect up to this.
For 15,000 psi well testing the data header is of solid block construction with 3" Grayloc clamp connections, the bore of
this data header is 2-9/16".
For high pressure / high temperature wells there should never be more than one instrument / recorder / pump / etc.
connected to a single tapping so instrument manifolds should not be made up.
The 15,000 psi data header should only be fitted with Autoclave fittings and valves which will be suitable for the expected
well parameters.

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3.13 CHOKES AND CHOKE MANIFOLDS
3.13.1 CHOKE MANIFOLDS
The majority of the following procedures can be used for both the standard and modified choke manifolds
providing valve #5 (on modified choke) is left open for all operations until it is required to divert flow via the
testing system loop and isolate the clean-up system.
All the following procedures refer to the numbering on the following diagrams.
Refer to Fig. 3.20 SINGLE BLOCK CHOKE MANIFOLDS
3.13.1.1 OPEN WELL AT CHOKE MANIFOLD
ASSUMPTIONS:
All valves on manifolds closed (except #5)
1. Bleed off valves closed and gauge open to read downstream pressure on duty side.
2. Flow to be directed via side with valves #1 and #2 and via the clean-up line (4" outlet) on the modified
manifold.
3. On the modified manifold, the testing system (3" outlet) side is isolated at the heater inlet valve or a
suitable isolation valve placed between the choke manifold and the heater.
4. Open valve #2 on side to flow via (duty side).
5. Open valve #1 on duty side.
NOTE: On high pressure wells if using a needle type adjustable choke, this may have to be opened slightly
before the valve is opened to prevent choke from pressure locking.
6. For an adjustable choke, open choke slowly to desired setting.
7. Tighten the set screw on bonnet to hold stem in place (if required).
8. Note the choke downstream pressure to check velocity.
NOTE: By watching downstream pressure this will also give early indication of the choke cutting out (tubing
pressure dropping flow rate rising) and choke plugging off (tubing pressure rising flow rate dropping).
3.13.1.2 CHANGING SIDES ON CHOKE MANIFOLD
ASSUMPTIONS:
Correct adjustable choke size selected / bean installed.
1. Slowly open valve #4 on side to flow via (standby side).
NOTE: Observe choke box for leaks while opening this valve. If any leaks observed, close either back valves
#2 or #4, bleed off pressure in choke box and carry out remedial action.
2. Open valve #3 on side to flow to (standby side) and simultaneously close valve #1 on the duty side.
The duty side now becomes the standby side and vice versa.
This operation will require two personnel.
NOTE: Attempt to keep the downstream pressure constant during this operation to avoid any increase in
drawdown on the well.
3. Close valve #2 on the standby side.
4. Vent pressure in standby choke box in order to check / change.

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3.13.1.3 BLEEDING OFF PRESSURE IN CHOKE BOX
1. Ensure choke box isolated at upstream and downstream valves.
2. Bleed pressure in choke box via upstream (if applicable) and downstream 1.2" valves or bleed plug on
choke body (if fitted).
NOTE: a) On later model McEvoy chokes there may be a bleed hole added to the bonnet nut. This
bleed hole will allow quicker venting of pressure from the body cavity after only one turn of
the bonnet nut in the counter-clockwise direction.
b) All Masterflo chokes incorporate pressure vents which guarantee that pressure will not be
present in the valve body during disassembly.
c) The pressure venting is accomplished by the body seals being withdrawn from their sealing
area before the bonnet bolting is fully removed. Pressure cannot be internally trapped in
one section of the valve as loosening of the valve bonnet ensures that the upstream and
downstream sides of the valve are not sealed from each other. This is independent of
whether the valve is in the open or closed position.
d) The model P-2 Choke venting occurs as the bonnet seal is removed from the valve body
bore before the bonnet nut is fully removed. Vent ports in the valve bonnet insure that total
venting will occur.
e) The model P-3 Choke venting occurs as the body balance seal is moved into the body
recess or as the bonnet and balance sleeve separate. These actions occur before the
bonnet bolting is fully removed.
5. The choke can now be removed / inspected as required.
Prior to removal of adjustable or positive chokes it is imperative that all pressure should be
known to have been bled off the choke box.
For high pressure wells, it is recommended that a man stands by a remote shut-down station ready to
close the well in, in the event that a problem occurs with a valve isolating the open choke box during
the removal / inspection operation.
6. When choke re-installed close bleed off valves and ensure gauge open to read downstream pressure
on standby side.
3.13.1.4 CLOSING WELL IN AT CHOKE MANIFOLD
1. Close well in at front valve (either #1 or #3).
2. Close back valve (either #2 or #4).
3. Follow procedures to bleed off choke box if choke to be removed / inspected.
3.13.1.5 FOR THE MODIFIED CHOKE MANIFOLD TO DIVERT FLOW FROM THE CLEAN-UP SIDE TO THE
TESTING SYSTEM SIDE
ASSUMPTIONS:
a) Testing system lined up as required downstream of heater inlet valve or testing system
isolation valve.
b) The required choke bean to flow through has been installed in the side with valves #3 and
#4.
1. Switch sides if required to line up flow via choke bean installed in side with valves #3 and #4.
2. Open heater inlet valve (or bypass valve if flow is not required to pass through the heater coils).

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NOTE: Ensure flowpath is as required and flare is lit at gas overboard line.
3. Close in clean-up line at clean-up line gas diverter manifold.
4. Close valve #5 on rear of choke manifold (to isolate clean-up line).
NOTE: One valve on the clean-up line gas diverter manifold should be opened to prevent pressure build up in
clean-up lines should valves leak on the choke manifold.
3.13.1.6 FOR THE MODIFIED CHOKE MANIFOLD TO DIVERT FLOW FROM THE TESTING SYSTEM SIDE TO THE
CLEAN-UP SIDE
ASSUMPTIONS
a) Clean-up line is lined up to selected flare downstream of the choke manifold.
#2.
c) The choke at the flare boom is set at the required size.
1. Open valve #5 at the rear of the choke manifold.
NOTE: Ensure flare is lit at clean-up overboard line.
2. Close heater inlet or testing system isolation valve.
3. Switch sides on choke manifold as required, following guidelines on page #2.
DOUBLE BLOCK CHOKE MANIFOLDS
Again, the majority of the following procedures can be used for both the standard and modified choke manifolds
providing valve 9 (on modified choke) is left open for all operations until it is required to divert flow via the testing
system loop and isolate the clean-up system.
All the following procedures refer to the numbering on the following diagrams.
Refer to Fig. 3.21 DOUBLE BLOCK CHOKE MANIFOLDS
3.13.1.7 OPEN WELL AT CHOKE MANIFOLD
ASSUMPTIONS
a) All valves on manifold closed except valve #9.
b) Bleed off valves closed, gauge open to read downstream pressure on duty side.
1. Open inner back valve #3 on side to flow via (duty side).
2. Open outer back valve #4 on side to flow via (standby side).
3. Open inner front valve #2 on duty side.
4. Open outer front valve #1 on duty side.
NOTE: On high pressure wells if using a needle type adjustable choke, this may have to be opened slightly
before the valve is opened to prevent choke from pressure locking.
5. For an adjustable choke, open choke slowly to desired setting.
6. Tighten the set screw on bonnet to hold stem in place (if required).
7. Note the choke downstream pressure to check velocity.

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NOTE: By watching downstream pressure this will also give early indication of the choke cutting out (tubing
pressure dropping flow rate rising) and choke plugging off (tubing pressure rising flow rate dropping).
3.13.1.8 CHANGING SIDES ON CHOKE MANIFOLD
ASSUMPTIONS
a) Correct adjustable choke size selected / bean installed.
1. Open inner back valve #7 on side to flow via (standby side).
2. Slowly open outer back valve #8 on side to flow via (standby side).
NOTE: Observe choke box for leaks while opening this valve. If any leaks observed, close both back valves,
bleed off pressure in choke box and carry out remedial action.
3. Open inner front valve #6 on side to flow to (standby side).
4. Open outer front valve #5 on standby side while simultaneously closing outer front valve #1 on duty
side.
The duty side now becomes the standby side and vice versa.
NOTE: Attempt to keep the downstream pressure constant during this operation to avoid any increase in
drawdown on the well.
This operation will require two personnel.
5. Close outer back valve #4 on standby side.
6. Vent pressure in standby choke box in order to check / change as below.
3.13.1.9 BLEEDING OFF PRESSURE IN CHOKE BOX
1. Ensure choke box isolated at outer upstream and downstream valves #1 and #4.
2. Bleed pressure in choke box via upstream (if applicable) and downstream 1/2" valves or bleed plug on
choke body (if fitted).
NOTE: On later model chokes there may be a bleed hole added to the bonnet nut. This bleed hole will allow
quicker venting of pressure from the body cavity after only one turn of the bonnet nut in the counter-
clockwise direction.
3. When all pressure bled off, close in bleed off valve and observe pressure in choke box for 10 minutes
or as required by client (via downstream pressure gauge).
4. When satisfied as to the integrity of the outer front and back valves #1 and #4, close the inner front
and back valves #2 and #3.
5. The choke can now be removed / inspected as required.
Prior to removal of adjustable or positive chokes it is imperative that all pressure should be known to
have been bled off the choke box.
3.13.1.10 CLOSING WELL IN AT CHOKE MANIFOLD
1. Close well in at outer front valve (either #1 or #5).
2. Close outer back valve (either #4 or #8).
3. Follow procedures to bleed off choke box if choke to be removed, inspected, else close inner front
and back valves (either #2 or #6 and #3 or #7).

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3.13.1.11 FOR THE MODIFIED CHOKE MANIFOLD TO DIVERT FLOW FROM THE CLEAN-UP SIDE TO THE
TESTING SYSTEM SIDE
ASSUMPTIONS:
a) Testing system lined up as required downstream of heater inlet valve or testing system
isolation valve.
#4.
1. Switch sides if required to line up flow via choke bean installed in side with valves #5, #6, #7 and #8.
2. Open heater inlet valve (or bypass valve if flow is not required to pass through the heater coils).
NOTE: Ensure flowpath is as required and flare is lit at gas overboard line.
3. Close in clean-up line at clean-up line gas diverter manifold.
4. Close valve #9 on rear of choke manifold (to isolate clean-up line).
NOTE: A valve on the clean-up line gas diverter manifold should be opened to prevent pressure build up in
clean-up lines should valves leak on the choke manifold.
3.13.1.12 FOR THE MODIFIED CHOKE MANIFOLD TO DIVERT FLOW FROM THE TESTING SYSTEM SIDE TO THE
CLEAN-UP SIDE
ASSUMPTIONS:
a) Clean-up line is lined up to selected flare downstream of the choke manifold.
#2.
c) The choke at the flare boom is set at the required size.
1. Open valve #9 at the rear of the choke manifold.
NOTE: Ensure flare is lit at clean-up overboard line.
2. Close heater inlet or testing system isolation valve.
3. Switch sides on choke manifold as required, following guidelines as per 3.13.6.
3.13.2 McEVOY MODEL 'H2'
3.13.2.1 INSTALL AN ADJUSTABLE CHOKE
1. Lubricate seat threads in choke body.
2. Inspect new seat:-
a) Ensure seat gasket is clean and flat against the shoulder of the seat.
b) Center gasket on the choke seat by bending down the lugs on the gasket.
3. Apply light coat of lubricant to seat threads and gasket. (Silver Seal or Copper Seal).
4. Install new seat using appropriate wrench and torque to 1500 ft.lbs.
5. Ensure choke stem backed out into bonnet assembly before installation on choke body.
NOTE: This is to prevent damage to the seat during installation.
6. Lubricate adjustable choke bonnet seal surface on choke body.

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7. Place bonnet gasket in groove on choke body.
8. Install bonnet assembly onto choke body and make up nut hand tight.
9. Using hammer tighten bonnet nut completely.
10. Zero the adjustable choke.
3.13.2.2 INSTALL A POSITIVE CHOKE BEAN
1. Inspect the choke bean to install.
a) Ensure choke bean gasket is clean and flat against the shoulder of the bean.
b) Centre gasket on the choke bean by bending down the lugs on the gasket.
NOTE: If possible have the bean size verified by another crew member to avoid mistakes.
2. Apply a light coat of lubricant to the choke bean and gasket (Silver seal or Copper seal).
3. Install new choke bean and torque to +/- 500 ft.lbs (for 15,000 psi choke the torque should be +/- 1500
ft. lbs).
4. Apply light coat of lubricant to seal area of blanking plug, external threads of choke body and threads
of bonnet nut.
5. Install blanking plug assembly onto choke body.
6. Using a hammer tighten the bonnet nut completely.
3.13.2.3 REMOVE AN ADJUSTABLE CHOKE
1. Isolate choke by closing upstream and downstream valves (if applicable).
2. Bleed off any pressure in choke box via downstream 1/2" valve.
3. Fully retract choke stem (if not fully open already).
4. Using a hammer loosen the adjustable choke nut.
5. Break seal on adjustable choke bonnet prior to removal of nut.
6. Remove adjustable choke, inspect stem for erosion.
7. Inspect seat, remove and replace if any signs of erosion.
3.13.2.4 REMOVE POSITIVE CHOKE BEANS
2. Bleed off any pressure in choke box via upstream or downstream ball valves.
3. Using a hammer, loosen the bonnet nut.
4. Break seal on blanking nut prior to removal of bonnet nut.
5. Remove bonnet nut and blanking plug assembly (the gland nut, plug, retainer ring and blanking plug
will come out as one assembly).
6. Remove the blanking plug bonnet gasket.
7. Inspect bonnet gasket, replace as necessary.

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8. Remove the choke bean using the appropriate wrench.
3.13.2.5 CHANGE ADJUSTABLE CHOKE STEMS
Assuming adjustable choke removed from choke body.
1. Remove handwheel hex nut and washer from choke stem and remove handwheel.
2. Loosen set screw on micro sleeve and remove micro sleeve from stem.
3. Remove retainer ring from bonnet body.
4. Slide bonnet nut over bonnet body (it may be necessary to remove stem locking screw prior to this).
5. Temporarily replace the handle and wind the choke stem clockwise and out through bottom of bonnet.
6. Once threads of choke stem are clear of threads on bonnet body then the stem can be pulled
downwards clear of the bonnet.
7. Inspect stem packings in bonnet, replace as required.
a) Remove packing retainer ring.

b) Remove all packings from bonnet body.
c) Lightly grease 'o-ring' groove and packing bore of bonnet body. Install 'o-ring' in groove.
d) Heavily grease threads in bonnet body.
e) Lubricate new set of packings.
f) Install in order:-
g) Metal junk ring.
h) Back-up ring (part of J-packing set).
i) J-packing set.
j) Support ring.
k) Retainer ring.
8. Lubricate stem and stem threads.
9. Slowly slide stem (threaded end first) through packing end of bonnet body.
10. Engage threads of stem with threads of bonnet body.
11. Using handlwheel, rotate stem fully counter clockwise.
12. Remove handwheel and slide micro sleeve over stem. Install set screw in micro sleeve.
13. Slide bonnet nut over bonnet body until it bottoms out against bonnet flange.
14. Install retainer ring on bonnet body.
15. Insert stem locking screw into tapped hole on bonnet body (if required).
16. Install handlwheel, washer and hex nut on stem.
3.13.2.6 ZERO-ING ADJUSTABLE CHOKE
1. After the bonnet nut is made up tight, run the choke stem in against the seat.
2. Align the zero setting on the micro sleeve with the notch . mark on the bonnet body.
3. Tighten the micro sleeve set screw to prevent slippage.
4. Run the choke stem to fully open.
5. Run the choke stem in against the seat to check for slippage of micro sleeve.
6. If micro sleeve has slipped repeat process.

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3.13.3 FOLEY MODEL 'FH2'
3.13.3.1 INSTALLING AN ADJUSTABLE CHOKE (INCLUDING SEAT)
1. Lubricate seat threads in choke body.
2. Inspect new seat:-
a) Ensure seat gasket is clean and flat against the shoulder of the seat.
b) Centre gasket on the choke seat by bending down the lugs on the gasket.
3. Apply light coat of lubricant to seat threads and gasket. (Silver Seal or Copper Seal).
4. Install new seat using appropriate wrench and torque to 1500 ft/lbs.
5. Ensure choke stem backed out into bonnet assembly before installation on choke body.
NOTE: This is to prevent damage to the seat during installation.
6. Lubricate adjustable choke bonnet seal surface on choke body.
7. Place bonnet gasket in groove on choke body.
8. Install bonnet assembly onto choke body and make up nut hand tight.
9. Using hammer tighten bonnet nut completely.
3.13.3.2 ZERO-ING ADJUSTABLE CHOKE
1. After the bonnet nut is made up tight, run the choke stem in against the seat.
2. Align the zero setting on the micro sleeve with the notch / mark on the bonnet body.
3. Tighten the micro sleeve set screw to prevent slippage.
4. Run the choke stem to fully open.
5. Run the choke stem in against the seat to check for slippage of micro sleeve.
6. If micro sleeve has slipped repeat process.
3.13.3.3 INSTALLING A POSITIVE CHOKE BEAN
1. Prior to assembly, clean and inspect all parts.
a) Check blanking cap seal and seal area for, scratches, burrs or nicks.
b) Check choke bean bore for wear, and threads for damage.
c) Check choke bean seal and seal areas for pitting, scratches or erosion.
d) Check choke body for signs of cutting and erosion.
2. Inspect choke bean orifice, threads and the bean seal ring.
3. Inspect threads and bean seal area on the choke body.
4. Clean, grease, and install seal ring onto choke bean. Apply a light coat of lubricant to the choke bean
and seal (Silver seal or Copper seal).
5. Install choke bean into choke body.
NOTE: If possible have the bean size verified by another crew member to avoid mistakes.

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6. Tighten choke bean to +/- 200 ft-lbs using Foley Bean Wrench.
7. Install blanking plug assembly onto choke body.
8. Using a hammer tighten the bonnet nut completely.
3.13.3.4 REMOVING ADJUSTABLE CHOKE
2. Bleed off any pressure in choke box via downstream 1/2" valve.
3. Fully retract choke stem (if not fully open already).
4. Using a hammer loosen the adjustable choke nut.
5. Break seal on adjustable choke bonnet prior to removal of nut.
6. Remove adjustable choke, inspect stem for erosion.
7. Inspect seat, remove and replace if any signs of erosion.
8. IF REQUIRED to remove seat, use Foley Bean Wrench.
9. Remove seat seal and inspect, replace as required.
3.13.3.5 REMOVE POSITIVE CHOKE BEAN
2. Bleed off any pressure in choke box via upstream or downstream ball valves.
3. Using a hammer, loosen the bonnet nut.
4. Break seal on blanking nut prior to removal of bonnet nut.
5. Remove blanking nut.
6. Remove the choke bean using the Foley Bean Wrench.
7. Remove and inspect choke bean seal.
3.13.3.6 CHANGING ADJUSTABLE CHOKE STEMS
NOTE: Assuming adjustable choke removed from choke body.
1. Remove handwheel.
2. Loosen set screw on indicator and remove indicator from stem.
3. Loosen thumb screw in side of bonnet.
4. Temporarily replace the handwheel and wind the choke stem clockwise and out through bottom of
bonnet.
5. Once threads of choke stem are clear of threads on bonnet body then the stem can be pulled
downwards clear of the bonnet.
6. Inspect stem packings in bonnet, replace as required.
a) Remove Spirolox retainer ring.
b) Remove junk ring from bonnet.

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c) Remove all packings from bonnet body.
d) Heavily grease threads in bonnet body.
e) Lubricate new set of packings.
f) Install in order:-
g) J-packing set. (Ensure rounded Teflon end faces the pressure).
h) Junk ring.
i) Retainer ring.
7. Lubricate stem and stem threads.
8. Slowly slide stem (threaded end first) through packing end of bonnet body.
9. Engage threads of stem with threads of bonnet body.
10. Using handwheel, rotate stem fully counter clockwise.
11. Remove handwheel and slide indicator over stem.
12. Clean, grease and replace bonnet seal ring.
13. Install bonnet onto body, being careful not to damage bonnet seal.
14. Tighten bonnet nut using a hammer.
15. Insert stem locking screw into tapped hole on bonnet body (if required).
16. Install handlwheel, washer and hex nut on stem.
3.13.4 MASTERFLO CHOKES
Masterflo chokes, as used by Expro, are a production style choke which incorporates a plug and nozzle-seat
style sealing mechanism.
Accurate flow is achieved by two sets of control holes in the nozzle-seat, the first row consists of small diameter
holes for low flow conditions while high flow conditions are controlled by a second set of larger diameter holes.
1. To open the choke, turn the hand wheel anti-clockwise.
2. To close the choke, turn the hand wheel clockwise.
READING THE CHOKE SETTING
The choke setting can be read off the micrometer indicator as below.
The indicator mechanism consists of the stem nut having marks from 0 to 9 around the circumference of the
calibration head, graduated to correspond to full turns of the hand wheel.
This system provides positive position readings corresponding to every 36 of hand wheel movement.
Calibration of the indicator is accomplished by positioning the indicator head so that the zero markings
correspond to each other when the choke is in the closed position.
Refer to Fig. 3.22 MASTERFLO MICROMETER

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3.14 HEAT EXCHANGERS
On some wells, eg. high temperature wells, it may be desirable to use the heater only as a second stage choke or as a
cooling bath, and not for heating purposes.
TO DIVERT FLOW VIA HEATER
Where heat is required, ensure that the heater is up to the required temperature prior to diverting flow.
NOTE: In the case of indirect steam heaters, the time required to bring the water bath up to temperature will be greater
than for the direct steam heater, where steam is applied direct to process coils.
1. Set adjustable choke to desired setting.
2. Open process coil outlet valve (if not previously opened).
3. Open process coil inlet valve.
4. Close process coil bypass valve.
TO BYPASS HEATER
1. Open process coil bypass valve.
2. Close process coil inlet valve.
NOTE: a) The process coil outlet valve should be left open to prevent any possible problems through thermal
expansion of the well fluid in the process coils, where there is a unprotected closed system, ie. with inlet
and outlet valves closed. The open outlet valve will allow thermal expansion to take place in the line
downstream of the heater, which is protected from overpressure by a freestanding relief valve, or if a
freestanding relief valve is not fitted, then the separator relief valve.
b) A close watch should be kept on the heater temperature while flowing through it, in order that it does not
run too hot, flashing off lighter ends of the oil / condensate, or too cold permitting the formation of
hydrates.
c) If the temperature rises too high or drops too low then it should be altered through the correct use of the
temperature controller.
When a direct heater is being closed down, the vessel pressure gauge should be kept under
observation as it may be necessary to vent the vessel to atmosphere when atmospheric pressure
is reached in order to prevent possible damage to the rupture disk if a vacuum is allowed to build
in the vessel as it cools.

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3.15 FREESTANDING RELIEF VALVES
The relief valve skid as used by EXPRO is intended to protect the low pressure pipework downstream of the heat
exchanger (or choke if heat exchanger not used) from over-pressure, when flowing on separator bypass.
When flowing on separator bypass, if not using a relief valve skid, the only form of protection is a high pressure pilot tied
into an ESD loop on a control panel which will shut down a hydraulically actuated valve on the surface test tree or surface
safety valve. Even when this pilot is fitted with a pneumatic quick exhaust the closure time of the valve is still +/-8
seconds. While this complies with API 141, it may not be a quick enough reaction time to close the well in, in the event of
a pressure surge. As an extra safety measure, when requested, EXPRO install the relief valve skid between the heater
(or choke) outlet and separator inlet.
The skid itself is a very basic design with a tee piece orientated so the tee rises vertically. A relief valve is then fitted to
this with a high pressure relief line which is normally teed into the vent line from the separator and ran to the flare boom or
overboard. A frame placed around the skid protects the relief valve from damage during transportation.
Like the separator vent line, the relief skid vent line is sized to the particular application that it will be used for.
NOTE: On high pressure/temperature well testing, an additional relief valve may be placed between the choke manifold
and the heat exchanger. This will be set to +/- 4500 psig and protect the heat exchanger coils from overpressure.

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3.16 GAS, OIL AND WATER SEPARATORS
3.16.1 GENERAL OPERATING GUIDELINES
3.16.1.1 NITROGEN PURGE GUIDELINES
At some stage in a well test, eg before rigging down, it may be required to purge the separator with nitrogen eg after
pressure testing or on a high concentration sour well. Nitrogen bottles will be provided by EXPRO when requested for this
purpose.
Assuming separator has been flushed/filled with water:-
1. Connect nitrogen bottles to separator vessel. Isolate vessel from process lines, if not isolated already.
2. Connect hose to vessel drain and direct to a closed drain.
3. Open vessel drain and inject nitrogen to displace water.
4. Once liquid has drained from vessel close drain valve.
5. Open gas outlet line to overboard via gas diverter manifold and burner to depressurise vessel to +/- 30 psi
pressure unless total depressurisation is required.
6. Close gas outlet line to maintain 30 psi positive pressure in the vessel if required, eg if further well testing is to
take place.
7. Once nitrogen purging is complete isolate and disconnect drain and nitrogen purge lines.
3.16.1.2 USE OF THE SEPARATOR INLET MANIFOLD
The separator inlet manifold can be used in many ways:-
1. As a separator bypass.
2. To recombine oil/water into the gas stream.
3. To divert gas flow via oil line to oil burner head (useful in keeping flare alight on gas wells slugging water).
Care must be taken before separator 'start-up' to make sure valve alignment is correct for required flow path, obviously
gas does not want to be diverted to a gauge tank.
This manifold design will vary dependant on the separator design and operators should ensure their familiarity with proper
valve alignment for the particular separator in use.
3.16.1.3 FLOWING VIA SEPARATOR BYPASS
When flowing via testing system lines, flow will usually be routed initially via separator bypass to flare.
Where no dedicated clean-up line is in use flowing via bypass will prevent damage or plugging of liquid meters and
settling of solids or mud in separator during initial clean-up period.
Where a dedicated clean-up line has been used, eg for a post 'frac' clean-up, this will allow any proppant that has lain in
the flowline upstream of the heater inlet valve to be routed overboard without damaging separator internals.
If a client wants to flow via a separator before the well has properly cleaned up (ie when solids or mud etc still in the well
stream), they must be made fully aware of the possible consequences of this action, ie a separator that may not operate
properly later on during the test due to internal plugging off/damage and may possibly require major overhaul, with large
recharge costs.
NOTE: In Holland, all flow is routed via the separator from opening the well to closing it in, this is done to prevent pollution
(particularly during the well clean-up).
Another circumstance when it may be required to flow on separator bypass is when required to unload a liquid cushion
from the well-bore. Here the flow is diverted via the bypass to the oil line and will be diverted to the flare or gauge/surge
tank at the oil manifold.

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3.16.1.4 PROCEDURE FOR FLOWING ON SEPARATOR BYPASS
1. When flowing on separator bypass where a relief valve skid is not being used to protect the low pressure
pipework, then the inlet valve of the separator should be left open, with the outlets closed.
This will allow the separator relief valve to operate should an increase in pressure occur downstream of choke/heater and
safely relieve the pressure.
NOTE: This procedure will be followed regardless of whether any high pressure pilots are used to protect the system
downstream of heater/choke.
3.16.1.5 DIVERTING FLOW VIA SEPARATOR
To divert flow via separator take the following steps:-
The valve configuration shown below may vary for different separators.
1. Ease open the manual valve downstream of gas BPV.
2. Slowly close separator bypass valve monitoring separator pressure at all times.
3. As separator fills, adjust gas BPV to give required separator operating pressure.
NOTE: Do not lower orifice plate until pressure is set.
4. Closely monitor rising liquid level at sight glasses.
5. As liquid levels rise, open water or oil/condensate line manual valves as required.
6. Adjust liquid levels using level-trol instruments (as per Section 3.16.4) to give required level and interface.
Generally the liquid level is set before the interface, an exception to this would be for a gas well producing high water to
condensate ratios.
7. When separator pressure and liquid levels are under control, install orifice plate in Daniels Orifice Box.
NOTE: It is not necessary to by-pass the separator on closing in the well. In certain conditions, i.e. high GOR wells, the
extra back pressure generated by flowing oil and gas through one line can trip pressure sensors and can occur
when valves are manipulated during by-pass operations. In all operations and especially in by-passing, extreme
care must be exercised with good communication and coordination between crew members.
NOTE: When installing the first plate always err on the large size and work down to an acceptable orifice size. Ideal plate
size will give a differential pressure reading between 2/3 and 3/4 of full scale on the Barton chart.
8. Close equalising valves and open bleed valve on gas flow meter (Barton) manifold. Check that instrument pens
are marking chart.
9. Divert flow via liquid meters. For low flow rates flow on should be on meter bypass to a gauge tank or barrel.
NOTE: If low flow rates are being measured to a barrel, use an in-line choke (eg Teledyne Merla) to control the rate of
flow when dumping to the barrel.
10. Simultaneously close meter bypass manual valve and open manual valve downstream of the meter.
NOTE: Downstream valve of meter should never be opened first in case of 'back-flow' which could cause damage to
meter internals.
11. Separator functions, eg liquid level controllers, should be continually monitored for proper operation.
This procedure will be modified to accommodate varying well flow conditions such as low G.O.R., high water
content etc, however, the sequence of operations will remain similar to that above.
A CLOSE WATCH SHOULD BE KEPT ON SEPARATOR LEVELS AT ALL TIMES BY THE MAN MANNING THE
SEPARATOR, ESPECIALLY WHEN FLOWING LOW FLOW RATES TO A GAUGE TANK.
NOTE: The operation of the sight glasses should be checked periodically to ensure their proper operation.

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The Teledyne Merla has a 1/2" trim fitted as standard. This has been sized to minimise any flow of gas to the
gauge tank to a rate less than the tank can safely vent or relief through the weighted Whessoe hatch (set at 1 psi).
3.16.1.6 LIQUID RATE MEASUREMENT
For low flow rates, flow should remain on meter bypass and be directed to the gauge/surge tank or a graduated barrel.
If low flow rates are being measured to a barrel, use the Teledyne Merla to control the rate of flow when dumping to the
barrel.
3.16.1.7 TO PLACE LIQUID METERS IN SERVICE
1. Open manual valve upstream of meter selected for fluid volume metering.
2. Take note of meter reading.
3. Simultaneously close meter bypass manual valve and open manual valve downstream of the meter.
NOTE: Downstream valve of meter should never be opened first in case of 'back-flow' which could cause damage to
meter internals.
4. Observe rotation of counter head to ensure rotation is smooth and not 'jerky' or is not above meter capacity.
For vertical separators, with snap acting liquid controllers, ensure that liquid level is set to a minimum of 18" above
condensate outlet.
3.16.1.8 RISING LIQUID LEVELS
If the liquid/interface level rises and is in danger of going out of the relevant sight glass, the level in the separator should
be lowered to bring the level back to a point where it can be monitored accurately.
NEVER RUN BLIND
NOTE: If the level cannot be lowered then the well should be choked back until liquid levels can be controlled.
3.16.1.9 FALLING LIQUID LEVELS
If the liquid/interface level falls, it should not be allowed to drop out of the sightglass. The relevant controller should be
altered to maintain the level in the sight glass. If dump valve is closed but the level is still falling (possibly due to low flow
rates and a leaking dump valve) then the actuated dump valve can be opened fully and the block valve on the relevant
outlet line should be closed in until the level builds up sufficiently.
The liquid level can be controlled in this 'manual' fashion until such a time as the flow rate rises or maintenance can be
carried out on the dump valve.
IF RUNNING WITH A MANUAL LIQUID LEVEL CONTROL, THE SEPARATOR LEVELS MUST BE MONITORED AT
ALL TIMES.
3.16.1.10 RISING/FALLING SEPARATOR PRESSURE
If the separator pressure rises or falls greater than might be expected for the well under test, in the first instance the back
pressure controller should be checked to ascertain if the output signal to the B.P.V. has altered. If the output is as it
should be, the B.P.V. should be checked to see if it is operating correctly. If the separator pressure control equipment has
failed, it may be necessary to raise the orifice plate and bypass the separator in order to allow maintenance to take place.
If the separator pressure control equipment appears to be functioning properly, start at the boom and work backwards to
the separator to identify the area of the problem.
BEFORE ALTERING THE SEPARATOR PRESSURE FOR ANY REASON LIFT THE ORIFICE PLATE INTO THE TOP
CHAMBER.

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3.16.2 SETTING BACK PRESSURE WITH WIZARD 4150 CONTROLLER
3.16.2.1 CHANGE PRESSURE SET POINT
1. This adjustment is performed by rotating the outer dial around the graduated pressure setting dial. The
graduations on the dial face are approximate indications of control pressure set point.
2. Alternatively if fitted, loosen the knurled adjustment knob (as found on Fisher 2500 liquid controllers) and rotate
the knob around the RAISE LEVEL dial.
3. Do not rely only on the dial graduations when setting the back pressure, but keep checking the actual separator
pressure.
NOTE: When changing pressure set-point make several small adjustments rather than a large one, this will prevent
'surging' of separator pressure and possible difficulty in achieving desired set-point.
a) To raise separator pressure rotate dial or knurled knob to right.
b) To lower separator pressure rotate dial or knurled knob to left.
3.16.2.2 SETTING THE PROPORTIONAL BAND
The proportional band adjustment on the WIZARD determines the amount of change, in the separator pressure required
to alter the controller output signal to stroke the valve from fully open to fully closed, ie. from one limit of the output range
to the other limit.
The proportional band can be expressed as a percentage of the sensing element range.
At 100% setting on the proportional band the valve will require full element range to fully open or close (for a 1500 psi
Bourdon tube this would be 1500 psi). At 50% setting the valve will only require 1.2 element range to fully open or close
(for 1500 psi Bourdon tube this would be 750 psi).
The proportional valve dial is graduated from 0 to 10, corresponding to 0 - 100% setting.
For back pressure controllers, the proportional band is normally set between 1.5 and 3 (15 - 30%). For a 1500 psi
Bourdon tube, this would require a pressure change of between 225 and 450 psi to stroke the valve from fully open to fully
closed.
Generally the proportional band setting will not be changed during the course of a well test, however, if the back pressure
valve is 'hunting' (ie. continually stroking slightly open then closed) then the proportional band setting should be increased.
This will have the effect to increase the range of pressure surge required to stroke the valve, giving a dampening effect on
the controller output to the valve, thus reducing the valve stroking.
NOTE: The higher the setting of the proportional band the greater the level of change required to stroke the valve.
a) To adjust the proportional band rotate the knob on the dial clockwise to narrow and counter-clockwise to
broaden the proportional band.
NOTE: When the proportional band is adjusted this will affect the set point, in that increasing the band will increase the
output pressure. The set point will have to be re-adjusted.
3.16.3 LOWERING/RAISING ORIFICE PLATE
Refer to Fig. 3.23 DANIEL SENIOR ORIFICE METER
INSTALL ORIFICE PLATE WITH SEPARATOR UNDER PRESSURE
Orifice plates should always be stored in their proper box.
They should always be kept clean, never hung on metal objects eg. nails, handles etc. and should be installed with the
bevelled edge downstream.
The Daniels box should be positioned so the control handles are facing to the outside of the skid, towards the operator.

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1. During a plate change-over operation, one operator should be standing beside the ESD button, away from any
danger which may occur.
2. Open bleeder valve to relieve pressure in top chamber.
3. Lubricate with Daniels grease to make seal between top valve and valve strip.
4. If unsuccessful on seal, close bleeder, open equaliser and work sliding gate back and forth, lubricate when slide
gate is in closed position as required. With gate closed, close equaliser valve and re-open bleeder valve to relieve
pressure.
5. WHEN PRESSURE IS FULLY BLED OFF, LOOSEN CLAMPING BAR SCREWS.
6. Do not remove clamping bar yet.
7. Rotate upper shaft (counter clockwise) to lift up (or free) sealing bar and gasket.
8. ENSURE THAT YOU DO NOT ROTATE DOWN AS THE VALVE STRIP WILL BE PUSHED DOWN AND A
LEAK DEVELOP.
9. Remove clamping bar, sealing bar and gasket.
10. Rotate plate carrier completely out. Take out plate.
11. Install new plate correctly in holder.
12. Install plate holder correctly in carrier.
13. Place carrier evenly into upper chamber and engage with upper shaft and pinions.
14. Rotate plate carrier down with upper shaft (clockwise) until carrier is just below where sealing bar and gasket will
sit.
15. Inspect gasket and make sure it is in good shape, replace every third operation.
16. Replace clamping bar, sealing bar and gasket.
17. Tighten down clamping bar screws in a staggered pattern.
18. Make sure bleeder valve is closed.
19. Open equaliser valve to allow pressure into top chamber.
20. Open slide valve gate.
21. Rotate upper shaft to move carrier down and engage bottom shaft.
22. Rotate lower shaft to move plate carrier completely down into meter run.
23. Close sliding door.
24. Close equaliser valve.
26. Lubricate if necessary.
27. After pressure is relieved, close bleeder valve.
SLIDE VALVE LUBRICATION
1. Before lubricating, CLOSE slide valve and equaliser valve, OPEN the bleeder valve.
2. To lubricate, remove stem completely from grease fitting by turning in an anti-clockwise direction.
3. Insert lubricant stick, replace stem and slowly turn clockwise.

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NOTE: Inject lubricant slowly - if done hastily, high pressure from the lubricant may rupture the valve seat gasket or force
apart the valve and seat. It may also split the grease fitting.
4. Crank shaft all the way in to the grease fitting. If more lubricant is required, follow steps 2 and 3.
CHANGE ORIFICE PLATE WHILE SEPARATOR UNDER PRESSURE
1. Lubricate sliding valve (optional). Check that bleed-off is closed.
2. Open equalizer valve.
3. Open slide valve 1/4 turn clockwise.
4. Rotate bottom (lower) plate carrier shaft counter clockwise to lift plate carrier up towards upper chamber.
5. Engage plate carrier onto upper plate carrier shaft. (It may be necessary to rotate latter a little to engage).
6. Rotate upper plate carrier shaft to bring plate carrier fully into the upper chamber.
7. "Butt" the plate carrier up against the sealing bar and gasket.
8. Close sliding gate.
11. Lubricate with Daniels grease to make seal between top valve and valve strip.
12. If unsuccessful on seal, close bleeder, open equaliser and work sliding gate back and forth, lubricate when slide
gate is in closed position as required. With gate closed, close equaliser valve and re-open bleeder valve to relieve
pressure.
13. WHEN PRESSURE IS FULLY BLED OFF, LOOSEN CLAMPING BAR SCREWS.
14. Do not remove clamping bar yet.
15. Rotate upper shaft (counter clockwise) to lift up (or free) sealing bar and gasket.
16. ENSURE THAT YOU DO NOT ROTATE DOWN AS THE VALVE STRIP WILL BE PUSHED DOWN AND A
LEAK DEVELOP.
17. Remove clamping bar, sealing bar and gasket.
18. Rotate plate carrier completely out. Take out plate.
19. Install new plate correctly in holder.
20. Install plate holder correctly in carrier (bevelled edge of plate to downstream).
21. Place carrier evenly into upper chamber and engage with upper shaft and pinions.
22. Rotate plate carrier down with upper shaft (clockwise) until carrier is just below where sealing bar and gasket will
sit.
23. Inspect gasket and make sure it is in good shape, replace as necessary.
24. Replace clamping bar, sealing bar and gasket.
25. Tighten down clamping bar screws in a staggered pattern.
26. Make sure bleeder valve is closed.
27. Open equaliser valve to allow pressure into top chamber.

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28. Open slide valve gate.
29. Rotate upper shaft to move carrier down and engage bottom shaft.
30. Rotate lower shaft to move plate carrier completely down into meter run.
31. Close sliding valve.
34. Lubricate if necessary to ensure slide valve seal.
35. After pressure is relieved, close bleeder valve.
3.16.4 SETTING LIQUID LEVEL WITH FISHER 2500 CONTROLLER
3.16.4.1 CHANGE LIQUID LEVEL SET POINT
This adjustment is performed by loosening the knurled knob, which holds the set point steady, and rotating the knob
around the RAISE LEVEL dial.
By the use of a cam, this moves the flapper assembly closer to, or further away from the nozzle on the bourdon tube,
decreasing or increasing the vented air through the nozzle. This results in increased or decreased output pressure to the
valve thus opening or closing it.
1. To raise the liquid or interface level, rotate the knurled knob in the same direction as the arrow on the dial face.
2. To lower the liquid or interface level, rotate the knurled knob in the opposite direction as the arrow on the dial face.
NOTE: When re-tightening the knurled knob, care should be taken that the set-point does not move slightly, upsetting the
set level.
3.16.4.2 SETTING THE PROPORTIONAL BAND
The proportional band adjustment on the level-trol determines the amount of change, in the liquid/interface level, as
required to alter the controller output signal to stroke the valve from fully open to fully closed or vice versa. It is often
expressed as a percentage, based on the ratio of level change to displacer length, eg. if a 7" level change creates full
output pressure change and the displacer is 14" long, the controller is said to have a 50% proportional band.
A wide open proportional valve (fully counter-clockwise) permits feedback of the total output pressure signal change
producing a 100% proportional response. A closed or partially closed proportional valve produces smaller proportional
responses, because part of the output pressure change vents through the proportional valve exhaust.
The proportional valve dial is graduated from 0 to 10 corresponding to a 0 - 100% setting.
For level-trols, the proportional band should be determined from the chart relating to liquid specific gravities. (This chart
should be found inside the door of the controller.)
If the liquid dump valves starts 'hunting' (ie. continually stroking slightly open then closed) then the proportional band
setting should be increased. This has a dampening effect on any liquid level change as it increased the range of level (eg.
the amount of rise and fall of the liquid level) required to stroke the valve, giving a dampening effect on the controller
output to the valve, thus reducing the valve stroking.
Refer to Fig. 3.24 EFFECT OF PROPORTIONAL BAND ON LIQUID LEVEL
1. To adjust the proportional band, rotate the knob on the dial clockwise to narrow and counter-clockwise to broaden
the proportional band.
NOTE: When the proportional band is adjusted this will affect the liquid level set point, in that increasing the band will
slightly reduce the output pressure, closing the dump valve a little thus raising the level.

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The best setting of the proportional band is the one that is the lowest that prevents the valve from 'hunting' as this
will make the separator more responsive to liquid level changes.
3.16.5 SETTING LIQUID LEVEL WITH FISHER 2900 CONTROLLER
3.16.5.1 PRE FLOW SET-UP
1. For snap acting level control, with level below displacer:-
a) Adjust nozzle toward flapper until snapping point is reached (the point where output signal presure increases
rapidly to full supply pressure). Note this pressure where snapping occurs.
b) Adjust nozzle away from flapper until nozzle pressure is 2 psi lower than the pressure noted at snapping.
NOTE: Output pressure should now read zero.
2. For throttle acting level control, with level below displacer:-
a) Adjust nozzle until output pressure is 3 psi.
3.16.5.2 CHANGING SET POINT DURING FLOW
If it is required to adjust the level during flow:-
1. To raise level screw nozzle towards flapper.
2. To lower level screw nozzle away from flapper.
NOTE: For interface control the above procedure should be followed with the displacer completely submerged with the
lighter of the two mediums acting on that displacer, ie oil/condensate.
3.16.6 DIVERTING FLOW VIA LIQUID METERS
Refer to Fig. 3.25 LIQUID METERS SET-UP
Prior to flowing through the meter, ensure that valves #1 and #2 are closed and that valve #3 is open, ie. the meter is by-
passed.
Prior to meter placing the meter in service sufficient flow should always, if possible, be directed via the meter by-pass line
to flush any scale, debris, etc. away and prevent damage to the meter internals.
3.16.6.1 PLACING METER IN SERVICE
Assuming the separator interface / liquid level is set to maintain level +/- 18" above the oil / water line outlet and that flow
is directed via the meter bypass.
1. Take note of initial meter reading.
2. Open valve #1 to equalise and charge the meter.
NOTE: Valve #2 must never be opened first as this may result in damage to the paddle assembly through back-flow from
downstream to upstream as the line and meter fills with oil / condensate.
3. SLOWLY open valve #2 to permit flow to travel via the meter.
4. Close valve #3.
NOTE: The meter register should sweep around the dial smoothly, with no jerky action. If action is not smooth refer to
Field Maintenance Manual.
The liquid level control valve may have to be adjusted to permit the proper flow through the meter.

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5. The flow rate through the meter should be checked to ensure that it is within the meter's specification (ref.
Technical Information Manual).
If flow is below the meter's capacity, then the flow should be directed via a meter with a lower capacity, or valve #2
can be closed until the liquid level builds up to a level where it can be dumped at a rate that will be within the
meters capacity. This valve should be closed once the level has been dumped.
Alternatively, an in-line liquid choke can be used downstream of the liquid level control valve, instead of valve #2.
NOTE: The liquid level MUST not be allowed to build up to a level where carry-over is going down the gas line, or to flood
the separator.
The liquid level MUST also remain +/- 18" above the liquid outlet line when dumped.
Manually dumping liquids through the meter is man intensive as it requires a man to stand by the separator and
constantly watch the liquid level.
3.16.6.2 TO ISOLATE METER
1. Open valve #3, to allow flow to bypass the meter.
2. Close valve #2.
3. Close valve #1 to isolate the meter.
3.16.7 READING BARTON RECORDER
GENERAL PRACTICE CONSIDERATIONS
Observe the following practices when starting operation of the instrument.
1. Always start with the block valves closed.
2. Perform a zero check of the instrument according to the following procedure:-
a) Open one block valve, the vent valve, and (if used) the bypass valves. This procedure equalizes the
pressure between the sides of the instrument.
b) If the instrument does not indicate zero, check for gas or liquid entrapment in the lines or in the DPU
(depending on orientation of the piping layout).
c) If necessary, adjust the pen or pointer of the instrument by turning the zero adjustment screw.
NOTE: For gas service, it is recommended that the zero check be performed with both block valves closed. If the gas
flow is pulsating, there may be a standing wave effect in the process line which can displace the indicator and
appear as a zero error.
3. Check for manifold and piping leaks:-
a) Open both block valves, one shutoff valve and the bypass valve to pressurize the instrument.
b) Close the shutoff valve and the bypass valve. Any leakage will be indicated by pen movement.
CAUTION: Be careful not be subject the DPU to unnecessary shock or overrange pressure during startup
operations.
4. The way that the Barton chart will be read will depend on the range of the bellows and the static element.
Ensure that if the correct chart is not available that when taking the readings that you are aware of what each
division on the chart represents. This will ensure that the readings are correct.

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3.16.8 USING SIGHT GLASSES
A liquid level gauge consists of a set of valves or fittings known as the upper and lower valves, which are connected to the
separator vessel, and a glass insert joining the two valves. During normal operation the valves are wide open, allowing
the pressure to equalise in the system, thereby permitting liquid to seek it's true level. This can be observed in the glass
portion of the gauge.
TABLE 3-14 PRESSURE RATINGS OF GAUGE
Maximum Pressure Rating
Series RL or TL
2400 psi @ 100F
1360 psi @ 750F
Series RM or TM
3000 psi @ 100F
1700 psi @ 750F
Series RH or TH
4000 psi @ 100F
Liquid level gauges comprise of 7 basic parts (excluding valves):-
BODIES (LIQUID CHAMBERS)
These are accurately machined from bar stock to provide a perfect gasket seating for the gauge glasses. Materials include
carbon steel, types 304 and 316 stainless steel.
NOTE: Carbon steel bodies are rustproofed.
COVERS
These are made of steel in all sizes and ratings for higher strength and more dependable service. Carbon steel covers
are rustproofed. Other materials are types 304 and 316 stainless steel.
GLASSES
Domestic glass used only. Tempered borosilicate glass is used in all sizes and ratings. Reflex types have moulded
reflecting prisms. Transparent types provide a clear "see-through" view.
1. To place sight glasses in service ensure gauge lock is open fully.
REFLEX GAUGE GLASSES
These are constructed with vertical prisms extending the full length of the visible portion of the glass. These provide an
indication of the liquid phase level in the separator vessel. All liquids appear black, providing sharp contrast to the brilliant
silvery appearance of the gas phase. The gauges are tapped for 1/2" NPT connections, top and bottom. The normal
gauge type used on separators is the series "RL".
TRANSPARENT GLASSES
These use clear, see-through glass and are generally used in pairs with the liquid column enclosed between the glasses.
The liquid / interface level can be observed by looking through the two glasses of the gauge. This type of glass allows
both the colour and the interface of the liquids in the separator to be viewed. (A torch placed behind the glass is a useful
aid, especially at night). These gauges are also tapped for 1/2" NPT connections. The normal gauge type used is the
series "TL".

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GASKETS
All Daniel flat gauge gaskets are recessed for protection and dependability in all gauge sizes and pressure series. Special
non-stick gaskets and cushions are used to eliminate the problem of gaskets adhering to the chambers. These are cut
from high grade asbestos materials.
CUSHIONS
Gauge glass cushions are cut die-cut from felted, long fibre asbestos.
BOLTS
Gauge bolts are made of alloy steel, ASTM A-193 Grade B7, and rustproofed for long life.
NUTS
Gauge nuts are made of alloy steel, ASTM A-194 Grade 2H. All nuts are rustproofed.
3.16.9 METER FACTORS
Almost all liquid meters used in well testing are calibrated by a third party prior to installation on any separator.
Irrespective of this, these meters should be flow checked once the equipment has been hooked-up at the wellsite. In
some cases there is little or no guidance as to what the anticipated flowrates may be and therefore it is necessary to
obtain pre-test meter factors at various flow rates. An accurate record of the obtained meter factors should be included in
the final well test report.
There are several types of meter factor; where the meter is calibrated and NO shrinkage allowance is included in the
factor, and where a shrinkage allowance IS included in the factor.
TO CALIBRATE LIQUID METERS BEFORE A TEST
1. Have the flowpath lined up to a tank through the meter bypass line and the meter upstream valve open.
NOTE: If there is no tank available the meters can be checked against the meter reading on the pump unit.
2. Note the meter reading and tank level.
3. Simultaneously open the meter downstream valve and close the bypass valve.
4. Allow a certain amount of liquid to pass through the meter, eg. 10 bbls.
5. Simultaneously close the meter downstream valve and open the meter bypass valve.
6. The meter factor can be worked out by the following method:
METER FACTOR = TRUE VOLUME

METERED VOLUME
Example:
meter start reading 10.0 tank start level 14.5bbl

meter stop reading 20.0 tank stop level 24.0bbl
7. When calculating the oil flow rates during the test, a shrinkage will have to be measured of the process fluid and
applied to the meter readings, as well as a temperature correction to give the flow rates corrected to STB (stock
tank barrels).

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TO CALIBRATE LIQUID METERS DURING A TEST
With flow lined up though the meter to the flare:
1. Ensure valve on tank inlet manifold are lined up to flow to one side of the tank.
2. Note tank start level and temperature in the other compartment.
3. Divert flow to the tank from the flare at the oil manifold.
4. Switch sides on the tank, allowing flow to the side where you have recorded the start level. Have another man
record the meter reading and flowing oil temperature at the moment that you switch sides on the tank.
5. Allow the oil to flow to the tank for 30 minutes, if possible or until it becomes necessary to switch sides on the
tank.
5. Switch sides on the tank. Have another man record the meter reading and flowing temperature at the moment
you switch sides.
6. Divert flow to the flare at the oil manifold (ensure that the pilot is lit before flowing to the flare.
7. Allow the tank time to settle (eg. 15 - 30 minutes).
8. The meter factor can be worked out by the following method:-
METER FACTOR = TANK STOP LEVEL X K FACTOR - TANK START LEVEL X K FACTOR
METER STOP READING X K FACTOR - METER START READING X K FACTOR
Example:
meter start reading 10.0 flowing temperature 90F

meter stop reading 20.0 flowing temperature 92F
tank start level 14.5 bbl tank temperature 50F
tank stop level 24.0 bbl tank temperature 70F
Assuming an oil API of 37
Meter Factor = 24 x .9954 - 14.5 x 1.0046

20 x .9854 - 10.0 x .9863
Meter Factor = 0.9470
Where possible, meter factors should be taken at least once every 12 hour flow periods to ensure the continuing accuracy
of the meters.
During a Well Test all oil / condensate flow rates are reported in STB ie. Stock Tank Barrels. This means they are
corrected to 14.73 psi and 60 deg.F.
If it is not possible to use a gauge tank to calculate combined meter and shrinkage factors, eg. if a surge tank is being
used, then it is necessary to calculate oil / condensate shrinkage factors to correct the flow rate to STB.
3.16.10 SHRINKAGE FACTORS
The definition of Shrinkage is the decrease in volume of a liquid phase caused by the release of solution gas and / or the
thermal contraction of the liquid and is expressed as a percentage.
Basically a Shrinkage Tester works by receiving oil / condensate at separator pressure, and by then isolating the
separator allows the oil to be slowly bled off to atmospheric pressure. Ideally this should be done through approx. 1/64"
nozzle.

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The Shrinkage Tester comprises of two 'bulbs' connected with a tube fitted with a sight glass and a scale. It will have
been calibrated to either percentage of reduction or cubic centimetre reduction and works by the fact that as the pressure
reduces, the gaseous hydrocarbons (light ends) entrained in the crude 'break-out' or 'flash-off' and no longer contribute to
the volume of the hydrocarbon liquids.
When a known volume of liquids is transferred to the Shrinkage Tester at separator pressure and depressurised, the
lighter ends can be vented under controlled conditions. The reduction in volume can then be expressed as a figure:
eg. 1.000 - .05 (5% shrinkage) with temp in Tester = 60 deg.F
The shrinkage factor will thus be 0.9500 as K factor (volume reduction due to standard temperature) will equal 1.000.
It is important not to vent too quickly otherwise 'heavier ends' flash off, giving too great a reduction in volume.
Normally when using a gauge tank to calculate meter factors allowance is made for thermal contraction ie. the
temperature is corrected to 60 deg.F and the tank contents are allowed to settle for +/- 15 minutes, venting off gas in
solution (after 15 minutes there is no more appreciable shrinkage due to gas in solution venting off). In this case it is not
necessary to measure shrinkage factors to include in the oil calculations as the metered volume would have been reduced
to STB twice.
Refer to Fig. 3.26 SHRINKAGE TESTER
1. Level in separator must be higher than top of scale on shrinkage tester.
2. With shrinkage tester empty, open gas equalising line from separator (V1) to pressure up tester to separator
pressure.
3. Open liquid inlet line (V2) slowly to allow shrinkage tester to fill with oil.
Be careful when approaching top mark on scale not to overfill tester.
4. Once sample is at 'zero level' close V2 and V1.
5. Record pressure and temperature of sample in tester.
6. Open bleed off valve V3 slowly. If nozzle not fitted to bleed port.
Time to bleed sample to atmospheric should be +/- 30 minutes.
7. Once sample at atmospheric record reduction from scale.
8. Repeat operations as required to obtain average.
9. When completed close V3 and open V1 to recharge tester with separator pressure.
10. Open V4 to blow down level via drain line.

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Page 1 of 1
3.17 GAS DIVERTER MANIFOLDS
Refer to Fig. 3.27 GAS DIVERTER MANIFOLD
The 3" and 4" 2-valve Gas Diverter Manifolds are designed to enable flow to be diverted to either flare boom (when two
booms are being utilised) when required, eg. in the event of a change in wind direction.
They can also be used to divert flow to both booms (when operating conditions allow), to reduce back pressure in the
flowlines downstream of the separator.
3.17.1 OPERATING GUIDELINES
1. Before opening the well, check free movement of valves on gas manifold by cycling both valves from fully
closed to fully open.
2. Use the manifold to divert gas flow to selected burner (port or starboard) by opening the valve supplying that
burner.
3. Once the flare is established, close the other valve.
NOTE: It is important that one valve on the manifold remains open at all times during operations.
3.17.2 TO SWITCH FLARES
1. Open valve to divert gas flow to the selected burner (port or starboard) by opening the valve supplying that
burner.
2. Once flare established, close the other valve.

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Page 1 of 1
3.18 OIL DIVERTER MANIFOLDS
Refer to Fig. 3.28 OIL DIVERTER MANIFOLD
3.18.1 OIL FLOW FROM SEPARATOR TO BURNER
1. Open central valve #1.
2. Open valve to required burner either #4 or #5.
3. All other valves remain closed.
NOTE: If a gauge tank is in use, line to the tank from valve #2 will have an in-line choke fitted this will limit flow
to tank should valve #2 fail.
Return line from transfer pump into valve #3 will have a check valve fitted to prevent any pressure
leaking through valve #3 from back-flowing through transfer pump to tank.
3.18.2 OIL FLOW TO GAUGE/SURGE TANK
1. Open inlet valve on selected compartment of tank.
2. Simultaneously open oil manifold outlet valve to tank #2 and close central oil manifold valve #1.
3. Open valve to selected burner #4 or #5 in case flow has to be diverted from tank.
4. All other valves are closed.
3.18.3 OIL MANIFOLD OPERATION TO PUMP OUT TANK TO BURNER
1. Open outlet valve on tank compartment to be drained.
2. Ensure valves #4 and #5 are lined up to the correct flare for the prevailing wind conditions etc.
3. Open valve #3 on oil manifold (from pump discharge).
4. Assure burner pilot flame operating.

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Page 1 of 2
3.19 SURGE/GUAGE TANKS
3.19.1 START-UP AND GAUGING FLOW
For oil manifold line up refer to Section 3.18.
SURGE TANK
1. Take initial tank reading.
2. Open inlet valve to tank.
3. Divert fluid flow to tank using oil manifold.
4. Monitor surge tank pressure.
5. Gradually close gas B.P.V. until desired pressure within vessel is achieved.
NOTE: It may be required to utilise a surge tank as an atmospheric tank capable of withstanding a slight
pressure (<50 psig) build-up. If this is the case, then any valve (including the BPV), fitted on the gas
outlet MUST remain fully open.
The valves on the gas outlet may have been removed at EXPRO facility onshore, prior to shipping.
6. Take readings as and when required from the relevant sight glass over timed periods.
7. Pump out tank compartments as required.
8. At end of flow period divert flow from tank to burner using oil manifold.
9. Close tank inlet valve.
10. Note final level in tank compartment and compute flow (if required).
GAUGE TANK
1. Take initial tank reading.
2. Open inlet valve to tank.
3. Divert fluid flow to tank using oil manifold.
4. Take readings as and when required from the sight glass over timed periods.
5. Pump out tank compartments as required.
6. At end of flow period divert flow from tank to burner using oil manifold.
7. Close tank inlet valve.
8. Note final level in tank compartment and compute flow (if required).
3.19.2 TO SWITCH SIDES ON BOTH SURGE AND GAUGE TANKS
1. Note fluid level in empty tank compartment.
2. Open inlet valve on empty compartment and close inlet valve on full compartment, simultaneously.
3. Note fluid level on full compartment side and compute flow.

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3.19 SURGE/GUAGE TANKS
3.19.3 TO PUMP OUT ONE OR BOTH COMPARTMENTS
1. Check that you are not flowing to the compartment(s) that are to be pumped out, i.e. that the inlet
valve(s) are closed.
2. Start-up the Compressor and check that adequate air is coming out of the flaring boom's burner head.
3. Check flare is lit or burner pilot flame is operating.
4. Open the tank drain valve(s) on the compartment(s) to be drained.
5. Open valve from pump discharge on oil manifold.
6. Open valve to select burner on oil manifold.
7. Startup the Transfer Pump to pump out tank contents.
8. Monitor Compressor in case of shut-down, and loss of air to burner head. Check flare does not go out.
Monitor tank level.
9. When the tank compartment is empty, at the level required, switch off the Transfer Pump and close off
the drain valve(s).
10. Close valve to pump outlet on oil manifold.
11. Once it is evident that no more oil/condensate is leaving the burner head, shut-down the compressor.

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Page 1 of 1
3.20 TRANSFER PUMPS
Assuming that all tank / oil manifold valves are lined up.
3.20.1 ELECTRICAL PUMPS
START PUMP
1. Place breaker in ON position.
2. Press START button.
NOTE: The only way to control the discharge rate of an electrical transfer pump is to close in on a valve
downstream of the pump on the oil manifold valve. This is not an acceptable solution for long periods
as it may burn out the pump motor.
STOP PUMP
1. Press STOP button.
2. Place breaker in OFF position.
3.20.2 AIR DRIVEN PUMP DIAPHRAGM PUMP
START PUMP
1. Open air inlet valve to allow sufficient cycling rate for pump to prime (30-60 cycles per minute).
2. After pumping starts, adjust air inlet valve for the desired capacity.
NOTE: To control the pump discharge rate, alter the air supply to the pump, obviously more air will increase
the discharge rate and less air will decrease the discharge rate. For continuous use, this will not
affect the pump moving parts in any way.
Hydrating of the air exhaust can occur under certain conditions of temperature and humidity. When
pump performance suffers because of this, a non-sticky anti-freeze lubricant in the air line lubricator
will solve the problem. This is more likely to occur at high discharge pressures.
STOP PUMP
1. Shut-off air supply to pump.

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3.21 IGNITION SYSTEM
3.21.1 'MAGNITER' IGNITION SYSTEM
START-UP
1. Open main air feed to system.
2. Slowly open regulator until 20 psi is displayed on the regulator gauge.
3. Open the bypass valve for approximately 3 seconds then close and secure closed.
NOTE: The system should now be up and running at about 4000 RPM, although adjustments might be required
of the pressure regulator to obtain the desired operating speed.
SHUT-DOWN
1. TO STOP THE UNIT SIMPLY CLOSE THE MAIN AIR FEED VALVE.
EMERGENCY SHUTDOWN
1. Close main air feed valve to unit.
2. If step 1 fails to operate, shut regulator down until pressure gauge reads zero.
3. If steps 1 and 2 fail, sever the air feed line from air management unit to 'MAGNITER'.
NOTE: Once the air motor has stopped turning, the Magneto stops providing electrical power and does not retain
any electrical charge.
3.21.2 DIESEL IGNITION SYSTEM
LOCAL CONTROL
1. Switch on mains isolator.
2. Switch pump to 'LOCAL' position - pump will start and continue to run until switched off.
3. Push ignition button on panel for spark / ignition hold until flame established - release push button.
4. TO STOP - switch off pump.
REMOTE OPERATING PROCEDURES
1. Switch on mains isolator.
2. Ensure emergency stop on hand control is released.
3. Select pump control switch on panel to remote position.
4. Press black push button on hand unit - pump will run and ignition should be established - release push
button.
5. TO STOP PUMP
a) Press red emergency stop button on hand unit.

b) Turn red emergency stop knob anti-clockwise to release button prior to relighting pilot.

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Page 2 of 2
3.21 IGNITION SYSTEM
3.21.3 ELECTRIC IGNITION SYSTEM

START-UP
1. Open propane to feed the ignition chamber.
2. Slowly open the propane regulator until 20 to 30 psi gas pressure is displayed on the regulator gauge.
3. Switch power supply to 110 V or 220 V depending on the main power supply.
NOTE: a) As soon as the system is running, switch off the power supply to prevent the spark
plug from burning out.
b) It may be desirable to adjust the propane pressure in order to achieve the optimum
pilot flame.
SHUT-DOWN
1. Close the main propane supply.
NOTE: Once the main propane supply is closed, the pilot flame will stop burning.

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Page 1 of 5
3.22 BURNERS
In order to dispose of oil and gas during testing operations, it is a commonly accepted practice to flare the produced well
fluids.
For offshore installations, this requires that the burner head is placed on the end of a suspended boom to minimise heat
radiation on the rig and also for safety considerations.
Before diverting flow to a burner ensure that the following have been carried out:-
1. Check prevailing wind direction and select downwind burner suitable for operations.
2. Operate ignition system and ignite propane pilot (or lance) flame.
3. Open water supply to cooling screens.
4. Check that all valves downstream of the choke are lined up for the required flow to the selected flare boom, eg
via the dedicated clean-up line.
5. Open well to flare at choke manifold.
6. Once flare is alight observe flame stability and if necessary leave pilot (or lance) flame burning. During the
entire period of flaring, routine observations of the flame stability and potential fall-out should be made and
documented in a report.
7. When flowing via dedicated clean-up line maintain lance flame throughout.
8. Immediately prior to final flaring operations being completed, pump out contents of gauge/surge tank to flare.
NOTE: Each supergreen burner head has the capacity to burn 5,000 BOPD.(Depending on fluid parameters, see
Section.3.22 Page 4 for Air requirements graph.)
Pressure of oil at burner head should not exceed 120 psi under normal burning conditions (on high rate tests
this pressure may be exceeded, therefore 300psi compressors are recommended.)
3.22.1 SUPERGREEN CRUDE OIL BURNER MAINTENANCE GUIDELINES
These procedures should be carried out immediately any oil burning has been completed. If not, severe
corrosion of component parts may result.
3.22.1.1 DIS-ASSEMBLY
1. Grip outer housing of assembly in vice and unscrew lock collar from main housing.
2. Remove split rings from inner mandrel.
3. Remover inner mandrel and lock collar from assembly.
4. Remove 'O' Rings (No. 337) from outer housing.
5. Thoroughly clean and inspect all component parts for damage.
3.22.1.2 ASSEMBLY
1. Grip out housing of assembly in vice.
2. Apply a liberal coat of "Copper Dope" to internal faces of outer housing.
3. Replace 'O' Rings (No. 337) in outer housing.
4. Apply "Copper Dope" to internal thread of lock collar and external faces of inner mandrel.
5. Place inner mandrel through lock collar.
6. Insert inner mandrel through first 'O' Ring (No. 337) in outer housing.
7. Apply "Copper Dope" on split rings and install them on inner mandrel.
8. Firmly push inner mandrel into assembly until split rings mate with outer housing.

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Page 2 of 5
3.22 BURNERS
9. Screw lock collar onto assembly until hand tight (Do not overtighten).
10. Apply "Copper Dope" to external thread of outer housing and install 'O' Ring (No. 433).
11. Install end cap on assembly until hand tight (Do not overtighten).
3.22.1.3 PRESSURE TESTING
OIL LINE (TEST MEDIUM; WATER)
1. Insure end caps on atomising heads are secure.
2. Open needle valves on ends caps.
3. Make preparatory arrangements for pressure testing in accordance with installation Regulations.
4. Flush through oil line until all air has been expelled from the system.
5. Close needle valves on end caps.
6. Apply test pressure (Maximum 1440 psi) and monitor pressure for 15 minutes.
7. Vent all pressure from system.
N.B If oil line has valves seat tests must be carried out.
3.22.1.4 AIR LINE (TEST MEDIUM; AIR)
1. Close both oil diverter manifold valves.
2. Open compressor discharge valve and apply maximum air pressure to system.
3. Close compressor discharge valve and monitor pressure for 15 minutes.
4. Vent pressure from system and remove end cap from burner.
3.22.1.5 PRE FLOW TEST PROCEDURES
On completion of the pressure test programme the following preparatory tests should be conducted.
1. Start all compressors for five minute warm up period (see compressor operating guidelines).
2. Put single compressor on load and supply air to burner.
3. Record air delivery pressure at receiver/distribution manifold and engine revs/min.
4. Put second compressor on load and supply air to burner.
5. Continue repeating Step 3. and 4 until all information has been recorded.
6. Put third compressor on load and supply air to burner.
7. Repeat Step 3 and continue until all compressors have been checked.
ELECTRIC IGNITION SYSTEM (HIGH VELOCITY AND FOR USE WITH SUPERGREENBURNER)
3.22.1.6 START UP PROCEDURE
The system has been designed and tested specifically for use in conjunction with the supergreen crude oil
burner. It has been tested under severe critical conditions and has a proven operational record.
Expro Ignition System. (High Velocity).

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Page 3 of 5
3.22 BURNERS
INSTALLATION
1. Ensure that the unit is set for the correct power supply. ie. either 110 V or 230 V.
2. Secure pilot body (item 1) to the desired position on the burner/ atomising head assembly.
3. Connect probe (item 2) and H.T. cable (item 4) ensuring that a good earthing seal is obtained.
4. Install and secure enclosure (item 11) approximately 20 ft behind atomising head assembly.
5. Position cable reel (item 9) in a dry area (off the boom) and connect cable (item 8) to LODGE box by
connecting items 6 & 7.
6. Unwind cable (item 8A) and connect to power supply (again ensure correct power supply is selected).
3.22.1.7 ELECTRIC IGNITION SYSTEM (HIGH VELOCITY AND FOR USE WITH SUPERGREEN BURNER)
START UP
1. Open propane supply and adjust pressure to suit.
2. Switch on power supply and push start button.
NOTE: a) As soon as the system is running, switch off the power supply to prevent the spark plug
from burning out.
b) It may be desirable to adjust the propane pressure in order to achieve the optimum pilot
flame.
SHUT DOWN
1. Close the main propane supply.
NOTE: Once the main propane supply is closed, the pilot flame will become extinguished.
3.22.1.8 HEAT RADIATION SCREEN
It has been found that the water cooling rings normally incorporated as part of the traditional crude oil burner
has a detrimental effect on the supergreen burner performance.
When operating the supergreen, no water should be applied to the flame, this has an immediate cooling effect
and may result in minimal 'fallout'. To overcome this heat radiation screens (Drg no. TED080604) are
recommended. These units are placed at intervals along the boom, but not on the burner head. A water curtain
is produced behind the flame and between the burner and structure.

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Page 4 of 5
3.22 BURNERS

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Page 5 of 5
3.22 BURNERS
3.22.1.8 PARTS LIST (GENERAL ARRANGEMENT DWG:TED090101)
DRAWING DESCRIPTION MATERIAL QTY

NUMBER
OUTER HOUSING
TED090103 4140 1
(Air Inlet conn 3 602F)
INNER MANDREL
TED090104 4140 1
(oil inlet conn 2 602F)
TED090105 SPLIT RINGS 4140 2
TED090106 LOCK COLLAR 4140 1
TED090107 END CAP 4140 1
50 - 337 O - RINGS FR 5890 2
50 - 443 O - RINGS FR 5890 1

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Page 1 of 2
3.23 PRESSURISED LABORATORIES
1. Locate laboratory in required position as per layout diagram.
2. Remove air inlet / outlet transport covers and replace with duct spigots.
3. Locate fan in safe area as shown on the layout diagram.
4. Connect the flexible air intake conductor from the fan to the laboratory duct spigot.
5. Connect electrical supply to laboratory.
NOTE: A qualified electrician should do this.
6. Connect air supply to laboratory.
7. Connect an earthing strap.
8. Ensure fire dampeners are open.
9. Ensure there are no restrictions over the air in or out ducts.
10. Check door seals are in good condition (to prevent air loss from laboratory).
11. Ensure all M.C.T. blocks are in place.
12. Adjust the tappings on the main transformer and control circuit transformer in the pressurisation panel to suit the
incoming voltage.
13. Check that the outside door and escape hatch are closed.
14. Check that the fire dampers in the pressurisation inlet and extract ducts are in the open position.
15. Check that the volume control damper in the extract duct is partially closed.
16. Check that the key switch on the front of the Pressurisation Panel is in the "Normal" position (i.e. the key is in
the vertical position which is the only position in which it can be removed).
17. Turn on Rig Supply and Power Up Pressurisation Panel using the main Isolator Switch on the front of the Panel.
(Green "Power On" light will illuminate within the circular window on the panel front.)
18. Press the fan start button on the main panel.
NOTE: Check direction of the fan in the laboratory as with a centrifugal fan, the output will be vastly reduced if
the Impeller is revolving in reverse.
19. Once the pressurisation fan has been switched on this will pressurise the cabin and begin the pre set purging
cycle indicated by the external green light on the main panel. If the purging cycle does not commence check
items 2 - 4 and also check that the pressurisation fan is running in the correct direction.
20. When the purging cycle is complete the purge light will switch off automatically. Note that purge time is
adjustable between 0 and 60 minutes on the timer within the panel. Minimum purge time for this unit in a Zone
2 area should be 20 minutes.
21. When the purging cycle is complete press the main start button on the panel to bring power to the standard
electrical equipment in the cabin.
22. The pressure in the cabin should be balanced to 0.30 inches of water on the cabin pressure gauge by adjusting
the volume control damper in the extract duct.
23. If the pressurisation is lost in the cabin during operations an audible and visual alarm will sound to warn that the
shutdown timer has started and that pressurisation must be regained within 30 seconds or power to all standard
electrical equipment will be lost. If pressurisation is not regained and the power is lost, the cabin must go
through the complete purging cycle again before power can be applied to the standard electrical equipment.
24. If smoke or gas is detected within the cabin this will automatically shut off power to non Ex equipment.
25. After smoke or gas shutdown has occurred the reset button on the front of the panel must be pressed and the
purging cycle re-started from number 2 of operating instructions.

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Page 2 of 2
3.23 PRESSURISED LABORATORIES
26. All power in the cabin can be shut down by pressing the "main stop" button on the main panel.
27. The Purge and Pressurisation System can be over-ridden by using the key switch on the front of the Panel. In
the over-ride position the key is in the horizontal position and cannot be removed from the switch.
The Fire and Gas System will still be operative in the over-ride mode and will shutdown the cabin in the event of
high gas or smoke alarm.
Refer to Fig. 3.14 ROTATIONAL DIRECTION OF IMPELLER

SECTION 3
EQUIPMENT
Page 1 of 7
3.24 ANCILLARY EQUIPMENT
3.24.1 DEADWEIGHT TESTERS
CHANDLER/DEWIT
1. Read pressure gauge somewhere on pressure point manifold for estimate of what pressure (range) to
expect.
2. Put sufficient weights on piston table to exceed expected pressure.
3. Slowly open valve at pressure point.
4. Inspect tubing connections for leaks (oil dripping/squirting) and correct problem of leaks, if any.
5. Open pressure chamber valve and impart gentle rotation clockwise to weight stack on piston table.
6. Continue clockwise rotation of table weights and piston.
7. Remove weights until piston shaft seems to "float" freely and is stable between the two marks on the
rotating shaft.
8. Total the value of the weights, and add 50 psi for the table weight and note this information on data
sheet, plus the time the reading was taken.
9. Purge the deadweight liner regularly to ensure accurate readings.
BUDENBURG
1. Read pressure gauge somewhere on pressure point manifold for estimate of what pressure (range) to
expect.
2. Line up DWT valves as required:-
a) If under 2,000 psi use Range 1, back valve open, front valve closed.
b) If over 2,000 psi use Range 2, back valve closed, front valve opened.
3. Load the weight carrier with the weights equivalent to the estimated well pressure.
NOTE: The weights are marked with dual scales dependent on piston range in use. USE THE
CORRECT SCALE.
4. Slowly open valve at pressure point.
5. Inspect tubing connections for leaks, repair as required.
6. Remove/add weights as required until piston 'floats' freely in required pressure range.
NOTE: a) Low pressure (range 1) Blue band on piston.

b) High pressure (range 2) Red band on piston.
7. Total the value of weights, add value of weight carrier.
8. Note this information on data sheet, plus time reading was taken.

SECTION 3
EQUIPMENT
Page 2 of 7
3.24.2 PRESSURE/TEMPERATURE RECORDERS
1. Place the instrument close to the flowline manifold and connect up the necessary pipework.
2. Perform a zero check of the instrument with no pressure.
3. Connect temperature bulb:-
a) Insert the temperature bulb into the thermal well to its full depth.
b) Secure the gland nut into the thermal well with a wrench.
c) With the bulb properly installed, secure the packing nut into the gland nut.
4. Connect the static pressure element:
a) Use 1/4" O.D. stainless tubing (wall thickness 0.065"), found inside the foxboro box, to
connect up the process.
NOTE: On high pressure/temperature wells, autoclave fittings and liners rated to 15,000 psi will be
used.
b) Plumb into the required range at the back of the foxboro.
c) Connect remaining free end into the flowline manifold.

NOTE: Ensure suitable isolation valves are used to isolate process pressure prior to
hooking up static pressure line.
5. Slowly open isolating valve(s) and allow process pressure to register pressure on the Recorder.
6. Observe pen movement and read pressure off chart. Check pressure against suitable pressure
gauge to ensure that the liner is not plugged.
3.24.3 CHEMICAL INJECTION PUMPS
TEXSTEAM SERIES 5000/6000
1. To adjust for desired volume is done by either speeding the pump up or slowing it down, using the air
inlet valve.
Different volumes can also be achieved by changing the plunger stroke to either long or short. This is
done by moving the plunger travel pin to the plunger hole nearest the gland nut (for longest stroke) or
to the back hole for short stroke.
2. Methanol injection should commence prior to the opening of a well after a shut-in period, at a rate
determined from the Methanol Requirements for Lowering Freezing Points chart and stop once the
temperature has risen above the appropriate line (to be read from the Temperature at Which Gas
Hydrates will Freeze.
3. On High Deliverability wells, while flowing through the test separator, it may be necessary to inject
methanol upstream of the back pressure valve to prevent hydrates across it. In this case a
thermometer should be strapped (under cladding) to the pipework downstream of the B.P.V. and the
charts mentioned above referenced again.

SECTION 3
EQUIPMENT
Page 3 of 7
3.24.4 RANAREX GRAVITOMETER
1. CHECK ALL ACCESSORIES
All Ranarexs are sent offshore in a GRP container containing:-
a) 1 - Ranarex
b) 1 - Tub of unused Silica gel
c) 1 - 240 Vac to 115 Vac transformer
d) 1 - 115 Vac plug lead
e) 1 - Vent hose
f) 1 - Spare drive belt
g) 1 - Spare connecting tape
2. SELECT LOCATION
The instrument should be easily visible and readily accessible from the operator's position, not near
hot or cold objects. Allow at least 5" clearance on the left side and 3" on the right side for making
connections and normal operating functions.
3. INSTALL TRANSFORMER
If the laboratory is fitted with 240 Vac supply connect the transformer to the socket on the side of the
instrument - Do not start the instrument at this stage.
4. FILL AIR DRIER
The air drier must be removed from the upper left side of the instrument. Unscrew the two knurled
thumb nuts from the studs. Draw the plastic drier out of the gravitometer just far enough so the
rubber tube can be removed from the elbow at the rear of the drier. Remove the rubber closure plug
on the front of the drier by lifting the lever at the centre of the plug (but do not turn the lever).
Hold the drier horizontal with the front face up and pour silica gel through a funnel into the spout. Tap
or shake the drier vigorously and continue to fill to the base of the spout. Replace the rubber closure,
attach the rubber tube on the elbow at rear of drier, then install drier in gravitometer. The rubber tube
has an internal spring to prevent collapse; do not remove or lose this spring.
The drier is permanently riveted together as an assembly. Do not attempt to remove the rivets and
disassemble the drier.
The capacity of the silica gel will vary according to the atmospheric humidity and it should be
inspected through the drier cover at regular intervals. When the upper half of the narrow
compartment shows a change from deep blue colour to grey-pink colour, the silica gel must be
removed.
Active silica gel has a deep blue colour and should be kept in a tightly closed container. Exhausted
silica gel has a light greyish, pink colour and may be reactivated and used over and over again.
Merely heat it in an open pan at about 250F, for 2 hours, or until the dark blue colour returns, then
store in a tightly closed container.
NOTE: It is advisable to cover the air holes on the front of the drier with tape, to prevent moisture
from exhausting the silica gel, this MUST be removed prior to measuring the gas S.G. to
allow the reference gas to be drawn in to the gravitometer.
5. ATTACH OUTLET HOSES
If the Ranarex is operated in a confined space, as inside a laboratory, the gas sample must be
discharged outside of the unit. This will prevent contaminating the unit with noxious or hazardous gas
and air mixture. If measuring only gas below 1.000 specific gravity, attach a hose to the "light gas
outlet" nipple on the upper right side of the Ranarex case. If also measuring gases above 1.000

SECTION 3
EQUIPMENT
Page 4 of 7
specific gravity, also attach a hose to the "heavy gas outlet" nipple. These hoses must remain
attached when making "zero" check.
6. GAS FILTER
If the gas contains suspended particles larger than 25 microns, or if it is "wet", filtering is required. If a
commercial filter is not available, a suitable filter may be made of 1" pipe, 15" long, mounted
vertically. Cap both ends and install a drain cock in the bottom cap. Install an inlet connection from
the gas line 2" from the bottom and an outlet to the Ranarex 2" from the top. Fill the pipe loosely with
No.0 steel wool. Drain the filter frequently to keep the steel wool free of condensate.
7. GAS TEMPERATURE
If the gas pressure has been reduced more than 100 lb/in2, or if the gas flows through a temperature
zone more than 10F difference, from the ambient temperature of the gravitometer. If the gas is
passed through a section of 3.8" liner at least 5'. (Preferably 10') long, exposed to the ambient
temperature of the Gravitometer and located after the last pressure reduction, temperature
adjustment will be automatic. The tube may be coiled or bent in the form of a grid to fit the space
available.
8. LOCATION OF CONNECTIONS AND CONTROLS
CAUTION: The Ranarex is provided with a pointer lock which should be locked at all
times when the Ranarex is not operating. The function of the lock is to
exert tension on the flexible tape, which connects to the cam and reference
wheel. This tension maintains correct "tracking" of the tape when the
Ranarex is stopped. The user is cautioned to leave the lock applied until
after the Ranarex motor has been started and to apply the lock before
shutting off the motor, to avoid operating inconvenience and prevent
damage to the Ranarex.
The "lock" position of the pointer is at the upper right corner of the scale, near the 0.970 - 1.030
graduations. The position of the locking mechanism is shown by the arrow of the knob and the
legends on the Ranarex front cover.
To check if the pointer is locked, turn the knob to "UNLOCK" and observe if the pointer drifts
downwards, even though slightly. Then turn the knob to the "LOCK" position and observe if the
pointer snaps into the original position.
The correct procedure for operating the Ranarex gravitometer is described on the instruction plate
located over the centre of the indicating scale. It is recommended that the user observes the
sequence of steps as listed. By doing so maximum accuracy will be achieved with minimum effort
and time. In fact, the user is encouraged to read each item of the instructions each time the
instrument is used until the correct sequence becomes a matter of habit.
The following comments will also be helpful:-
ZERO ADJUSTMENT
The zero adjust screw should be turned in the direction opposite to the correction required in the
pointer reading. For example, if the pointer must be moved clockwise to read 1.000 on the scale, the
screw should be turned counter-clockwise. After making adjustments, allow the pointer to stabilize
because there is a tendency to overshoot when turning the zero adjust screw.
In normal operation the zero adjust screw should require only little adjustment, less than 1/4 turn, to
set the pointer to 1.000. If more than 1/2 turn is ever required, stop the motor and investigate the
cause. Never turn the screw full travel clockwise with the motor running; never turn the screw full
travel counter-clockwise.
RESPONSE TIME
When measuring gas at the normal flowrate of 12 SCFH, the response time to reach the final reading
is 40-45 seconds. This time can be reduced by operating at a higher flowrate, obtained by adjusting
the flowmeter valve so the float reads higher than the actual gas specific gravity.

SECTION 3
EQUIPMENT
Page 5 of 7
For example, when measuring 0.6 gravity gas, a flowmeter setting of about 1.2 will reduce the
response time to about 30 seconds. However, the flowmeter valve should not be opened so much
that the float is lifted against the stop at the top of the flow tube.
OVER PRESSURE PROTECTION
If by oversight the flowmeter valve is opened before the selector valve is turned to the "LG" or "HG",
the valve cover will lift off the body to relieve the pressure and will be reseated by the spring.
PURGING TO 1.000 AFTER READING ON GAS
This is a necessity in order to bring the pointer within operating reach of the pointer lock mechanism.
If the pointer starts towards 1.000 and then hesitates and remains at an intermediate reading, turn the
selector valve halfway beyond "0" towards the next position. If the pointer then continues toward and
reaches 1.000, check for an obstruction.
3.24.5 ULTRASONIC THICKNESS GAUGES
PRIOR TO USE
Visually inspect the unit for signs of damage and ensure that there are batteries fitted and working.
CALIBRATION CHECK
To assure that the Audit 100 is correctly measuring thicknesses, it should be checked against the calibration
block prior to use. If the calibration is out, it is recommended to change the unit out for a new one and to return
the old unit to the manufacturers.
OPERATING TECHNIQUE
1. The points to be thickness checked should be prepared by having all fouling, detritus, scale, etc.
removed.
NOTE: Surfaces do not have to be entirely flat or smooth, but in general, the poorer the surface, the less
satisfactory it is from a measurement point of view.
2. Connect the two leads from the transducer probe to the main "box" (red to red, black to black).
3. Use a suitable couplant between the transducer and the pipework / equipment.
NOTE: Alvania grease or Swarfega are ideal for this.
4. Hold the transducer squarely against the surface of the area to be measured and switch the gauge on
by pressing the switch on the front panel of the gauge.
5. Read the thickness value from the digital display.
NOTE: For the models used by EXPRO this will be in millimetres and displayed as two digits, a decimal point
and a further digit.
6. The Thickness Gauge can be switched on and off by pressing and releasing the pressure sensitive
switch on the instrument front panel.
NOTE: There are no controls to be adjusted.
FOR FURTHER INFORMATION ON PIPEWORK THICKNESSES REFER TO 3.10.1.

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EQUIPMENT
Page 6 of 7
3.24.6 FISHER 67FR AIR REGULATORS
If it is required top alter the regulator outlet pressure the following steps should be taken.
3.24.6.1 TO PLACE REGULATOR IN SERVICE
1. Connect an air supply of less than 250 psig to the valve inlet.
2. Ensure adjusting screw is backed out.
3. Open isolating valve on air supply line to allow input supply pressure to charge the line.
4. Slowly turn the adjusting screw clockwise until required outlet pressure is achieved.
NOTE: The outlet pressure should be monitored at a pressure gauge downstream of the regulator when
this adjustment is taking place.
5. Tighten locknut to prevent adjusting screw movement.
3.24.6.2 TO ADJUST REGULATOR SET PRESSURE
As above a pressure gauge should be monitored throughout the adjustment.
1. Loosen the locknut (if used) which holds the adjusting screw in position.
2. Turn the adjusting screw clockwise to INCREASE or counter-clockwise to DECREASE the outlet
pressure.
3. Re-tighten the locknut to hold the new position of the adjusting screw.
3.24.6.3 TO TAKE REGULATOR OUT OF SERVICE
1. Close air supply isolation valve.
2. Loosen adjusting screw locknut.
3. Turn adjusting screw counter-clockwise to bleed off pressure in air supply line.
3.24.6.4 TO DRAIN LIQUIDS FROM REGULATOR
It is necessary to periodically drain any liquids or moisture from the filter to prevent the filter diaphragm "sticking
or liquids passing down the outlet line. To do this perform the following:
1. Turn the drain valve counter clockwise and allow any liquids to "blowdown".
NOTE: The drain valve is found at the bottom of the filter.
2. Once "dry air" is blowing out of drain, turn the drain valve clockwise to close.

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Page 7 of 7
3.24.7 PRESSURE GAUGES
When measuring an unknown pressure, always fit the largest pressure gauge available and work down to a
level where the pressure is in the middle 60% of the gauge range.
Eg: On a 1,000 psi gauge, the pressure would be between 200 and 800 psi.
The thread of the pressure gauge should be treated with the appropriate liquid 'o-ring' or have a seal of two to
three layers of Teflon tape wound round. The Teflon tape should be wrapped following the thread so that when
the gauge is inserted in the tapping the Teflon is not backed off.
NOTE: In Holland, Teflon tape will not be used.
Refer to Fig. 3.29 WINDING TEFLON TAPE ON A THREAD
3.24.8 STICK THERMOMETERS
Stick thermometers filled with mercury should not be used, alcohol filled thermometers MUST be used.
1. Where stick thermometers are inserted in a thermowell, the thermowell should be filled with a heat
transferring medium, eg the hydraulic fluid from the Dead Weight Tester. If nothing else is available
grease could be used.
2. Where stick thermometers are strapped to the side of a pipe, they should be protected from radiated
heat from the sun as well as any wind chill from being exposed to the wind. It should be attached to
the pipe with grease tape or similar and have padding around the bulb end.
NOTE: A heat transferring medium such as grease or Chestertons Silver Seal can be applied to the padding
to aid heat transfer.

SECTION 3
EQUIPMENT
Page 1 of 2
3.25 VALVES
3.25.1 McEVOY
The operating procedures for all types of McEvoy valves are the same as follows:-
3.25.1.1 OPEN VALVE
3. If a valve is pressure locked, then the appropriate bleeder should be opened to release the pressure from
the gates prior to operating.
3.25.1.2 CLOSE VALVE
As above this leaves the stem in a "relaxed" position, which lengthens the life of the stem. It also provides
a position indicator, enabling you to determine whether the valve is open or closed by simply turning the
NOTE: It is important to count the number of turns when operating a valve to ascertain whether it is fully open or
fully closed this is especially so during wireline operations.
TABLE 3-15 REQUIRED NUMBER OF TURNS TO FULLY OPEN/CLOSE A McEVOY VALVE
SIZES
VALVE TYPE
1-13/16 2-1/16 2-9/16 3-1/16 4-1/16 5-1/8
MODEL C --- 13 16 18 17 22
MODEL E-2 7 9 10 12 17 ---

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EQUIPMENT
Page 2 of 2
3.25 VALVES
3.25.2 FOLEY
3.25.2.1 OPEN VALVE
As above this leaves the stem in a "relaxed" position, which lengthens the life of the stem. It also provides
a position indicator, enabling you to determine whether the valve is open or closed by simply turning the
NOTE: It is important to count the number of turns when operating a valve to ascertain whether it is fully open or
fully closed this is especially so during wireline operations.
3.25.3 MAGNUM CONVERTED
3.25.3.1 OPEN VALVE
1. Rotate the handwheel counter-clockwise until strong resistance is felt.
2. DO NOT back off the handwheel (to do so would move it away from the drift position and could cause
flowstream damage to gate and seats).
1. Rotate handwheel clockwise until substantial resistance is felt.
2. BACK OFF handwheel 1/8"-1/4" turn assure gate is allowed to "float".
NOTE: Number of turns required to open or close varies with bore size and pressure class of specific unit.

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Page 1 of 2
3.26 THIRD PARTY EQUIPMENT
3.26.1 COMPRESSORS
COMPRESSOR START-UP
1. Turn knob on fuel valve to start position.
2. Lift the Start/ Reset / Emergency stop Lever to the Start / Reset position, and hold in position.
3. Press engine Start button.
Release Start button when engine fires.
4. Press Reset green button and after 20 seconds release Start/Reset/Emergency Stop lever to central
position.
5. Allow machine to warm up for several minutes.
6. Press brass Start/Run button to engage regulation system.
7. When machine is running at full load, check if air filter restriction gauges show less than 30". If not
then air filter element service is required.
COMPRESSOR SHUT-DOWN (NORMAL)
1. Close service valve.
2. Allow machine to idle for several minutes.
3. Press normal Stop button.
4. Push horn stop button to silence shutdown warning horn.
COMPRESSOR SHUT-DOWN (EMERGENCY)
1. Move Start/Reset/Emergency stop lever down to stop position.
NOTE: Never use emergency stop lever for normal shut-down as this can lead to mechanical damage.
IF THE ENGINE SAFETY SYSTEM TRIPS WHILST THE ENGINE IS BEING USED IN A HAZARDOUS AREA
(INDICATED BY A TELL TALE SHOWING RED/WHITE), DO NOT ATTEMPT TO RESTART UNTIL ADVICE
HAS BEEN SOUGHT FROM THE WELL TEST SUPERVISOR.

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Page 2 of 2
3.26 THIRD PARTY EQUIPMENT
3.26.2 STEAM GENERATORS
On certain types of well test it is necessary to heat the well effluent whilst flowing the well. In the case of an oil
well, for instance, it may be that the oil has a high wax content which would tend to make the oil effectively more
viscous at lower temperatures which would lead to operational problems if the oil were to flow at ambient
conditions. It is with gas wells, however, that the requirement for heat input to the well stream is usually
necessary. This is due to the fact that as a gas is expanded through a choke, a dramatic temperature drop can
occur causing entrained water droplets and lighter petroleum distillates within the gas stream to freeze into solid
form causing obstructions or restrictions in the pipework. These solids, generally referred to as hydrates, can
cause a great deal of problems whilst well testing and it is for this reason that a Heat Exchanger would be used
to raise the temperature of the well stream in order to avoid hydrate formation.
The preferred form of heat input for the Heat Exchanger is steam. Due to the fact that most rigs either do not
have a Steam Generator or do not have excess capacity, a portable Steam Generator is usually required to
provide steam for the Heat Exchanger.
As Expro do not own their own Steam Generators they are hired in from a Third Party along with an Operator.
The following guidelines have been formulated for using Steam Generators. This is divided into two parts, the
first covering procedures and operator responsibilities, the second covering operation of the equipment.
1. The Steam Generator Operator is deemed to be an integral part of the well test crew and as such will
be under the direct supervision of the Expro Well Test Supervisor.
2. He is required to attend/contribute to all Safety Meetings and Toolbox Talks concerning the well
testing operations.
3. The Operator will ensure that the unit is fully operational prior to the commencement of the well test.
4. The Operator will liaise with the Well Test Supervisor or his deputy to ensure that steam is available at
a pre-agreed time (usually prior to the opening of the well).
5. The Operator is responsible for the manning of the Steam Generator unit. During Well testing
operations where there is a requirement for steam to be supplied to the Heat Exchanger the Steam
Generator must be attended at all times.
6. In an effort to define "attended", it is appreciated that part of the Operator's responsibilities are to
periodically check the integrity of the steam lines and to check the performance of the Heat
Exchanger in order to be able to assess the correct working of the whole system. It will also be
necessary for the Operator to top up the unit with fuel from time to time, therefore, we would say that
the unit is "attended" if the Operator is on the deck, in or close the area in which the unit is situated, is
able to see the unit and able to react immediately to any problems with the unit.
7. As can be seen from item 6, if the Operator is to be away from the unit (eg, for meal break etc) then
he should inform the Well Test Supervisor who can then designate a competent person familiar with
the shutdown systems on the unit to 'attend' the unit until the Operator returns.
8. The Operator is responsible for the day to day maintenance and upkeep of the unit and shall inform
the Well Test Supervisor of any defects, equipment failures and spare part requirements.

SECTION 3
EQUIPMENT
Page 1 of 1
3.27 PROPPANT KNOCKOUT VESSEL
3.27.1 INITIAL JOB START UP
1. On initial rig up and pressure testing observe the weight of the PKV vessel full of water. Once
pressure testing sequence is completed ensure the vessel is completely empty of water by opening all
the lower drain valves.
2. On opening the well direct all produced fluids (ie cushion) across the PKV bypass until hydrocarbons
are observed at surface.
3. Open outlet valve on PKV and carefully monitoring the downstream of choke pressure direct the
produced hydrocarbons through the PKV. Slowly close the bypass valve ensuring the flowing
pressure is below 200 psig setting of the relief valve.
4. Once hydrocarbons are being produced through the outlet side of the PKV, take note of the initial
weight of the vessel.
5. Monitor the produced BS&W downstream of the PKV at regular intervals, especially after choke
changes.
6. Constantly monitor the weight of the vessel and in conjunction with point 5 should give a positive
indication as to the amount of sand being "caught".
3.27.2 END OF TEST CLEAN OUT PROCEDURES
1. At the end of the test isolate the PKV by closing the inlet to the vessel. If required to purge the vessel
with Nitrogen, connect up the N2 line and purge the system overboard or to surge tank to displace
hydrocarbon gases. Once sufficiently purged isolate the vessel by closing inlet and outlet valves and
bleed to zero.
2. Connect up line from transfer pump or cement unit to PKV inlet. Slowly pump water and detergent (if
available) through PKV and direct the contents to the surge/holding tank. Continue the flushing cycle
until the majority of oil has been displaced to the tank. From the tank the water can be drained off and
the oil burnt at a later date.
3. The vessel should now be full of water and sand if the flushing has been successful. Connect up the
4" hoses to the underside of the vessel on the two outlets. To test the mobility of the sand/proppant
open the sampling point valve (2" on underside of vessel). If the fluid left in the PKV is clean enough
then the vessel contents may be dumped overboard. Prior permission should be obtained from the
relevant authority prior to dumping. If the sand and associated fluids are not clean then step 2 would
have to be repeated.
4. Should there be no natural movement of sand connect up a 4" water supply to both sparging system
inlets, (the rig fire system water supply should be sufficient). On injecting the water through the
sparging system nozzles the sand should then flow out from the vessel ports.

SECTION 3
Page 1 of 29
FIG: 3.1 ACTUATOR LOCK-OPEN CAP AND DISC

SECTION 3
Page 2 of 29
FIG: 3.2 PRESSURE PILOT AND REMOTE ESD TIE-IN

SECTION 3
Page 3 of 29
FIG: 3.3 HANDLING COFLEXIP HOSES

SECTION 3
Page 4 of 29
FIG: 3.4 PREFERRED HOOK-UP ON SEMI-SUBMERSIBLE RIGS

SECTION 3
Page 5 of 29
FIG: 3.5 PIPEWORK METAL BAND

SECTION 3
Page 6 of 29
FIG: 3.6 BARTON RECORDER HOOK-UP

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Page 7 of 29
FIG: 3.7 SAMPLE POINTS

SECTION 3
Page 8 of 29
FIG: 3.8 CLEAN-UP CHOKE MANIFOLDS

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Page 9 of 29
FIG: 3.9 SEPARATOR BARTON HOOK-UP

SECTION 3
Page 10 of 29
FIG: 3.10 GAS DIVERTER HOOK-UP

SECTION 3
Page 11 of 29
FIG: 3.11 OIL MANIFOLD HOOK-UP
OUTLET TO
FLARE OUTLET TO
FLARE
INLET
OUTLET INLET
TO FROM
TANK TANK

SECTION 3
Page 12 of 29
FIG: 3.12 CORRECT INSTALLATION OF DOGS ON LINES

SECTION 3
Page 13 of 29
FIG: 3.13 ENCLOSURE LAYOUT

SECTION 3
Page 14 of 29
FIG: 3.14 ROTATIONAL DIRECTION OF IMPELLER

SECTION 3
Page 15 of 29
3.9 COFLEXIP HOSES
FIG: 3.15 TYPICAL COFLEXIP HOSE STRUCTURE

SECTION 3
Page 16 of 29
3.10 PIPEWORK
FIG: 3.16 HAMMER UNION MATING PARTS
MALE SUB
WING NUT
FEMALE SUB

SECTION 3
Page 17 of 29
3.10 PIPEWORK
FIG: 3.17 CLAMP CONNECTOR COMPONENTS

SECTION 3
Page 18 of 29
3.12 DATA HEADERS
FIG: 3.18 DATA HEADERS

SECTION 3
Page 19 of 29
3.12 PIPEWORK
FIG: 3.19 FLANGE MAKE-UP SEQUENCE

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Page 20 of 29
FIG: 3.20 SINGLE BLOCK CHOKE MANIFOLDS

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Page 21 of 29
FIG: 3.21 DOUBLE BLOCK CHOKE MANIFOLDS

SECTION 3
Page 22 of 29
FIG: 3.22 MASTERFLO MICROMETER INDICATOR

SECTION 3
Page 23 of 29
FIG: 3.23 DANIEL SENIOR ORIFICE METER

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Page 24 of 29
FIG: 3.24 EFFECT OF PROPORTIONAL BAND ON LIQUID LEVEL

SECTION 3
Page 25 of 29
FIG: 3.25 LIQUID METERS SET-UP

SECTION 3
Page 26 of 29
FIG: 3.26 SHRINKAGE TESTER

SECTION 3
Page 27 of 29
3.17 GAS DIVETERS MANIFOLDS
FIG: 3.27 GAS DIVERTER MANIFOLD

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Page 28 of 29
3.18 OIL DIVERTER MANIFOLDS
FIG: 3.28 OIL DIVERTER MANIFOLD

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Page 29 of 29
FIG: 3.29 WINDING TEFLON TAPE ON A THREAD

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EQUIPMENT
WELL TEST OPERATIONAL GUIDELINES APPENDIX 3A
Page 1 of 5
APPENDIX 3A DRAWING INDEX
DRAWING TITLE DRAWING N
FIG 1- EXPRO 2" Supergreen Atomiser head Assembly - D090101

FIG 2- EXPRO Lodge Ignition System (High Velocity) - D080703
FIG 3- Typical Supergreen Burner Rig Up - D090108
FIG 4- Fan Type Radiation Screen - D080601

SECTION 3
EQUIPMENT
Page 2 of 5
FIG 1

SECTION 3
EQUIPMENT
Page 3 of 5
FIG 2

SECTION 3
EQUIPMENT
Page 4 of 5
FIG 3

SECTION 3
EQUIPMENT
Page 5 of 5
FIG 4

SECTION 4
SURFACE SAMPLING
Page 1 of 16
4.1 PVT SAMPLING
INTRODUCTION
Hydrocarbon surface sampling can be broadly divided into 4 types:
1. Sampling of a single phase fluid from the wellhead.
2. Sampling of two phase fluids by separately sampling the liquid and gas phases, measuring the production rates,
and recombining in the correct well stream proportions - separator recombination sampling.
3. Sampling bulk fluids as atmospheric samples
4. Production Process Sampling
Other techniques, such as split-phase and iso-kinetic sampling, are not considered here.
For any analytical technique to give valid data, the samples must be representative of the hydrocarbon stream being
sampled. In order to obtain representative samples the sampling program must be integrated into the entire test program,
rather than being conducted in an unstructured manner.
SAFETY
Engineers operating the mercury free surface sampling system are responsible for their own safe working practices. To
this end, it is a requirement that proper safety equipment be utilised at ALL times.
It is a requirement at most facilities that a work permit be obtained BEFORE any high pressure work is started. Check with
the facility supervisor.
The following protective equipment shall be used :
1. Safety glasses, or other approved protective eyewear.
2. Steel toed safety footwear.
3. Protective coveralls
4. Hard hat
5. Gloves when applicable.
In addition to the above, the Engineer must cordon off and mark a safe working area, to prevent unauthorised personnel
from entering a potentially dangerous work site.
FIELD ENGINEERS RESPONSIBILITIES
When personnel arrive on location, the equipment must be checked and function tested. The expected sampling
manifolds should be assembled with the required crossovers, fittings etc. These should be decided on as soon as
possible, in conjunction with Client Representatives and welltest operators, to ensure that all items are in order. On arrival
at the wellsite try to take time to choose a suitable place in which to set up the equipment. Ideally a dry, ventilated and
well illuminated site would be preferred.
It is the Engineers responsibility to ensure that the selected sampling points are suitable for obtaining high quality
samples. In order to reduce Fire Risk, it is necessary for all sampling points and sampling equipment to be appropriately
earthed.
In addition to the foregoing, the engineer is responsible for noting any deficiencies or defects in equipment and for
relaying this information to the workshop staff on the completion of the job by means of the equipment Status form. The
numbers of all sample cylinders filled should also be noted. Defective equipment must be tagged with a red label, which
should be annotated with a brief description of the fault, be dated and be signed. In this way when equipment returns to
base it can be quickly and easily accounted for.

SECTION 4
SURFACE SAMPLING
Page 2 of 16
4.1 PVT SAMPLING
WELL CONDITIONING
It is essential that the well flow is stable prior to, and during, the sampling period. Unstable production results from flow
rates that are too low to achieve stable flow in a given completion size. This can result in slugging and liquid hold-up.
Examination of well / completion performance lift curves, and well designed completions can eliminate this problem.
Some criteria by which stable flow may be judged:
1. Stabilisation of FTHP and FTHT with a constant flow rate.
2. Stabilisation of separator gas composition - if on-site gas chromatography is available.
3. Stabilisation of the well GOR / CGR. This criteria should be used in conjunction with the above, since changes
in separator temperature / pressure result in changing GOR / CGR.
4. Stabilisation of water content, along with monitored water chlorides, or other trace elements.
The time taken for a well to achieve stable flow can be considerable - several days, with some gas wells taking weeks -
and sufficient time should be allowed within the structure of the program for well conditioning. In general, it takes from 8 -
24 hours to condition a well.
NOTE: Simply shutting the well in , and allowing the reservoir pressure to build up to above the saturation pressure will
NOT result in a spontaneous return to single phase, and the two phases will continue to exist in the reservoir -
around the well-bore.
TYPES OF SURFACE SAMPLING
Wellhead single-phase sampling
High pressure single-phase sampling can be conducted at the wellhead - upstream of the choke manifold. Recent
developments can maintain the sample in a single phase, even as the sample is recovered at the surface and is cooled,
though it is more usual to obtain the mono-phasic sample and then reduce the pressure in the sample cylinder for
shipping. The critical factor in obtaining representative wellhead samples is that the sample is obtained in a mono-phasic
state at the sampling point.
Oil samples can be validated by onsite saturation pressure determination, a minimum requirement of which should be that
the validations agree to within 2%.
NOTE: It is not possible to accurately determine a saturation pressure on a single phase sample without destroying its
single phase status.
Separator sampling
Samples are taken from the gas and liquid outlets of a surface separation system, and are recombined in a PVT
laboratory in the GOR / CGR ratio measured by the surface metering system. Representative samples taken from this
system are only reliable if accurate pressure / temperature / flow rates are obtained at the time of sampling.
The main reasons for non-representative samples being obtained are as follow:
1. Liquid carry over in the gas stream, as a result of:

a) Excessive flow rates
b) Inefficient separation
c) High separator levels
d) Foaming
2. Gas carry under in the liquid stream, as a result of:

a) Gas flow rates too high
b) Low fluid levels
c) Inefficient separation
3. Inaccurate liquid metering, as a result of:

a) Gas carry under
b) Wrong meter sizing
c) Calibration errors

SECTION 4
SURFACE SAMPLING
Page 3 of 16
4.1 PVT SAMPLING
4. Inaccurate gas metering, as a result of:

a) Liquid carry over
b) Wrong range meter
c) Badly calibrated instrumentation
d) Inaccurate gas densities
5. Wrongly sited sampling points.
It should be ensured that meter calibrations have been determined, and are correct prior to the test, and that the separator
is working within its design limits. Sampling points must be as close to the separation vessel as is possible, preferably
upstream of any bends or obstructions. The gas sampling point should be in a vertical section of pipe.
Ensure sampling points and sampling equipment are appropriately earthed.
Atmospheric Stock Tank PVT Samples
Atmospheric samples recovered from the separator are used in a number of laboratory studies:
1. Distillation
2. Rheology
3. Emulsion investigations
It is usually sufficient to collect the samples in 11 litre UN / ICOA cans, although for some experimental work, such as wax
studies, large volumes are required and it may be preferable to collect these in 45 gallon drums or in IBCs.
Hydrocarbon samples should NOT be collected in polythene type containers, unless special analyses are required.
Sampling Technique Recommendations
Reservoir Fluid Single-Phase Single-Phase Separator

Bottom Hole Wellhead Recombination
Black Oil
Volatile Oil (1) (1)
Wet / Dry Gas (3) (2)
Gas / Condensate (1) (2)
Valid sampling technique
May be valid sampling technique, depending on well conditions
(1) Valid if saturation pressure at bottom hole temperature is lower than the bottom hole pressure.
(2) Recommended if dew point at the sample point is lower than the sample point pressure.
(3) Dependant on individual well / reservoir characteristics. Valid if dew point at the sample point is lower than the
sample point pressure, and well conditioning is possible.

SECTION 4
SURFACE SAMPLING
Page 4 of 16
4.1 PVT SAMPLING
Other Reservoir Fluid Samples
Formation Water
Representative formation water samples are of critical importance for the design of water treatment plant, and for
investigating the compatibility of any injection water / formation water mixing, possibly increasing the scaling tendency.
During any well test chlorides (Cl-) should be continually monitored, by onsite chemistry, on samples from the separation
system. The most sensitive water samples should be obtained by using single-phase bottom hole samplers. This allows
the best evaluation of gas solubilities (CO2 and hydrocarbons), along with water pH and compositional analysis.
Hydrogen Sulphide - H2S
Onsite monitoring of H2S concentrations in the hydrocarbon gas should be conducted throughout the test, using Draeger
Tubes. Where H2S concentrations need to be more accurately measured, wet chemistry methods are available.
H2S and mercaptans can be absorbed into alkaline solutions on the well site, and then analysed either by titration at the
well site or in the laboratory. The Tutweiler method can be used if a field laboratory is available.
SAMPLING POINTS
It is the Engineers responsibility to ensure that samples are taken from a suitable location and all sampling points and
sampling equipment are appropriately earthed. If this is not possible, the Client representative should be informed and
appropriate recommendations submitted.
Should a sample be taken from a non-approved point, it is probable that it will be non representative of the produced well
effluents.
Wellhead : a) Immediately upstream of the choke manifold`

b) No closer than 5 feet from a bend or obstruction in the pipework
c) On the side of the flowline
d) Sample point projects into the centre of the flowline, facing into the flow
If the sampling point is immediately downstream of a bend or obstruction in the flowline, it will be in a zone of turbulence or low
pressure. This will result in gas or liquid breakout, especially if the flowing pressure is close to the saturation pressure, which will
result in an invalid sample
Separator Gas : a) As close to the separation vessel as practicably possible

b) Located in a vertical section of flowline
c) Upstream of any obstruction i.e. straightening vanes and orifice plates
d) Separator gas line upstream of any obstructions or pipework diameter changes
e) Sample point projects into the centre of the flowline, facing into the flow
Separator Oil : a) As close to the separation vessel as practicably possible

b) Separator oil line upstream of any meters
c) Separator oil line upstream of any obstructions or pipework diameter changes
d) No closer than 3 feet from a bend or obstruction in the pipework
e) On the side of the flowline
If the oil sampling point is mounted on the bottom of the flowline, any water that may still be present in the liquid stream will
probably be sampled in preference to oil. If the sampling point is on the top of the flowline, excess gas may be sampled. Either
way the sample will be invalid.

SECTION 4
SURFACE SAMPLING
Page 5 of 16
4.1 PVT SAMPLING
Atmospheric Oil : a) As close to the separation vessel as practicably possible

b) Separator oil line sampling point
c) Gauge or stock tank flowline, following flushing with well fluids
If the oil sampling point is mounted on the bottom of the flowline, any water that may still be present in the liquid stream will
probably be sampled in preference to oil. The sample will be contaminated. If sampling from a stock or gauge tank, ensure that
it is well flushed before being used for sample sourcing. It is preferable for samples to be obtained from the flowline to the
gauge / stock tank.
Produced Water : a) As close to the separation vessel as practicably possible

b) Separator water line
c) Flowline to the gauge or stock tank, following flushing with produced water
DATA REQUIREMENTS
The following items of data pertaining to the sampling should be collected, and collated to enable the Sample Data and Sample
Listing Sheets to be completed :
1. Calendar details
a) Date of sampling
b) Time of start and finish of sampling
c) Sampling duration
2. Sample Cylinder Details

a) Sample cylinder identification number
b) Partner sample cylinder identification numbers
c) Sample cylinder volume
d) Sample volume
e) Volume of ullage - if applicable
f) Final sample pressure and temperature
3. Sample Details
a) Sample number
b) Sampling point location
c) Sampling pressure and temperature
d) Time since the well flow was declared to be stable
4. Sampling Conditions
a) Choke size
b) Separator pressure and temperature
c) Wellhead pressure and temperature
d) G.O.R., corrected and uncorrected for shrinkage
e) Oil flow rate, corrected and uncorrected for shrinkage
f) Gas flow rate corrected to standard conditions
g) Water rate
h) Sequence of events

SECTION 4
SURFACE SAMPLING
Page 6 of 16
4.1 PVT SAMPLING
5. Well Details
a) Well number
b) DST or Test number
c) Customer
6. Factors
a) Liquid meter
b) Liquid densities
c) Gas Specific Gravity
d) H2S ppm
e) CO2 %
f) Orifice Differential Pressure
g) Z (Gas compressibility factor)
7. Comments
a) Contaminants in the well stream, i.e. anti-foam or methanol. If possible obtain a sample of the
contaminant, so that it can be fingerprinted, and excluded from compositional reports
b) Well stability
Refer to Appendix 3 for examples of Sample Details Sheets
SPS SAMPLE CYLINDERS
The Type 6 SPS Cylinder has an internal sample volume of 700 cc, and a nitrogen reservoir of 100 cc.
Top of Sample Cylinder Valve Configuration :

1. 1 x 1/4NPT - Sample In / Out
2. 1 x Cylinder Evacuation Port
Bottom of Sample Cylinder Valve Configuration :

1. 1 x 1/4NPT - Water Glycol In / Out Red Marking
2. 1 x Internal Valve - Nitrogen Reservoir Fill Blue Marking
3. 1 x Internal Valve - Nitrogen Crossover Valve Yellow Marking
4. 1 x 1/8 Autoclave Plug in side of vessel - Nitrogen access point for Nitrogen Reservoir.
Cylinder Preparation
Warning
Uncontrolled Release of High Pressure Nitrogen Can Have Serious Implications
It is a requirement at most facilities that a work permit be obtained BEFORE any high pressure work is started. Check with
the facility supervisor.
1. Check that the sample cylinder certification is in date, and that the serial number on the cylinder matches that
on the certificate. If it fails to do so, discard the cylinder and select a different one. Identify the discarded cylinder
with an appropriately marked RED label.
2. Ensure sampling equipment is appropriately earthed prior to use.
3. Ensure that the Yellow / Nitrogen Crossover Valve is closed, and the Red / 1/4NPT valve is open. This will
ensure that in the case of the Yellow valve leaking there is no pressure build-up in the sample cylinder.
4. Ensure that the Blue / Nitrogen Reservoir Fill Valve is closed, and remove the 1/8 Autoclave plug from the port
in the side of the sample cylinder.

SECTION 4
SURFACE SAMPLING
Page 7 of 16
4.1 PVT SAMPLING
5. Carefully open the Blue / Nitrogen Reservoir Fill Valve, and ensure that there is no pressure contained within
the Nitrogen Reservoir.
6. Using a vacuum pump, ensure that the Nitrogen Reservoir is fully evacuated. Once the Nitrogen Reservoir is
fully evacuated, close the Blue / Nitrogen Reservoir Fill Valve.
7. Loosely connect the high pressure liner from the Nitrogen Pump to the Autoclave port in the side of the Sample
Cylinder, and carefully purge the liner with Nitrogen.
8. Tighten the fitting connecting the Nitrogen Pump liner to the sample cylinder.
9. Open the Blue / Nitrogen Reservoir Fill Valve, and listen to the nitrogen flowing into the Nitrogen Reservoir.
Once the sound of flowing Nitrogen Gas has stopped, utilise the Nitrogen Pump to pressurise the Nitrogen
Reservoir to the required pressure.
10. Observe the Nitrogen pump pressure for 5 minutes, until the gas in the Nitrogen Reservoir has had a chance to
cool to the ambient temperature. Re-pressurise the reservoir to the required pressure.
11. Close the Blue / Nitrogen Reservoir Fill Valve. Shut off the nitrogen supply to the Nitrogen pump and bleed off
the pressure in the Nitrogen Pump liner in a safe manner.
12. Remove the Nitrogen Pump liner from the sample cylinder.
13. Check all of the valves and ports on the bottom section of the sample cylinder for leaks, using an appropriate
detection device - such as SNOOP.
14. If any of the valves / ports exhibit signs of a leak, carefully de-pressurise the sample cylinder, and attach a RED
label - appropriately marked - to the cylinder.
15. Replace the Autoclave port plug, and place the sample cylinder upright in a cylinder stand.
16. Using a hand pump, pressurise the sample cylinder from below the floating piston to a pressure approximately
1000 psig above the Sample Reservoir Pressure.
The cylinder is now ready for attaching to the FTU.
WELLHEAD MONO-PHASIC SAMPLING
Refer to the previous Sampling Points and SPS Sample Cylinderssections
Should the well flowing conditions become unstable for any reason, sampling operations should be suspended until approval to
continue is gained from the client representative.
SAFETY NOTE : The engineer should only install fittings in pressure rated pipework after conferring with the Well test
supervisor, and gaining their consent. Be aware that there may be pressure in the line when installing
fittings.
SAFETY NOTE : Always use fittings of the correct thread size and pressure rating, ensuring that they are installed in the
appropriate manner. If in doubt, ASK.
SAFETY NOTE : Never unscrew an existing fitting without being certain that there is no pressure behind it.
FIRE HAZARD : In order to minimize the risk of fire use earthed sampling points, lines, manifolds, containers and earthing
rods. Connections to earth should be verified before use.
The Client Permit to Work System must be adhered to at all times.

SECTION 4
SURFACE SAMPLING
Page 8 of 16
4.1 PVT SAMPLING
Obtaining a Wellhead / Monophasic Sample
1. Install the sampling point take off valve, together with a back-up valve, in the instrument manifold immediately
upstream of the choke manifold, having liased with the Well Test supervisor as to its exact location. There will
ideally be a 5 foot straight section of pipework immediately upstream of this sampling point.
2. It is recommended that all sampling lines be kept as short as practically possible, without straining connections.
Check the certification date on the sample vessel. Reject the vessel if it is out of date.
3. Check that all sample vessels have retained the vacuum above the piston. Any that have not should be
replaced, and returned to the base together with a brief explanatory note on the attached red label.
4. Ensure that the sample cylinder stands and sample lines will not form an obstruction to safe access and egress
from the sampling area. If they do, move accordingly.
5. Ensure that the sampling manifolds have gauges of the correct expected range installed.
At the appointed time, decided upon after consultation with the Well test supervisor and the Client representative, the
Engineer shall prepare to start sampling operations.
6. Place a sample cylinder in the cylinder stand.
7. Remove the thread protectors and valve blanking plugs.
8. Connect the bottom sampling manifold to the bottom valve on the sample cylinder.
9. Connect the hand pump to the manifold, and pressurise the sample cylinder below the piston to a pressure
approximately 250 psig in excess of the sampling pressure.
NOTE : This prevents the sample from moving the cylinder piston when it initially flows in.
10. Dis-connect the hand pump, and connect the 1/4 clear tube, with the open end in a measuring cylinder.
NOTE : The next step will form a pressure test on a previously formed connection. Proceed with caution.
11. Connect the top sampling manifold to the sampling line from the flowline instrument manifold, and open the
valve to permit fluids to fill the sample line to the sampling manifold.
12. Flush the sample line through the sampling manifold, into an appropriate vessel with the vent line being lead to
a safe exit point. Use the Hydrogen Sulphide knockout pot, as appropriate.
13. Connect the top sampling manifold to the top valve on the sample vessel.
14. Ensure that the bottom valve (Red on SPS Cylinders) on the sample cylinder is still closed.
15. Install the evacuation nipple in the evacuation port in the top of the sample cylinder and connect the hand
vacuum pump.
16. Confirm the evacuated state of the top of the sample cylinder.
17. Open the sample cylinder top valve, and evacuate the sample line to the sample manifold.
18. Close the evacuation port, and disconnect the vacuum pump and evacuation nipple from the evacuation port.
19. Close the sample cylinder top valve.
SAFETY NOTE : The next step will form a pressure test on a previously formed connection. Proceed with caution.
20. Open the top manifold valve to permit sample to flow into the sample line. Observe the sample line in case of
leaks.
21. Open the sample cylinder top valve.
22. Open the bottom sample cylinder valve.

SECTION 4
SURFACE SAMPLING
Page 9 of 16
4.1 PVT SAMPLING
Note the sample start time
23. Crack open very slowly the valve on the bottom sampling manifold, such that water / glycol mix is seen to
dribble through the plastic tubing into the measuring cylinder. Set it to run at a rate that will take 15 minutes to
take a 600cc sample - 40cc/minute.
24. Observe the two sampling manifold gauges. The readings should match +/- 1%. If there is a significant variation
between the two, or the needle on the bottom manifold appears to be juddering, it is probably the cylinder piston
sticking slightly. Usually it clears itself with a pressure differential across the piston of approximately 30 psig.
25. When 600cc of water / glycol has been measured into the measuring cylinder, the bottom manifold valve should
be closed.
26. Close the sample cylinder top valve
Note the sample finish time
If using SPS sample cylinders proceed to step 27a) and DO NOT remove fluid from the bottom of the sample cylinder to form a
gas cap, as you will be introducing a nitrogen gas cap, if using conventional PDS sample cylinders proceed to step 27b).
27. a) Open the yellow valve on the bottom of the sample cylinder, to allow the nitrogen cushion to make contact
with the bottom of the sample chamber piston. Note the pressure as the Final Pressure on the sample
sheet.
b) Remove a further 60cc of the water : glycol mix - to form a gas cap. Note the final pressure on the bottom
gauge - for the sample sheet.
SAFETY NOTE : A gas cap is formed as a safety measure in the liquid sample. Should the sample be exposed to elevated
temperatures, the internal pressure would be expected to rise substantially due to the liquids coefficient of
thermal expansion. An average rise of 1.8deg F (1 deg C) will increase the liquid pressure by 142 psig. A
gas cap gives a cushion sufficient to prevent a large pressure rise due to its high compressibility.
28. Close the bottom sample cylinder valve, and remove the pressure remaining in the bottom manifold. Remove
the bottom manifold from the cylinder, and install a blanking plug in the sample cylinder valve.
29. Isolate the top sampling manifold from the sample cylinder top valve.
30. Remove the top sample manifold from the sample cylinder, and place to one side in a safe place.
31. Install a blanking plug in the top sample cylinder valve.
32. Check both sample cylinder valves for leaks. Replace the sample cylinder thread protectors, and lay the sample
cylinder to one side in a safe place. In the unlikely event that the top cylinder valve be leaking, set the cylinder to
one side and take a new sample into a fresh cylinder. A leaking bottom valve is not so serious, as the piston will
prevent the sample leaking from the cylinder.
33. Install a fresh sample cylinder in the stand, and repeat steps 6 to 32 inclusive until the sample programme has
been completed.
34. Should the programme require that the samples be validated, proceed to the next section on sample validations,
and refer to Appendix 2.
Complete the sample data sheets, attaching a copy to the sample cylinder and supplying the customer with copies of the
data sheets and the sequence of events.
SATURATION PRESSURE
Having captured the sample in the piston sample cylinder, we can begin to determine the saturation pressure. In the piston
cylinder, an agitation facility has been built in to aid the mixing of the gas and oil. Ensure equipment is appropriately earthed.

SECTION 4
SURFACE SAMPLING
Page 10 of 16
4.1 PVT SAMPLING
1. Stabilise the sample pressure in the sample cylinder at a pressure in excess of the reservoir pressure, by
alternately pressuring and rotating the cylinder 180 anti-clockwise first, then 180 clockwise. Repeat until the
pressure remains stable.
2. Open the bottom valve on the sample cylinder two complete turns. CloseV7. Note the pressure reading.
3. Open V8 and withdraw 2 cc from the constant volume device (CVD) into a graduated cylinder then close again.
4. Close the bottom valve on the sample cylinder and agitate the cylinder as before.
5. Open the bottom cylinder valve two complete turns and note pressure reading. Quickly open and close V7 to
allow the indicator rod on the CVD to reach its full stroke. Release the 2 cc into the graduated cylinder by
opening V8 then closing again.
6. Close the bottom valve on the sample cylinder and repeat steps 1 to 5 above.
7. Initially, for every 2 cc withdrawn a relatively large decrease in pressure will be observed until the bubble point is
reached, thereafter a smaller decrease in pressure will be observed. Obtain at least 5-6 points above the bubble
point and 5-6 points below the bubble point.
8. The bubble point graph may now be plotted with volume withdrawn on the x-axis and pressure on the y-axis.
The point where the two extrapolated lines intersect is the bubble point pressure for that sample at ambient
temperature.
NOTE: Bubble point pressure must always be quoted with the temperature at which is was measured.
9. Before disconnecting the sample cylinder withdraw a further 60 cc of fluid from when the bubble point was
reached to provide a gas cap, or ullage. Note the final pressure and temperature.
SAFETY NOTE : A gas cap is formed as a safety measure in the liquid sample. Should the sample be exposed to
elevated temperatures, the internal pressure would be expected to rise substantially due to the liquids
coefficient of thermal expansion. An average rise of 1.8deg F (1 deg. C) will increase the liquid
pressure by 142 psig. A gas cap gives a cushion sufficient to prevent a large pressure rise due to its
high compressibility.
10. Close the bottom valve on the sample cylinder.
11. De-pressurise the system by slowly opening V4 then V5 to allow fluid to drain back into the tank. Close V5.
12. Disconnect the liner from sample cylinder and plug the bottom valve. Fit the cylinder end caps and return it to
its box.
13. Continue with the next sample.
14. Once all transfers and validations have been completed, label the sample cylinders and fill out the sample data
sheets in triplicate, including one copy with the piston sample cylinder.
15. Put the piston sample cylinder back into its transport box ready for despatch.
SEPARATOR GAS SAMPLING
Refer to the previous Sampling Points section and Fig 4.1
supervisor, and gaining their assent. Be aware that there may be pressure in the line when installing
fittings.

SECTION 4
SURFACE SAMPLING
Page 11 of 16
4.1 PVT SAMPLING

SECTION 4
SURFACE SAMPLING
Page 12 of 16
4.1 PVT SAMPLING
SAFETY NOTE : NEVER unscrew an existing fitting without being certain that there is no pressure behind it.
1. Install the sampling point take off valve together with a back-up valve in the separator gas line, having liased
with the Well Test supervisor as to its exact location. It will be as close as is practicably possible to the
separation vessel , in a vertical section of pipework.
SAFETY NOTE : Check the certification date on the sample vessel. Reject the vessel if it is out of date.
3. Check that all sample vessels have retained their vacuum. Any that have not should be replaced, and returned
to the base together with a brief explanatory note on the attached red label.
5. Ensure sampling points and sampling equipment are appropriately earthed.
6. Ensure that the sampling manifold has gauges of the correct expected range installed.
At the appointed time, decided upon after consultation with the Well test supervisor and the Client representative, the Engineer
shall prepare to start sampling operations. This separator gas sampling section is usually performed in conjunction with the next
section on separator oil sampling.
7. Place a sample cylinder in the cylinder stand.
8. Remove the valve blanking plug from the top valve.
9. Connect the sampling manifold to the sampling line from the separator gas flowline.
10. Connect the sampling manifold to the top valve on the sample vessel.
11. Open the manifold valve to permit sample to flow into the sample line. Observe the sample line in case of leaks.
12. Flush the sample point sample line and the short sample line through the sampling manifold vent valve, into an
appropriate vessel with the vent line being lead to a safe exit point. Use the Hydrogen Sulphide knock-out pot as
appropriate.
13. Open the sample cylinder top valve.
14. Crack open very slowly the valve on the sampling manifold, such that you can just hear the gas entering the
sample vessel. Set it to run at a rate that will take 30 minutes to take a 20 litre sample.
15. Periodically check the sample cylinder to check that gas is still flowing in, as the valves may become blocked
with ice particles when hydrates form. These can usually be cleared by working the valve.
16. When the sampling time has elapsed close the sample cylinder valve. Note the sampling pressure.
17. Close the valve on the separator flowline, and reduce the pressure on the sample line, such that the manifold
pressure is seen to drop 5 - 10 psig.
18. Open the sample cylinder valve, whilst observing the manifold gauge. The gauge should return to the recorded
sampling pressure. Open the valve on the flowline sampling point, to ensure that the sample cylinder is at the
full sampling pressure. Following this pressure equalisation, close the flowline valve.

SECTION 4
SURFACE SAMPLING
Page 13 of 16
4.1 PVT SAMPLING
NOTE : If the pressure fails to return to the recorded sampling pressure, the sample vessel has not been completely filled.
This could be due to a blockage in one of the following :
a) Sample cylinder valve

b) Sample manifold
c) Sample line from the separator flowline.
Should one of these be blocked, the Engineer must remedy the fault, and retake the sample, as it will not be a true
partner to the oil sample that was being taken simultaneously.
19. Close the sample cylinder valve.
20. Remove the sample manifold from the sample cylinder, and place to one side in a safe place.
21. Install a blanking plug in the sample cylinder valve.
22. Check both sample cylinder valves for leaks. Replace the sample cylinder thread protector, and lay the sample
cylinder to one side in a safe place.
been completed.
24. Complete the sample data sheets, attaching a copy to the sample cylinder and supplying the customer with
copies of the data sheets and the sequence of events.
SEPARATOR OIL SAMPLING
supervisor, and gaining their consent. Be aware that there may be pressure in the line when installing
fittings.
1. Install the sampling point take off valve together with a back-up valve in the separator oil line, having liased with
the Well Test supervisor as to its exact location. There will ideally be a 3 foot straight section of pipework
immediately upstream of this sampling point.
SAFETY NOTE : Check the certification date on the sample vessel. Reject the vessel if it is out of date.
3. Check that all sample vessels have retained the vacuum above the piston. Any that have not should be
replaced, and returned to the base together with a brief explanatory note on the attached red label.
5. Ensure that the sampling manifolds have gauges of the correct expected range installed.

SECTION 4
SURFACE SAMPLING
Page 14 of 16
4.1 PVT SAMPLING
At the appointed time, decided upon after consultation with the Well test supervisor and the Client
representative, the Engineer shall start sampling operations. This separator oil sampling section is usually
performed in conjunction with the previous section on separator gas sampling.
6. Place a sample cylinder in the cylinder stand. Ensure sampling points and sampling equipment are
appropriately earthed.
7. Remove the thread protectors and valve blanking plugs.
8. Connect the bottom sampling manifold to the bottom valve on the sample cylinder.
9. Connect the hand pump to the manifold, and pressurise the sample cylinder below the piston to a pressure
approximately 250 psig in excess of the sampling pressure.
NOTE : This prevents the sample from moving the cylinder piston when it initially flows in.
10. Dis-connect the hand pump, and connect the 1/4 clear tube, with the open end in a measuring cylinder.
11. Connect the top sampling manifold to the sampling line from the flowline instrument manifold, and open the
valve to permit fluids to fill the sample line to the sampling manifold.
12. Flush the sample line through the sampling manifold, into an appropriate vessel with the vent line being lead to
a safe exit point. Use a Hydrogen Sulphide knockout pot if appropriate
13. Connect the top sampling manifold to the top valve on the sample vessel.
14. Ensure that the bottom valve on the sample cylinder is still closed.
15. Open the top manifold valve to permit sample to flow into the sample line. Observe the sample line in case of
leaks.
16. Open the sample cylinder top valve, and purge sample through the cylinder evacuation port. Once the purge
cycle is complete, close the evacuation port.
17. Open the bottom sample cylinder valve.
18. Crack open very slowly the valve on the bottom sampling manifold, such that water / glycol mix is seen to
dribble through the plastic tubing into the measuring cylinder. Set it to run at a rate that will take 30 minutes to
take a 600cc sample - 20cc/minute.
19. Observe the two sampling manifold gauges. The readings should match +/- 1%. If there is a significant variation
between the two, or the needle on the bottom manifold appears to be juddering, it is probably the cylinder piston
sticking slightly. Usually it clears itself with a pressure differential across the piston of approximately 30 psig.
20. When 600cc of water / glycol has been measured into the measuring cylinder, the bottom manifold valve should
be closed.
21. Close the sample cylinder top valve
22. Remove a further 60cc of the water : glycol mix - to form a gas cap. Note the final pressure on the bottom
gauge - for the sample sheet.
SAFETY NOTE : A gas cap is formed as a safety measure in the liquid sample. Should the sample be exposed to elevated
temperatures, the internal pressure would be expected to rise substantially due to the liquids coefficient of
thermal expansion. An average rise of 1.8deg F (1 deg. C) will increase the liquid pressure by 142 psig. A
gas cap gives a cushion sufficient to prevent a large pressure rise due to its high compressibility.

SECTION 4
SURFACE SAMPLING
Page 15 of 16
4.1 PVT SAMPLING
23. Close the bottom sample cylinder valve, and remove the pressure remaining in the bottom manifold. Remove
the bottom manifold from the cylinder, and install a blanking plug in the sample cylinder valve.
24. Isolate the top sampling manifold from the sample cylinder top valve.
25. Remove the top sample manifold from the sample cylinder, and place to one side in a safe place.
26. Install a blanking plug in the top sample cylinder valve.
27. Check both sample cylinder valves for leaks. Replace the sample cylinder thread protectors, and lay the sample
cylinder to one side in a safe place. In the unlikely event that the top cylinder valve be leaking, set the cylinder to
one side and take a new sample into a fresh cylinder. A leaking bottom valve is not so serious, as the piston will
prevent the sample leaking from the cylinder.
been completed.
29. Should the programme require that the samples be validated, proceed to the earlier section on sample
validations, and refer to Appendix 2.
30. Complete the sample data sheets, attaching a copy to the sample cylinder and supplying the customer with
copies of the data sheets and the sequence of events.
ATMOSPHERIC SAMPLING
Of all the methods of sampling, Atmospheric sampling has the highest potential fire risk.
supervisor, and gaining their assent. Be aware that there may be pressure in the line when installing
fittings.
SAFETY NOTE : When taking atmospheric samples into vessels, ensure that the sampling equipment is earthed, by using
the supplied earthing device. When attaching the strap ensure that the clips make a good electrical contact
to both the sample vessel, and to a suitable earthing point.
1. Install the sampling point take off valve together with a back-up valve in the relevant line, having liased with the
Well Test supervisor as to its exact location.
3. Check that all sample vessels to be used are clean and unused.
4. Ensure that the sample vessels and sample lines will not form an obstruction to safe access and egress from
the sampling area. If they do, move accordingly.
At the appointed time, decided upon after consultation with the Well test supervisor and the Client representative, the
Engineer shall start sampling operations.

SECTION 4
SURFACE SAMPLING
Page 16 of 16
4.1 PVT SAMPLING
5. Flush the sample line through the sampling manifold, into an appropriate waste vessel. Use a Hydrogen
Sulphide knockout pot as appropriate.
6. Crack open very slowly the valve on the sampling line until an appropriate flow rate is achieved into the selected
vessel.
NOTE : Many oils will foam when depressurised into an atmospheric sample vessel. To reduce this it is advisable to direct
the flow against the side of the vessel, encouraging the gas to separate from the liquid.
7. Fill the selected vessel to 90% of its total volume, leaving a space for expansion as the temperature changes.
8. Set the sample vessel to one side and allow the sample to de-gas, ensuring that no contaminant - such as rain
or deluge system effluent - may enter the vessel.
9. Commence the sampling procedure for the next vessel, repeating steps 6 to 8 inclusive until the sample
programme has been completed.
10. Complete the sample data sheets, attaching a copy to the sample vessel and supplying the customer with
copies of the data sheets and the sequence of events. Ensure that the vessel top is securely closed before
attempting to move them.
SUITABLE VESSELS
All sample vessels must be UN approved, and be stamped as such with the UN stamp, which appears as a u mounted on top
of an n enclosed in a circle.
Acceptable vessels include, but are not limited to, the following :
a) 210, 25, 10, 5 and 1 litre metal cans
b) 25, 5 and 1 litre polypropylene cylinders
c) 5000, 1000, 500, 250, 100cc glass cylinders
It should be noted that hydrocarbon samples are not normally taken into polypropylene vessels, and water samples are not
normally taken into metal cans, except in special circumstances.

SECTION 4
SURFACE SAMPLING
Page 1 of 1
4.2 MEASURING GAS S.G.
Gas specific gravitys are normally collected from the test separator using a bladder or stainless steel sample bottle.
To collect the gas sample for analysis by the RANAREX gravitometer, proceed as follows:-
1. "Blow down" gas sample line (normally taken from the top of the separator gas outlet).
This will ensure that a representative sample is collected and any condensation etc. that has accumulated in the sample
line is blown clear prior collecting the gas sample.
2. Once sample line has been "blown down", place bladder over fitting, or connect the sample bottle to the end of
the sample line.
3. Crack open the isolating valve on the sample line and fill the bladder or bottle.
NOTE: Do not over-pressurise the bladder as it is not a pressure containing device and will rupture if excess pressure is
applied.
4. Vent the gas in the bladder or bottle in order to purge the container.
5. Repeat steps 3. and 4. so that at least three purge cycles have been completed.
6. Fill the bladder or bottle with gas and measure the specific gravity using the RANAREX gravitometer as per the
procedures outlined in Section 3.24.5.

SECTION 4
SURFACE SAMPLING
Page 1 of 1
4.3 MEASURING LIQUID S.G.
1. Purge through the oil sample line on the separator until the contents of the line has been displaced twice.
2. Collect a sample from the oil line on the separator into a measuring cylinder.
NOTE: a) The cylinder should have enough height to allow for a 1 inch clearance between the bottom of the
hydrometer and the base of the measuring cylinder.
b) The i.d. of the cylinder should be at least 1" greater than the o.d. of the hydrometer.
3. Allow any foam on the top of the sample to settle (or skim off) and place the sample in an area free from air
currents.
4. Lower the hydrometer carefully into the sample to a point 2 of the smallest divisions above that at which it will
float.
Release the hydrometer.
5. When the hydrometer comes to a rest, the gravity should be read at the point at which the surface of the sample
cuts the scale.
NOTE: The hydrometer should not touch the side of the measuring cylinder.
If the scale cannot be read properly, deduct 0.1 from the reading.
6. Take the temperature of the sample and note results on the data sheet.
NOTE: It is preferable to use a hydrometer that combines the thermometer and hydrometer functions.
Refer to Fig. 4.4 HYDROMETER IN CYLINDER

SECTION 4
SURFACE SAMPLING
Page 1 of 1
4.4 MEASURING B S & W
1. Pour 50ml of solvent into a clean centrifuge tube.
2. Add 1-3 drops of demulsifier and shake tube until solvent and demulsifier are well mixed.
NOTE: This step would only be done when emulsion is present.
3. Shake sample container vigorously and pour in 50ml of crude oil into centrifuge tube with the solvent and
demulsifier (if used).
4. Shake the centrifuge by hand, for several minutes to mix thoroughly the sample with demulsifier and solvent
(if used).
5. Repeat this procedure for a second centrifuge tube if enough collected sample.
6. If required, heat the centrifuge tubes until the sample temperature is 140F.
7. Once the sample has been heated, shake well and place in the centrifuge.
NOTE: When shaking the sample, ensure that none of the sample is spilled.
8. Spin the sample for approximately 3-10 minutes.
9. Read the BS&W content.
NOTE: Read to the nearest .05 ml (between 0.1 and 1 ml) and to the nearest 0.1 ml when over 1 ml.
10. If the two samples (for comparison) agree, or are very close, add the percentages together to achieve the true
BS&W.
NOTE: If only one sample was taken then the result should be multiplied by two since halve the sample was solvent.
If the sample was not cut with solvent (eg. for light crudes or condensates) the percentage of BS&W should
be read directly. If two samples were taken, the results should be added together and the combined total
divided by two.
11. On completion of the test, all equipment should be washed and cleaned ready for the next test.
NOTE: On HPHT wells, no samples should be taken from upstream of the choke manifold apart from monophasic
samples.
On every well test we should always be aware of the potential dangers when taking samples from upstream of
the choke manifold. The potential for problems (valve washout etc..) increase in the following circumstances:
a) High flowing pressures
b) Gas wells
c) Rat hole at surface (mud)
Regardless of where samples are taken there should always be two halves in place with the inside valve fully
open. The outside valve should always be used when taking samples to control flow etc..
If the outside valve is washed out the inside valve should be immediately closed and another valve added or
plug off the sample point.
If a third valve has been added, open the inside valve and use the outside valve to control flow etc..
If the sample point has been plugged off the point cannot be used until the needle valves have been changed
at a convenient point in the last test programme eg. rigging up Wireline.

SECTION 4
SURFACE SAMPLING
Page 1 of 1
4.5 MEASURING SALINITY (CHLORIDES)
1. Pipette 1.00 ml of sample into the titration dish and dilute to 40 or 50 ml with distilled water.
2. Add four or five drops of potassium chromate indicator solution.
3. Add standard silver nitrate solution from an automatic burette or a pipette dropwise and slowly, all the while
stirring continuously with a stirring rod, until the sample just turns from yellow to orange or brick red.
4. The number of ml of standard silver nitrate used to obtain this end point is multiplied by 10 000 when 0.01 g
silver nitrate solution is used or by 1 000 when the 0.001 g silver nitrate solution is used to obtain parts per
million (ppm) of chloride (Cl) ion.
RESULTS
The salt content in the sample is expressed as parts per million chloride (ppm Cl). Multiply ppm Cl x 1.65 for ppm NaCl.
COMMENTS
1 The volume of sample may be adjusted to use more practical volumes of standard silver nitrate, not to exceed
10.00 ml, when the salt content is lower or greater than usual. If other than 1.00 ml of sample is used, divide the
result obtained in step 4 by the number of ml of sample used to obtain the correct concentration.
2 If the sample is alkaline prior to dilution in step 1, it should be made colourless to phenolphthalein using N/10
sulphuric acid.
3 If the filtrate is so deeply coloured by thinner that the end point cannot be seen in the diluted sample, the
following procedure may be used. Add 1M nitric acid to a measured volume of the original filtrate until the colour
changes to tan. Add a small quantity of chloride-free powdered activated charcoal, stir thoroughly and filter.
Wash with distilled water, collecting the washings with the first filtrate until the volume reaches 50 ml. Add an
excess of powdered c.p. calcium carbonate so that some remains undissolved and proceed with step 2 of the
procedure.
4 If sulphides are present, as indicated by a brownish black precipitate, take a new sample, add 1ml 1M nitric
acid, and 2 ml of potassium chromate indicator. If it is necessary also to remove thinner, it can be done at this
point, starting with sentence 3 of step 3 above. If removal of thinner is not necessary, add 1 gram of powdered
c.p. calcium carbonate, dilute to 50 ml and proceed with step 3 of the procedure.

SECTION 4
SURFACE SAMPLING
Page 1 of 1
4.6 MEASURING VISCOSITY
The viscometer used by EXPRO is a battery powered unit which has various size cups for various ranges of viscositys.
Beside each range on the readout is a number that refers to each individual cup.
1. Pour some of the oil into the test container and select a cup suitable for the estimated viscosity (the P.E. will
probably be able to advise of this).
NOTE: If the meter goes off scale another cup will have to be fitted.
2. Once the required range has been found the viscosity can be read from the scale (in centipoise).
NOTE: Always take the temperature of the oil when taking viscositys and quote viscosity at a certain temperature, ie.
15 CP @ 90F.

SECTION 4
SURFACE SAMPLING
Page 1 of 1
4.7 MEASURING CLOUD/POUR POINT
The cloud / pour point equipment consists of test jars, cork stoppers and a bath.
1. Pour a sample of the oil in about four test jars and then place them in the bath (with the bath filled with ice).
NOTE: A fridge could also be used if available (eg. there may be a fridge in the mud loggers unit).
2. Let the samples cool down until the oil is thick and does not pour when the jars are tilted.
3. Discard the ice (or remove the jars from the fridge) and fill the bath with warm or hot water.
NOTE: Warm water is better for a gradual increase in temperature and a more accurate determination of pour point.
4. Keep monitoring the temperature and tilting the samples.
5. The pour point temperature is the temperature at which the fluid first starts to pour or flow.
NOTE: Once a pour point temperature has been recorded, it will probably be more accurate on subsequent tests, as a
more gradual increase in temperature can be effected around the known pour point temperature.

SECTION 4
SURFACE SAMPLING
Page 1 of 1
4.8 MEASURING RESITIVITY OF WATER
1. Fill the cell with fluid, being careful to remove all air bubbles (purge chamber three times to thoroughly wet the
surface).
2. Connect the cell to the Resitivity Meter.
3. Press the black button and adjust for full scale reading on the meter.
4. While keeping the black button depressed, press the red button.
5. The reading on the meter is the resitivity of the fluid (if testing mud it may be necessary to allow 3 to 5 minutes
after putting mud in the cell before taking a reading to allow the cell and mud to reach temperature equilibrium).
6. Record the resitivity reading and the temperature of the cell.
7. Remove the cell and clean with distilled water.
NOTE: a) A pipe cleaner can be used to remove particles of mud that cannot be flushed out with water.
b) When cleaning the cell use only fresh or distilled water to clean the cell, DO NOT use any type
of solvent.
c) If using a pipe cleaner, be careful not to scratch the inner surface of the cell.
To replace the battery:
d) When full scale reading cannot be obtained when the black button is depressed, the battery needs to
be replaced.
e) Use a 22.5V Burgess U-15 or equivalent battery.
f) Be sure to observe polarity when replacing the battery in order to prevent damage to the transistor.
8. Measure the resitivity and temperature as described above.
Using the chart on the following page
9. Trace across a horizontal line from the measured temperature (Y-axis).
10. Trace a vertical line upwards from the measured resitivity (X-axis).
11. At the point of intersection, run an imaginary line parallel to the other lines up to the top of the chart and read off
the chlorides measurement on the required scale.
eg. For a temperature of 150F and a resitivity of 0.08 Ohm-meters the measured chlorides would be
40,000 ppm.

SECTION 4
SURFACE SAMPLING
Page 1 of 1
4.9 USING DRAEGER TESTER
1. Select tube of correct type and range.
2. Squeeze Draeger body to compress bellows and insert unbroken tube into valve aperture.
NOTE: a) If bellows do not expand then integrity of bellows is assured and sampling can continue.
b) If bellows expand then the bellows are leaking and false results will ensue if that tester is used.
REPLACE the bellows unit.
Refer to Fig. 4.5 USE OF DRAEGER TESTER
3. Collect gas sample in bladder / stainless steel cylinder.
NOTE: Ensure bladder / cylinder is purged adequately to obtain a representative sample.
The sample must be at atmospheric pressure for the purpose of reading the Draeger tube, if the sample bladder contains
pressure this will create an artificially high reading.
4. Break open both ends of the Draeger tube.
5. Compress body to expel air from bellows and insert tube in valve aperture.
Refer to Fig. 4.6 INSERTING DRAEGER TUBES
NOTE: Check arrow on tube side for correct end to install - arrow indicates direction of flow (from sample to tester).
6. Once tube secure in valve aperture, release bellows and allow chain to go taut.
NOTE: The chain MUST be allowed to go taut for a correct reading to be obtained. This is because the volume of the
bellows is a calibrated amount which is related to the reagent used in the tubes and any differing volume will
cause errors.
7. Repeat compression / relaxation sequence as required for n times.
NOTE: The value of n is indicated on the tube and will be dependant on the tube and scale used (for multi scale tubes).
8. Once all compression / relaxation sequences completed, remove the bladder and tube from the valve aperture
and read off the discoloration from tube against the relevant scale.
For MERCAPTANS replace step 8/ with the following:-
9. Once the sample has been sucked through the tube n times, the tube should be broken at the breaking point
(between the two dots) so that the inner reagent ampoule breaks.
10. Shake out the contents of the ampoule in the direction of the indicating layer and suck the solution through the
layer.
NOTE: The indicating layer should be completely wetted by the solution.
TAKE CARE THAT THE CONTENTS OF THE AMPOULE DOES NOT ENTER THE PUMP
11. Read the off the discoloration against the scale in ppm.
IF UNSURE ABOUT METHODS READ THE LITERATURE CONTAINED WITH THE TUBES IN THE TUBE
HOLDER.
NOTE: On HPHT wells no samples for H2S & CO2 should be taken from upstream of choke manifold.
Consideration should be given on every well test as to the need to sample for H2S & CO2 upstream of the
choke manifold. Gas samples will be the same downstream of the choke manifold and if the valve washout
occurs the choke can be closed in or diverted to other choke.

SECTION 4
Page 1 of 6
4.1 PVT SAMPLING
FIG: 4.1 GAS PVT SAMPLING HOOK-UP
PRESSURE
GAUGE
VALVE
VALVE
FROM
SEPARATOR
CONNECTION
TO EARTH
GAS
CYLINDER
CONNECTION
TO EARTH
VALVE

SECTION 4
Page 2 of 6
4.1 PVT SAMPLING
FIG: 4.2 OIL PVT SAMPLING HOOK-UP
PRESSURE
GAUGE
VALVE
VALVE
FROM
SEPARATOR
CONNECTION
TO EARTH
OIL
CYLINDER PISTON
CONNECTION
TO EARTH PRESSURE
GAUGE
VALVE
VALVE
MEASURING
CYLINDER

SECTION 4
Page 3 of 6
4.1 PVT SAMPLING
FIG: 4.3 ATMOSPHERIC SAMPLING
VALVE
FROM GAS VENT
SAMPLING IF REQUIRED
POINT
CONNECTION
TO EARTH
CONNECTION EARTHING
TO EARTH ROD
SAMPLE
CONTAINER

SECTION 4
Page 4 of 6
4.3 MEASURING LIQUID S.G.
FIG: 4.4 HYDROMETER IN CYLINDER

SECTION 4
Page 5 of 6
FIG: 4.5 USE OF DRAEGER TESTER

SECTION 4
Page 6 of 6
FIG: 4.6 INSERTING DRAEGER TUBES

SECTION 5
SAFETY
Page 1 of 1
5.1 GENERAL SAFETY
5.1.1 GENERAL
The Company Health and Safety Manual, and the Health and Safety System Procedures, shall be used as reference with
regard to the mandatory requirements of the Company's Safety and Environmental policy.
1. The appropriate protective clothing and equipment, provided either by EXPRO or the client, to protect against a
specific risk must be used for the full duration of the exposure to the risk as stated in EXPRO's safety policy.
2. Well Test equipment shall be positioned and only operated in areas for which it is designed to operate in, in
accordance with IP "Model Code of Safe Practice in the Petroleum Industry" which classifies areas as:
(a) Zone 0 In which a flammable atmosphere is continuously present, or present for long periods
(more than 1000 hours per year).
(b) Zone 1 In which a flammable atmosphere is likely to occur in normal operation (about 10 to 1000
hours per year).
(c) Zone 2 In which a flammable atmosphere is not likely to occur in normal operation, and if it occurs
will exist only for a short period (less than 10 hours per year).
3. Barriers and warning signs shall be posted. Announcements shall be made to warn all personnel to stay clear
of the area as required.
4. All passengers are required to produce a passport or Contract Company ID Card, complete with photograph for
identification purposes.
5.1.2 EMERGENCY
1. STATION BILL/EMERGENCY STATIONS
It is the responsibility of all personnel new to an installation to familiarise themselves with the Station Bill and fire
equipment layout. The O.I.M. or his designate will inform personnel of emergency stations immediately after
arrival on the facility.
Personnel may be given responsibilities under the emergency procedures, those personnel should ensure that
the instructions received are clearly understood.
2. EMERGENCY SITUATIONS
During an emergency situation, all personnel should to co-operate with drilling company or operating company
personnel and comply with standing Emergency Procedures.

SECTION 5
SAFETY
Page 1 of 2
5.2 HOOK-UP & RIG DOWN
5.2.1 HOOK-UP
1. Locate main items of equipment in the designated area taking into account:-
a) Hook-up as shown on the layout diagram
NOTE: If anything affecting the hazardous areas eg. rig vents or power points is altered from the layout
diagram, then this should be brought to the attention of the OIM or Company man.
b) Ease of hook up, minimising bends, tidiness of pipe pins etc.
2. During rig up, sampling and inspection points should be orientated downwards and fitted with double
isolation valves.
3. Whilst assisting in the positioning of equipment during hook-up operations, the handling of loads must
be supervised and carried out by properly trained personnel. Expro personnel should liase with crane
operators, roustabouts and banksmen for the siting of equipment and other heavy loads, but the
actual operations should only be done by those personnel on board properly authorised to do so.
4. All items of equipment should be fitted with suitably sized earthing straps (11mm cross section multi-
strand) and should be earthed to the rig structure, on a place where there is no paint, as part of the
hook-up procedure. This will then earth any static electricity (generated by the friction of flowing
fluids) and prevent any discharge with the associated dangers this would create.
NOTE: If an item of equipment is not earthed and it is subject to a build up of static electricity, this static can
build up to a infinite level before it discharges (this level will be dependant on what the equipment can
discharge. Obviously if it is in contact with a metal deck it will discharge at a lower level than if
discharging to people or even the atmosphere).
ONSHORE
If no earthing points are available at the well-site then the equipment should be earthed by driving a
spike into the ground, to a depth of 3 feet. The area around this spike should then be watered
regularly.
5. All piping containing hydrocarbons will be securely tied down using 11 mm diameter wire rope which
will be wound around and clamped to all pipework and anchored by clamps to the deck, or to any
permanently installed pad eyes. Pipe stands should be welded to the deck where practical to hold
pipework securely in the event of a shock loading.
6. During sand clean up wall thicknesses will be monitored at selected areas of the pipework, eg. bends,
targets etc. to monitor possible areas of erosion. This will be performed with an ultrasonic thickness
gauge. Process fluid velocities must also be checked using the relevant formula. This is especially
critical immediately downstream of pressure drops.
7. Electrical equipment is to be tied into the power source by a qualified electrician only. The correct
function of such equipment MUST be checked fully prior to use.
8. Vent hoses and bleed off lines to be run to locations as per the layout diagram. These will be
previously decided 'safe' area.
NOTE: The vent hoses must be suitably tied down.
9. Rig to burner boom access points should have properly secured hand rails even if of a temporary
nature.
10. The test equipment area should be as far as is practical free of all rig equipment, baskets, containers,
etc.
11. When rigging up a steam generator, the steam return line should be laid to overboard and not
returned to the steam generator. This is to prevent the possible migration of hydrocarbons to the
steam generator in the event of a process coil failure in the heat exchanger.
The steam vent line should be hard piped (not necessary when using a degasser where this is
plumbed into the steam return line).

SECTION 5
SAFETY
Page 2 of 2
5.2 HOOK-UP & RIG DOWN
12. To prevent injury from whiplash through burst hoses, air hoses must be fitted with a means of
securing the end fittings. Small bore air hoses must be fitted with Safety R Clips or similar and
Whipchecks or similar on 2 or larger hoses.
NOTE: The degasser should be calibrated for the type of gas expected on a particular test and will produce
an alarm or can be used as part of the Safety Shutdown System (when tied into the ESD loop) to
close in the well in the event of a failure in the heat exchanger process coils.
5.2.2 RIG DOWN
It is important that none of the pressure containing equipment or parts of the equipment are rigged down,
dismantled or removed until the well is officially declared dead and safe and instructions are received to rig
down. Well testing systems, including ESD and Relief systems can be complex and premature rigging down
without authority can result in hazardous situations.
Before commencing a rig down, all vessels, lines, etc. should be depressurised and flushed prior to breaking
out. Great care should also be taken when breaking out equipment after a sour service well test.
NOTE: After a sour service well test, the equipment/flowlines should be purged with N prior to breaking out.
1. Any possible falling objects during back-loading should be removed.
a) Tools should be put away and not left on equipment.
b) Sand filter davits should be securely tied down.
c) Pipework should retained in the pipe racks using the proper bars.
d) Valve handles should be pinned or removed.
2. Gauges on equipment should be removed and tappings plugged to prevent damage during transit.
3. All loose objects should be packed in the well test container in such a way as to minimise movement
during transit.
4. All vessels should be EMPTIED as far as possible. NEVER attempt to lift a tank etc. when full.
5. Valves on vessel drains should be closed and outlet(s) plugged, to prevent possible spillages during
transit.
6. Female (thread) end connections should be fitted with protectors or have grease tape wound round to
prevent damage during transit.
7. When loading baskets be aware as to the maximum weight of the basket. DO NOT OVERLOAD
basket.

SECTION 5
SAFETY
Page 1 of 1
5.3 PRESSURE TESTING
1. Prior to pressure testing taking place, the area around the equipment/flowlines being pressure tested should
be cordoned off using the Expro supplied barrier tape or chains etc.
2. Notify key personnel that pressure testing is commencing eg. Tool Pusher, Driller, Crane operator, Company
Representative (to witness test).
NOTE: The permit to work system should be implemented ie. a cold work permit should be issued (and signed off) by
the appropriate personnel.
3. An announcement should be made over the rig tannoy system informing personnel to the effect that high
pressure testing is taking place on Expro equipment and non-essential personnel should stay clear of
cordoned off areas.
NOTE: If pressure testing is continuing for some time then regular announcements should be made, eg, every half
hour, stating that pressure testing is still ongoing and to continue to avoid cordoned off areas.
4. Prior to pressure testing commencing all lines that will be pressure tested should be tied down and clamped
as per OSP.
5. Prior to flushing lines to booms, ensure that there are no vessels below that fluids will fall on ie. supply boats
etc.
6. DO NOT REMOVE SAFETY GLASSES! Eye protection as always is essential during pressure testing
operations.
PROTECT YOUR SIGHT
7. When increasing pressure for each test using a high volume pump such as the cement unit, this should be
done in stages, eg. 20% increments. This pressure should be held for a few minutes, without loss, before
increasing by the next increment. This will reduce the risk of equipment failure and subsequent severe
damage.
8. When using a dedicated pressure test pump, if a relief valve is used at the pump outlet, this should be preset
to + 10% of the test pressure.
NOTE: The relief valve should be set against an accurate dial gauge prior to commencing the pressure test and all
components to be tested should be checked to ensure that this relief valve setting is within their working limits.
9. When pressure testing the Well Test System, ensure that the pressure test pump is connected upstream of
the choke manifold and all fittings, liner, etc. used are rated to at least the test pump discharge pressure,
regardless of whether a relief valve is used on the pump outlet or not.
e.g. If a 15,000 psi pump is used for pressure testing to lower pressures, then the fittings/liner used for pump
connection to the system should be rated to 15,000 psi.
10. If any leaks discovered, pressure should be bled off system under test prior to remedial action taking place.
11. Valves downstream of any valve under pressure must be open and vented to prevent overpressure on
downstream lines.
12. During the course of pressure testing, if a relief valve has been activated then that valve should be removed
and replaced due to the possibility that the valve has not re-seated correctly.

SECTION 5
SAFETY
Page 1 of 1
5.4 SURFACE SAMPLING
During surface sampling, personnel safety is of prime consideration due to the nature of collecting highly inflammable
samples under high pressure, often using mercury as a transferring medium.
1. Prior to being shipped offshore, each sample bottle (both oil and gas) will have had it's certification checked, be
cleaned and have a visual inspection carried out. If requested oil bottles will be filled with mercury, although this
is normally carried out offshore.
2. Sample bottles have a yearly inspection to full working pressure and a five yearly inspection to 1 1/2 times full
working pressure. After the annual survey each bottle is marked with an "Available" sticker with the date that
the next inspection is due.
NO BOTTLE SHOULD BE USED IF THIS AVAILABLE TO DATE HAS BEEN PASSED
3. In no case, during sampling, storing or transportation must the sample pressure exceed the MAWP of the bottle
ie:-
a) 10,000 psi for oil bottles.
b) 2,750 psi for gas bottles at 60 deg/F.
NOTE: Full bottles of liquid should not be stored in direct sunlight or close to a heat-source.
An average increase of 1.8 deg/F (1 deg/C) will increase the pressure inside the bottle by 142 psi.
For this reason a gas cap equal to 10% of sample volume must be taken off during oil sampling for ullage.
4. Great CAUTION should be taken when handling mercury if used as a transferring medium for oil/condensate
sampling.
a) Work in open or well ventilated areas (especially in countries with a hot climate, where more vapour
will be given off).
b) Wear the protective clothing provided in the Surface Sampling Kit.
Mercury can enter the body by absorption through the skin, ingestion and inhalation (minute particles of mercury
suspended in contaminated air enter the bloodstream via the lungs).
a) Do not drink, eat or smoke during working with mercury and always maintain personal hygiene.
b) Recover any spilt mercury immediately using brush and pan provided, store this contaminated
mercury in a marked bottle.
If filling oil bottles offshore, great care should be taken during filling process to avoid spillages.
On completion of working with mercury all contaminated tools must be placed in the proper box, clearly labelled
that contents have been in contact with mercury.

SECTION 5
SAFETY
Page 1 of 1
5.5 SAFETY OF PERSONNEL WHILE WORKING ON BURNER BOOMS
Prior to going out on the boom, the standby boat must be called in to close watch, and the weather conditions MUST
permit the launching of the rescue craft (eg. the Zodiac) to pick up any man in the water.
1. The permit-to work system for a particular installation MUST be observed before going out on the boom.
2. A bright coloured workvest is to be worn when working on the boom.
3. A buoyancy aid (eg. Billy Pugh/Helly Hansen) should be worn.
NOTE: This may double as the bright coloured workvest if suitable.
4. A person must observe the personnel on the boom at all times from a suitable vantage point, preferably in radio
contact with the standby boat.
NOTE: The watchman should be aware of the position of the rescue equipment (life belt and line), should this be
required, and the man overboard procedures.
5. No person is permitted to go on the boom in high winds (probably if there was high winds then the rescue craft
could not be launched). It is not possible to be specific about a definition of "high winds" as each situation will
be slightly different and have to be judged on it's merits. However, it is recommended that the situation be
reviewed when wind speeds exceed 30 knots (Force 7 'Near Gale').
6. A safety harness/line tethered to the boom is mandatory when working outside the handrail area.
NOTE: When within the handrail, it is not mandatory to tether the safety harness/line.
7. It is not recommended that personnel have access to the boom at night, however where access is necessary, it
is essential that an observer be present and in direct radio contact with the standby boat or radio room.
Also the area around and below the boom should have adequate lighting to enable the man to work and be
spotted in the water if he should fall.
NOTE: In the event of an emergency the watchman must not leave his post and should raise the alarm by contacting
the standby boat/radio room by radio. The radio room should then raise the man overboard alarm.
It is of the utmost importance that the watchman remains in visual contact with the victim and can issue
instructions to the rescue team.

SECTION 5
SAFETY
Page 1 of 1
5.6 CORROSIVE AND HAZARDOUS SUBSTANCES
Refer also to the Health and Safety System No. 9 - Control of Exposure to Hazardous Substances
All operations which require the use of corrosive or hazardous substances shall be performed within the following general
rules:
1. All persons involved in operations which require the use of corrosive or hazardous substances shall be fully
briefed on the procedures, precautions and first aid procedures required.
2. The transport, handling and storage and use of any corrosive or hazardous substance shall be carried out in
accordance with the Health and Safety at Work Act and COSHH regulation chemical data sheet for that
substance.
3. At no point should any protective clothing be allowed to enter the accommodation.
4. Where large quantities of contaminated components are stored the storage area should be monitored regularly
for spread of the contamination.
5. All surface equipment should conform with NACE MR-01-75 and be certified for service in a sour environment.
NOTE: Corrosive conditions are either 'Sweet'; wells have CO2 in the production stream or 'Sour'; wells that have any
traces of H2S in the production stream, in combination with or without CO2.

SECTION 6
CONTINGENCY
Page 1 of 1
6.1 EQUIPMENT FAILURE
Should an equipment failure occur during the course of a Well Test where the test cannot continue safely while the
equipment is taken out of service and repaired, then the following should take place:-
1. The well should be shut-in at the choke manifold.
2. Pressure should be bled off and the choke manifold closed.
3. If the failure is upstream of the choke manifold then the master valve should be shut-in as well as the flow-wing
valve.
A double block is required upstream of where maintenance is taking place and the system vented
before the maintenance starts.
NOTE: Special attention should be paid to potential consequences if Wireline or Coiled Tubing is in the hole prior to
closing the master valve.

SECTION 6
CONTINGENCY
Page 1 of 2
6.2 HYDRATES
Refer also to Health and Safety System No. 21 - Methanol
Hydrates are crystalline water structures filled with small gas molecules. In oil/gas systems they will occur when light
hydrocarbons (or carbon dioxide) are mixed with water at the correct temperature and pressure conditions. Under the
correct conditions hydrates will form spontaneously and do not require a pressure drop to form. However the refrigeration
effect from a pressure drop, such as across a choke, may be sufficient to create the optimum pressure and temperature
conditions for hydrate formation.
Hydrates require the presence of liquid water to form, particularly in the presence of Methane, Ethane, CO and H S
gas. Butane and heavier hydrocarbons tend to inhibit hydrate formation.
The risk of hydrate formation increases with increasing pressures and decreasing temperatures, however, the problem
can be eliminated by maintaining the wellstream temperature above the hydrate formation temperature. Alternatively
inhibitors such as methanol or glycol can be used.
Hydrates usually form where there is a restriction or obstruction in the equipment, eg. at valves, elbows, across chokes
etc. giving difficulties in operation and eventually complete blockage.
1. Generally a hydrate can be dissolved by:
(a) A chemical hydrate inhibitor, such as Methanol or either Mono-Ethylene or Tri-Ethylene Glycol, can be
used to change the composition of the water. A Glycol/water based mixture is best, though incorrect
mixes, particularly with Tri-Ethylene Glycol, will significantly reduce the effectiveness of the mixture,
generally a 60/40 Glycol/water mixture is best suited for most applications. Refer to Table 6-1
Freezing Points of Glycol/Freshwater Mixes.
(b) If the well is not plugged, flow the well to raise the well temperature above the hydrate formation
temperature to dissolve it.
2. Where there is a potential danger of the formation of hydrates, eg. high pressure gas wells or in a wet gas
environment, Methanol or Glycol should be injected continuously as a chemical inhibitor to prevent hydrate
formation.
NOTE: Methanol is the more effective hydrate inhibitor than either Mono-Ethylene Glycol or Tri-Ethylene Glycol, though
caution should be given to its use as it dissolves sealing greases in wellhead Xmas tree valves.
3. Free water should never be allowed to enter the system, through pressure testing. Always use a Glycol/water
mix. Refer to Table 6-1 for Glycol/water mix specifications.
(a) Glycol can be mixed with fresh water, sea water or reservoir water without any direct effect.
Methanol/Glycol can be injected at strategic positions in the Well Test package to eliminate hydrate hazards, the normal
positions being:-
a) Sub-Sea Test Tree
b) Surface Test Tree
c) Upstream Choke Manifold
d) Upstream Separator Back Pressure Valve

SECTION 6
CONTINGENCY
Page 2 of 2
6.2 HYDRATES
PROCEDURE TO FOLLOW AFTER HYDRATE PLUG FORMATION
If a hydrate plug occurs then the well should be closed in upstream of the plug (as close as possible), the pressure bled
off downstream, and it should be allowed to evaporate. If possible then a methanol soak should be performed by injecting
methanol onto the hydrate until it clears.
Care should be taken during this operation due to the pressure build-up upstream of the plug may cause the plug to clear
with some force and velocity, eg. like a cannon shell.
If hydrates are beginning to form across a valve eg. on the choke manifold then a line can be ran from the steam
generator (if used) to the valve and steam applied directly onto where the hydrates are forming.
TABLE 6-1 FREEZING POINTS OF GLYCOL/FRESHWATER MIXES
MONO-ETHYLENE
GLYCOL/WAT TRI-ETHYLENE GLYCOL
GLYCOL
ER
% FREEZING FREEZING
S
MIXTURE POINT POINT SG
G
(deg C) (deg C)
1. 1.1
100/0 -7 -5
12 3
1. 1.1
90/10 -28 -22
11 2
1. 1.1
80/20 -43 -37
1 2
1. 1.1
70/30 -60 -38
09 1
1.
60/40 -60 -35 1.1
08
1. 1.0
50/50 -44 -23
07 8
1. 1.0
40/60 -27 -12
05 7
1. 1.0
30/70 -17 -7.5
04 5
1. 1.0
20/80 -9.5 -4.5
03 3
1. 1.0
10/90 -5.5 -2
01 2

SECTION 6
CONTINGENCY
Page 1 of 1
6.3 LEAKS
6.4.1 ON SEMI-SUBMERSIBLE RIGS
If bad weather is forecast then provisions must be made to disconnect from the Subsea Test Tree.
Procedures for disconnection and reconnection are laid out in the Subsea Manual.
For safety reasons, every attempt should be made to kill the well before unlatching.
6.4.2 ON ALL RIGS
During periods of thunderstorm activity where there is a risk of lightning, then personnel should not 'go out' on
the boom for any reason. If the flare goes out and cannot be relit using the pilot system then the well should be
closed in at the choke manifold until weather conditions permit a man to go out on the boom and service the
pilot system.
Personnel should also avoid working outside the cone of protection provided by equipment structures.

SECTION 6
CONTINGENCY
Page 1 of 1
6.4 SUSPENSION OF OPERATIONS DUE TO BAD WEATHER
6.4.1 ON SEMI-SUBMERSIBLE RIGS
If bad weather is forecast then provisions must be made to disconnect from the Subsea Test Tree.
Procedures for disconnection and reconnection are laid out in the Subsea Manual.
For safety reasons, every attempt should be made to kill the well before unlatching.
6.4.2 ON ALL RIGS
During periods of thunderstorm activity where there is a risk of lightning, then personnel should not 'go out' on
the boom for any reason. If the flare goes out and cannot be relit using the pilot system then the well should be
closed in at the choke manifold until weather conditions permit a man to go out on the boom and service the
pilot system.
Personnel should also avoid working outside the cone of protection provided by equipment structures.

SECTION 6
CONTINGENCY
Page 1 of 1
6.5 HIGH TEMPERATURES
Temperatures will be monitored and recorded at various points in the Well Test package the most critical being upstream
of the Coflexip hose.
The Coflexip hose used by EXPRO is rated to 266F continuous use, which means the flowing temperature in this hose
should be limited to 250F by beaning back the well at the choke manifold.
When high temperatures are expected it is recommended to use the "Edge" pressure and temperature monitoring system
which has built in audible alarms when operator defined levels are reached. This enables instant action to take place
once a critical level is approaching.

SECTION 6
CONTINGENCY
Page 1 of 1
6.6 MISCELLANEOUS
6.6.1 CONTINGENCY PROCEDURES
At all times should a problem arise the appropriate action should immediately be taken to make the situation
safe and the action taken reported, this should include any action taken outwith the agreed program.
6.6.2 SURFACE DATA LOGGER
Central to the collection of surface data for high pressure/high temperature wells is the Data Acquisition system.
This provides a focal point where continuous monitoring of pressures and temperatures can be achieved, with
the added advantage that audible alarms can be set when the pressures or temperatures reach pre-determined
high-low levels. This will provide a greater degree of safety during flowing operations and will alert well test
personnel to any problems before they occur.
6.6.3 DATA POINTS
A temperature probe can be connected to the BOP stack to monitor the stack temperature, useful to monitor the
temperature of the stack, which must be remain below 250F to prevent possible problems through the
breakdown of the elastomer rams fitted in the stack.
Also a temperature probe should be connected to a point upstream of the Coflexip hose (if used) to ensure the
temperature in the Coflexip is maintained below the safe continuous working temperature.

SECTION 6
CONTINGENCY
Page 1 of 1
6.7 LEAKING DANIELS SENIOR ORIFICE METER
In the event of a leaking Daniels Senior Orifice Meter one of the following courses of action should be taken :-
OPTION 1
1. Close in the well at the choke manifold or an ESD device.
2. Vent the separator pressure to flare through the gas overboard line (ensure that the back pressure valve does
not close before the separator pressure has fully bled off.
NOTE: There exists the possibility of "blowing" the orifice plate down the line if the separator pressure is vented too
quickly. EXPRO's philosophy is that, the less time there is for the accumulated gas volume to vent in an
uncontrolled manner, the safer the conditions will be for all personnel on the rig. If the orifice plate is blown
down the line, it can be removed when remedial work is carried out to the Daniels Meter.
OPTION 2
1. Open the separator by-pass valve.
2. Close the separator inlet valve.
3. Close the separator gas outlet valve.
4. Ensure that the oil diverter manifold is lined up to the required flare boom (depending on wind conditions).
5. Bypass any liquid meters in operation.
6. Open the oil outlet valve.
7. Vent the separator pressure using the liquid level controller until all pressure has been bled off.
OPTION 3
This option is for where there is a dedicated clean-up line rigged up.
1. Ensure choke manifold is lined up to allow flow to be diverted to the clean-up line.
2. Ensure any isolation valves are lined up to allow flow through the clean-up line.
3. Open clean-up line diverter manifold (if not open) to the required flare boom (depending on the wind conditions).
4. Isolate the production system line at the heat exchanger or other isolation valve.
5. Vent separator pressure through the gas overboard line (ensuring the back pressure controller does not close
before all pressure has been vented down).

SECTION 6
CONTINGENCY
Page 1 of 1
6.8 H2S LEAK
In the event of a leak where H S is released to atmosphere personnel should consider their own personal safety and the
safety of any personnel in the vicinity of the leak.
If H2S levels in the Wellstream are such that B.A. sets are constantly being worn, then the well should be closed in and
the H2S alarm raised immediately via remote ESD stations at a point upstream of the leak.
If B.A. sets are not constantly being worn and if the well can be closed in without endangering life, then this should be
done immediately. If this is not possible then personnel should leave the area and close the well in from a remote ESD
station in a "SAFE" area (if possible) and raise the alarm.
When moving to a "SAFE" area consideration must be given to wind direction and position in relation to the leak.
Personnel should move to a location upwind and preferably higher than the point of the leak.
The alarm should be raised as soon as possible to inform all personnel on the rig of the problem and allow them to take
the appropriate action.

SECTION 6
CONTINGENCY
Page 1 of 1
6.9 CHOKE MANIFOLD
CHOKE MANIFOLD
1. If the tubing head pressure is continually falling after having been stable and the flowrate is rising this is
indicative of a choke wash-out. The procedure for this is to:-
(a) Set adjustable choke to the same setting as the positive choke or install a positive choke of the same
bean size as the adjustable choke, in the other side of the choke manifold.
(b) Divert flow via the non washed-out choke.
(c) Isolate and depressurise washed-out choke.
(d) The choke should be inspected for damage (refer to Section 3.13 for the correct type of choke).
NOTE: (i) Serious erosion should be a matter of concern as the Well Test system could potentially be
exposed to serious damage which could lead to a compromise in safety levels.
(ii) If the tubing head pressure is seen to rise along with a fall in flowrate, this is indicative of a
plug in the system. This will invariably occur at the choke manifold. The procedure
described above should be used for this. If the plug is at another point in the system, then
the well should be shut-in at the choke manifold and sourced.
2. If the tubing head pressure is rising after having been stable and the flow rate is falling this is possibly indicative
of a plugged choke. If in the event of a plugged choke great care should be taken while removing the blockage
as only the upstream side can be vented through the bleed port. The procedure for this is:
(a) If the well is flowing with the separator on bypass, the downstream side of the choke may be bled off
by opening the downstream valves on the choke manifold.
(b) If the separator is pressurised it is necessary to shut in the well and bleed off all pressure
downstream of the choke manifold.

SECTION 7
MSRV
Page 1 of 2
7.1 SPECIFICATIONS AND FEATURES
The Expro Group have designed and developed an innovative safety feature, the M.S.R.V. (Multi Sensor Relief Valve)
providing the optimum protection for hostile environment process systems.
The revolutionary M.S.R.V. is a rapid acting relief valve without the limitations of existing safety valves, allowing a greater
flexibility in safety system design. In an overpressure situation the M.S.R.V. will respond through utilisation of its safety
logic and protect the whole system.
The M.S.R.V. is a hydraulically operated ball valve actuated by well pressure from primary sensor points. Protection is
achieved through constant monitoring of the process pressure at the respective sensor points.
The impulse sensors comprise of a high pressure lockable valve and coupling containing an interchangeable rupture disc.
When the process pressure exceeds a pre-determined value the disc ruptures and the respective impulse line is
energised and the valve is opened.
Once actuated the M.S.R.V. will remain open until pressure is applied to the respective closure port.
SPECIFICATIONS
Maximum Working Pressure 10000 psi

Operating Temperature -25 Deg F to 300 Deg F
Service Conditions H2S, CO2
Outer Diameter 7.7 inches
Internal Diameter Ball - 2.0 inch
Overall Length 24.00
Effective Flow Area Orifice - 3.14 Sq. inches (Standard)
(Orifice interchangeable, sized to
required specification)
Inlet/Outlet Connections To required specification
CERTIFICATION
Bureau Veritas Design Approval - SI 289, API 6A

SECTION 7
MSRV
Page 2 of 2
7.1 SPECIFICATIONS AND FEATURES
HIGH RELIEF CAPACITY

High Flow Rate Discharge Capability.
INSENSITIVE TO SYSTEM BACK PRESSURE

In contrast to conventional and bellow type valves the M.S.R.V. is unaffected by back pressure.
Allows use of smaller diameter pipework.
POSITIVE ACTING WITH NO SIMMERING OR CHATTERING

Nature of opening is impulsive due to the operating piston being directly responsive to the process pressure.
ACCURATE SETPOINT PRESSURE

Calibrated rupture disc ensures accurate opening at the pre-determined setting.
EXTREME HIGH PRESSURE INTEGRITY

High pressure integral ball valve and impulse system.
MULTI SENSOR FACILITY

Each valve has four impulse ports giving the ability to monitor the process pressure and protect a plurality of specification
breaks.
MULTI OPERABLE CAPABILITY

In the event of activation the M.S.R.V. can be safely and reliably reset onsite. Simplicity in resetting of system only
requires closure of the valve and replacement of single rupture disc.
Integrity of system retained and confirmed by onsite pressure testing.
ESD CONTROL LOGIC

During actuation a repeat impulse can be sent to an SDV and isolate the well.

SECTION 7
MSRV
WELL TEST OPERATIONAL GUIDELINES SUB SECTION 7.1.1
Page 1 of 1
7.1.1 MSRV

SECTION 7
MSRV
WELL TEST OPERATIONAL GUIDELINES SUB SECTION 7.1.2
Page 1 of 1
7.1.2 MSRV

SECTION 7
MSRV
Page 1 of 1
7.2 DIS-ASSEMBLY PROCEDURES
1. Unscrew end cap (TED180106) from main housing (TED180102). End sub 'B' (TED180104) should be eased
out of main housing (TED180102) as end cap (TED180106) is unscrewed.
2. Remove split ring quarters (TED180107) from end sub 'B' (TED180104) and slide off end cap (TED180106).
3. Insert assembly tool (TED180122) into ball cage (TED180109) drilled holes and unscrew ball seat (TED180108)
from mandrel (TED180105).
4. Insert 2 x 1/4" UNC Screws into ball cage (TED180109) tapped holes and remove assembly, separate all
components.
5. Unscrew ball ball seat ring (TED180108) from ball (TED180118) using assembly tool ( Allen key).
6. Unscrew loading piston retainers (TED180114) from end sub 'A' (TED180103) using assembly tool
(TED180123) and remove die springs.
7. Remove loading pistons (TED180113) from end sub 'A' (TED180103) using 1/4" UNC Screw and remove steel
balls.
8. Unscrew end sub 'A' (TED180103) from main housing (TED180102).
9. Remove mandrel (TED180105) from main housing (TED180102).
10. Remove two off " UNC cap screws from seal ring retainer (TED180117) and unscrew retainer from mandrel
sealing ring (TED180115) using assembly tool (TED180125).
11. Dis-assemble mandrel sealing ring (TED180115) from mandrel (TED180105). Remove from threaded end of
mandrel.
12. Unscrew mandrel choke (TED180116) (if installed) from mandrel (TED180105) using assembly tool
(TED180124).
13. Clean all components, remove all seals and inspect all components for damage. Replace where necessary.
(Address all faults recorded on the operational report.)
"READY FOR RE-ASSEMBLY"

SECTION 7
MSRV
Page 1 of 1
7.3 ASSEMBLY PROCEDURES
1. Redress all necessary components with new seals as per general assembly drawing (TED180101).
NOTE: 1. MSRV Assembly TED180101

2. If required screw the choke (TED180116) into the mandrel (TED180105) using assembly tool (TED180124).
NOTE: Choke will be of a specific orifice, sized # for the clients proposed maximum flowrate.
#Sized and approved by region support engineer and operations supervisor.
3. Slide mandrel sealing ring (TED180115) onto mandrel (TED180105). Screw seal ring retainer (TED180117) into
sealing ring and tighten manually with assembly tool (TED180125). Insert two off " UNC cap screws and lightly
tighten up.
4. Install mandrel (TED180104) into main housing until it bottoms out.
NOTE: Sensor ports should be open during installation of mandrel.
5. Screw end sub 'A' (TED180113) onto main housing (TED180102).
6. Insert steel balls die springs, and loading pistons (TED180113) into end sub 'A' (TED180103) then screw in
loading piston retainers (TED180114) using assembly tool (TED180123).
7. Slide ball cage halves (TED180109) onto ball seat (TED180108).
8. Screw ball seat ring (TED180112) onto ball (TED180118) using a allen key
NOTE: 1. MSRV Assembly TED180101 (10K MAWP)

a) Thread locking compounds should not be applied to the male right hand thread.
9. Install ball assembly between slots in ball cage (TED180109) ensuring ball is in the closed position.
10. Install ball retainer (TED180110) over ball cage (TED180109).
11. Install ball retaining segments (TED180111) between slots in cage (TED180109) and ball retainer
(TED180110).
12. Screw ball seat and cage assembly onto Mandrel (TED180105) using assembly tool (TED180122) with the
MSRV main housing in the horizontal position.
13. Slide end cap (TED180106) over end sub `B' (TED180104) and install split ring quarters (TED180107).
14. Screw end assembly onto main housing (TED180102).
NOTE: While screwing assembly onto housing, keep sub supported outwards to ensure split ring
remains in correct position inside end cap.
15. During assembly all thread connections should only be torqued up manually.
Install 9/16" AESL plugs into three off sensor ports and tighten. Hydraulic testing/function line should be
installed into remaining port.
"READY FOR TESTING"

SECTION 7
MSRV
Page 1 of 2
7.4 PARTS LIST TED180101 (10K MAWP)
TED180101 GENERAL ASSEMBLY
TED180102 MAIN HOUSING
TED180103 END SUB A
TED180104 END SUB B
TED180105 INNER MANDREL
TED180106 END CAP
TED180107 SPLIT RING
TED180108 BALL SEAT
TED180109 BALL CAGE
TED180110 BALL RETAINER
TED180111 BALL RETAINER SEGMENT
TED180112 BALL SEAT RING
TED180113 LOADING PISTON
TED180114 PISTON RETAINER
TED180115 MANDREL SEALING RING
TED180116 MANDREL CHOKE (OPTIONAL)
TED180117 SEAL RING RETAINER
TED180118 BALL
CX 26 x 32 6 OFF BALL DIE SPRING

6 OFF LOADING PISTON STEEL BALL
TED180122 BALL CAGE ASSEMBLY TOOL
ALLEN KEY BALL SEAT RING ASSEMBLY TOOL
TED180123 LOADING PISTON RETAINER

ASSEMBLY TOOL
TED180124 CHOKE ASSEMBLY TOOL
TED180125 SEAL RING ASSEMBLY TOOL

SECTION 7
MSRV
Page 2 of 2
7.4 PARTS LIST TED180101 (10K MAWP)
SEALS LIST
'T' SEALS No. REQUIRED ITEM
427-EXT-1 1 OFF END SUB-B
427-EXT-2 1 OFF MANDREL SEALING RING
335-INT-1 1 OFF BALL SEAT
335-INT-1 1 OFF MANDREL SEALING RING
335-INT-2 1 OFF MAIN HOUSING
332-EXT-2 1 OFF INNER MANDREL
'O' RINGS LIST
'O' RINGS No. REQUIRED ITEM
222 1 OFF MANDREL CHOKE
436 1 OFF MAIN HOUSING
20 6 OFF LOADING PISTON

SECTION 7
MSRV
Page 1 of 3
7.5 PRESSURE & FUNCTION TESTS
Connect pressure line from test pump to valve open pressure port.
MSRV - TED180101(10,000 psi MAWP)
The Pressure test rating varies according to the maintenance level performed.
LEVEL 1 - Pressure test is performed at 1.5 times the proposed cold setting pressure.
LEVEL 2 - Pressure test is performed at MAWP of the valve.
LEVEL 3 - Pressure test is performed at 1.5 or 2 times the MAWP of the valve.
(Normally only performed for Certifying i.e. Major Survey)
(0-5000 psi MAWP x 2)

(5000 - 10000 psi MAWP x 1.5)
MAINTENANCE LEVEL 1
7.5.1 HYDRAULIC CHAMBER PRESSURE TEST
Operate test pump and apply minimum pressure to function inner mandrel and open valve.
NOTE: Record applied operating pressure to function mandrel.
Pressure up test pump to 1.5 times to proposed setting pressure.
(i.e. Rupture disc burst pressure - 1300 psi +/- 5% - Pressure test-2050 psi.
NOTE: Loading pistons will lift and be flush with the piston retainers as an indication of the mandrel
functioning and valve opening.
Bleed off pressure upon completion of test.
Visually inspect through inside of valve to ensure valve is open.
Drift internal diameter of Mandrel to 1.5".
Inspect valve inlet and outlet connections ensuring the sealing faces are clean and free from any damage.
Inspect and assemble seal rings and test hubs to valve connections. Tighten test hubs to manufacturers
recommendations.
Fill valve through inlet hub, set up inlet and outlet test manifolds for pressure testing. Ensure pressure testing is
monitored at a chart recorder.
7.5.2 INTERNAL BODY TEST
Operate test pump and pressure up to 1.5 times cold setting pressure.
Hold pressure test for 3 minutes.
Visually check valve for fluid leakage.
Bleed off pressure.
Repeat pressure test for 15 minutes.
Bleed off pressure once test complete.
Connect pressure line to valve closure port and function inner mandrel to close valve.
NOTE: Loading pistons will retreat into inner mandrel recess as an indication of the mandrel functioning
and valve closing.

SECTION 7
MSRV
Page 2 of 3
DO NOT APPLY MORE THAN 500 PSI HYDRAULIC PRESSURE TO CLOSE. - BLEED OFF WHEN
CLOSED.
7.5.3. CLOSED BALL VALVE PRESSURE TEST
Open relief valve outlet test manifold.

Observe for fluid leakage downstream of seat at outlet manifold.
Bleed off pressure upon completion of pressure test.
7.5.4 BALL VALVE GAS LEAK TEST
Ensure ball valve is closed and end chamber is filled with water against closed ball.
Operate Nitrogen test pump and pressure against ball and seat to 200 psig. Perform pressure leak test for 10
minutes.
NOTE: The Gas Test should be conducted with the outlet test hub liner submerged in water.
Record leakage rate in BPM (Bubbles per Minute).
Increase Nitrogen pressure to 1,000 psig. Hold pressure for 2 minutes, perform pressure / leak test for 10
minutes.
inutes.
Bleed off Nitrogen pressure. Leave M.S.R.V. in closed position.
7.5.5 SEAT LEAKAGE CRITERIA AS PER API 527
Leak test pressure 51 to 1,000 psig. Max allowable leak rate 20 BPM.
ALL HYDROSTATIC AND GAS TESTING PERFORMED AT AMBIENT TEMPERATURES.
MAINTENANCE LEVEL 2
7.5.6 HYDRAULIC CHAMBER PRESSURE TEST
Pressure up test pump to MSRV MAWP and hold hydraulic pressure for 15 minutes.
NOTE: Loading pistons will lift and be flush with the piston retainers as an indication of the mandrel
functioning and valve opening.
Bleed off pressure upon completion of test.
Visually inspect through inside of valve to ensure valve is open.
Drift internal diameter of Mandrel to 1.5".
Inspect valve inlet and outlet connections ensuring the sealing faces are clean and free from any damage.
Inspect and assemble seal rings and test hubs to valve connections. Tighten test hubs to manufacturers
recommendations.

SECTION 7
MSRV
Page 3 of 3
Operate test pump and pressure up to MSRV MAWP.

Visually check valve for fluid leakage.
Bleed off pressure.
Bleed off pressure once test complete.
NOTE: Loading pistons will retreat into inner mandrel recess as an indication of the mandrel functioning
and valve closing.
DO NOT APPLY MORE THAN 500 PSI HYDRAULIC PRESSURE TO CLOSE. - BLEED OFF WHEN
CLOSED.
7.5.8. CLOSED BALL VALVE - PRESSURE/FUNCTION TEST
Open relief valve outlet test manifold.

Observe for fluid leakage downstream of seat at outlet manifold.
Do not bleed off pressure.
Operate test pump, apply pressure through impulse system and open valve with pressure differential.
7.5.9 BALL VALVE GAS LEAK TEST
Ensure ball valve is closed and end chamber is filled with water against closed ball.
Operate Nitrogen test pump and pressure against ball and seat to 200 psig. Perform pressure leak test for 10
minutes.
Increase Nitrogen pressure to 1,000 psig. Hold pressure for 2 minutes, perform pressure / leak test for 10 minutes.
minutes.

SECTION 7
MSRV
Page 1 of 2
7.6 ONSHORE MAINTENANCE LEVEL 3
7.6.1 HYDRAULIC CHAMBER PRESSURE TESTS
Connect pressure line from test pump to valve open pressure port.
Pressure up test pump to MSRV MAWP and hold hydraulic pressure for 15 minutes.
NOTE: Loading pistons will lift and be flush with the valve housing as indication of the mandrel
functioning and the valve opening.
Bleed off system pressure upon completion of test.
Visually inspect through inside of valve to ensure valve is open and drift internal diameter of ball to 1.5".
Inspect valve inlet and outlet connections ensuring the sealing faces are clean and free from any
damage.
Inspect and assemble seal rings and test hubs to valve connections.
Tighten test hubs to manufacturers recommendations.
Operate test pump and pressure up to 1.5 or 2 x MAWP.

Visually check valve externally for fluid leakage.
Bleed off pressure.
BLEED OFF PRESSURE ONCE TEST COMPLETE.
NOTE: Loading pistons will retreat into inner mandrel groove as an indication of the mandrel functioning and
valve closing.
DO NOT APPLY MORE THAN 500 PSIG HYDRAULIC PRESSURE TO CLOSE - BLEED OFF WHEN
CLOSED
7.6.3 BALL VALVE PRESSURE/FUNCTION TEST
Operate test pump and pressure up to MSRV MAWP against ball seat.
Observe for fluid leakage downstream of seat at valve outlet manifold.
DO NOT BLEED OFF PRESSURE.
Operate test pump apply operating pressure through impulse system, open valve with pressure differential.
NOTE: Record applied operating pressure required to function valve.
Close MSRV ball and perform 5 pressure differential cycles at the MAWP.
On each occasion hold the MAWP for approximately 1-2 minutes prior to cycle.

SECTION 7
MSRV
Page 2 of 2
7.6 ONSHORE MAINTENANCE LEVEL 3
7.6.4 BALL VALVE - GAS LEAK TEST
Apply pressure through valve closure port and function inner mandrel to close valve. On closure of valve bleed off
impulse line pressure to zero. Fill end chamber with water against closed ball valve.
Operate Nitrogen test pump and pressure against ball and seat to 200 psig.
Hold on pressure and observe for 2 minutes. Perform pressure/leak test for 10 minutes.
minutes.
minutes.
NOTE: Loading pistons will retreat into inner mandrel groove as an indication of the mandrel
functioning and valve closing.
DO NOT APPLY MORE THAN 500 PSIG HYDRAULIC PRESSURE TO CLOSE.
The Certifying Authority shall witness all the pressure and function tests performed and upon completion will
hand stamp the appropriate valve. A certificate of conformity by the C.A. shall also be issued.
7.6.6 POST OPERATIONS FUNCTION TEST
On return from operations the MSRV shall be activated to verify the operability of the valve.
Ensure MSRV is set up in enclosed pressure test bay with all the necessary safety measures taken.
Connect pressure test pump onto tee piece manifold. Check rupture disc isolation valve is open and fill manifold
against closed MSRV valve with water.
Operate test pump and apply necessary pressure to burst rupture disc. ( Rupture discs should burst at set
pressure +/- 5%) Once disc ruptures test pump should be continued until MSRV has been fully pumped open.
Operating pressure required to move piston should not exceed 200/300 psi.
This procedure and any observations shall be logged onto the specific job card.

SECTION 7
MSRV
Page 1 of 2
7.7 INSTALLATION AND TESTING OF RUPTURE DISC
Select rupture disc of desired pressure setting. Rupture disc must be compatible with safety head design. (Example:
FIKE q" Angled rupture disc compatible for installation with Autoclave engineers 9/16" AEHP-q" Angled Safety Head).
Selected disc must be approved by third party witness.
NOTE: Disc should be supplied in an individual sealed box. Box should be labeled with disc
Information. Ie. SETTING, MATERIAL, BATCH No., ..etc
Inspect the rupture disc carefully. If necessary clean the disc using an appropriate solvent.
NOTE: Handle the rupture disc with extreme care. Do not make contact with the disc rupture area. Any scratches or
damage could result in leakage or rupture of the disc outside the specified tolerances.
Dis-assemble rupture head gland from lower body. Inspect the seating surface of the holder and ensure clean. If
necessary use a solvent or very fine emery cloth. Lubricate the threads of both holder and gland with a lubricant or very
light oil.
Install the rupture disc gently with the crown of the disc upwards into the lower holder. Position the hold-down ring
carefully onto the rupture disc. The angled side of the hold-down ring with the radius on the inner diameter contacts with
the disc. The flat side is the outlet side. Locate rupture head gland into the lower body and thread together until the gland
mates to the hold-down ring. Tighten the coupling to the manufacturers recommended torque. Torque value stated on
certificate of conformity supplied with disc and on tagplate.
Install sensor line to valve and selected T-piece as per drawing: (TED180121)
Assemble additional sensor lines to requirements as per drawing (TED180126)
Install rupture head into MSRV assembly. Fill sensor system with glycol through tee blocks against closed isolation valve.
Ensure MSRV is closed. Inspect valve inlet connection ensuring the sealing faces are clean and free from any damage.
Inspect and assemble seal ring and test hub to valve inlet. Tighten test hub to manufacturers recommendations.
Fill test hub with water.

Connect pressure test line and set up test manifold for recording at chart recorder.
Operate test pump and apply hydraulic pressure to 90% of rupture disc lower burst tolerance. Open disc isolation valve.
Hold pressure test for 3 minutes and observe. Continue pressure test for a further 10 minutes. Bleed off pressure once
complete.
EXAMPLE - Disc nominal burst pressure - 1300 psig

Tolerance +/- 5% - 1235-1365 psig
Test pressure - (1100 psig max.)
- Disc nominal burst pressure - 4500 psig

Tolerance +/- 5% - 4275-4725 psig
Test pressure - (4000 psig max)
7.7.1 ONSITE TESTING - RUPTURE DISC INSTALLED
The following procedures should be followed onsite/offshore especially when pressure testing with the Rig
Cement Unit and the MSRV is installed within the process system. This applies whether the valve sensor is in-
line or on a vessel.
Close rupture disc isolation valve prior to performing and pressure testing of the Well Test system. Ensure
applied pressure test is being monitored at a chart recorder/gauge in addition to the cement unit system. This
should be installed and observed closer to source and at the choke manifold or separator bypass.

SECTION 7
MSRV
Page 2 of 2
7.7 INSTALLATION AND TESTING OF RUPTURE DISC
7.7.1 ONSITE TESTING - RUPTURE DISC INSTALLED (CONT'D)
Perform pressure test of system as per well test program. The test pressure at the specification break or vessel
where the MSRV is installed should not exceed the MAWP of the valve.
Perform pressure test against closed MSRV ball and isolation valve. Maintain stabilised pressure test for 15
minutes and bleed off when complete.
Pressure up system cautiously to a maximum of 90% of rupture disc lower burst tolerance. Once pressure has
stabilised gradually open disc isolation valve and perform test against disc. Hold pressure test for 15 minutes
and observe. Bleed off pressure when complete.

SECTION 7
MSRV
Page 1 of 1
7.8 OPERATIONS WITH EMERGENCY SHUTDOWN SYSTEM
The MSRV linked to the ESD system provides a system with the ability to minimise any hydrocarbon release in the
event of an undesirable event. In the event of the MSRV being activated in a live well condition, the valve would open
and hydrocarbons would be diverted through the vent lines to overboard. In a conventional situation relief venting would
continue until the relief valve closed or the well is isolated. Operation with the ESD is capable simply by the installation
of a PSH (High pressure pilot) into one of the MSRV sensing ports. The PSH is then connected into the pilot pneumatic
circuit of the ESD system. The system should be set up that in the event of initiation the Wellhead Shutdown Valve is
closed (SDV).
7.8.1 INSTALLATION
Select PSH of desired setting.

The PSH will have previously been calibrated. This is normally preset at approximately 250 psi but can be
preset to specific requirements. It is recommended that the pilot is not set any less than this.
(Onsite PSH should be connected to dead weight tester and functioned to check.)
Remove 1 off 9/16" AESL plug from MSRV sensor port.
Install X-over 9/16" MP RESATO x 1/2" NPTF (ML3-CFT-SG) & the PSH into selected sensor port and tighten.
(A ball valve should be in place between the PSH and port adapter as a contingency.)
Connect pneumatic pilot line of PSH to pneumatic circuit of ESD and ensure pilot ball valve is open. Ensure that
all sensor connections are checked tight and all remaining 9/16" AESL sensor ports are plugged off and secure
with the specified 9/16" AESL plugs.
The system is now setup and ready for operation.
NOTE: To function the PSH in situation would require activation of the MSRV and this is not recommended
as part of the routine pre-test operating procedures.
7.8.2 OPERATION PRINCIPLE
In an overpressure situation the system would operate as follows with the MSRV installed between the steam
exchanger and separator considering the following detectable conditions.
Conditions
High pressure detected in system downstream of steam exchanger due to blockage, closure of valve etc.
The in-line PSH set at approximately 1100/1200 psi fails to respond.

Second stage level of protection provided is the MSRV.
MSRV rupture disc is burst due to overpressure.

The process pressure is then transmitted through the MSRV sensor line into the piston chamber.
System response;
The MSRV opens to relieve the overpressure.
The PSH detects the pressure within the chamber and is functioned. Pneumatic circuit of ESD is depressurised
and consequently vents the hydraulic pressure and initiates a SDV closure.
The MSRV and the ESD system will have to be re-initilised after a shutdown has occured.
Close MSRV as detailed in the contingency procedures.
Pressure up ESD pneumatic circuitry as per Well test operating procedures.

SECTION 7
MSRV
Page 1 of 3
7.9 CONTINGENCY PROCEDURES
In an overpressure situation the M.S.R.V. will respond by opening to relieve and control the situation. Once actuated the
valve remains open until pressure is applied to the closure port. Only once the well has been isolated and the relief
system is depressurised should the valve be closed.
7.9.1 ONSITE PRESSURE TESTING - VALVE LEAKS
Ensure in-line system pressure or vessel is bled to zero.
Close rupture disc isolation valve.
Disconnect impulse/sensor line from 9/16" AESL sensor port.
Isolate MSRV high pressure pilot or remove from MSRV and plug of sensor port. (Otherwise pilot will activate
when manually functioning valve)
Install adapter into impulse system/sensor port.

Apply hydraulic pressure and cycle MSRV to the open position.
(A maximum of 300 psi will be sufficient to function open the valve.)
Observe loading pistons to check position of valve.

The loading pistons will lift and be flush with the piston retainers as an indication of the mandrel operating and
valve opening.
Remove adapter from impulse system/sensor port. Leaving port open.
Apply hydraulic pressure and close MSRV through closure port.
NOTE: The MSRV can be closed by applying hydraulic or pneumatic pressure. However when hydraulically
closed the fluid must be drained from the closure chamber.
(Fluid in piston chamber will be displaced out through open sensor port. This is to ensure that the fluid in the
operating chamber is not compressed within a closed system when the piston travels from the open to closed
position.)
Do not apply more than 500 psi to close MSRV.
Bleed off pressure and drain fluid in closure system. Install 1/4" JIC cap onto closure port nipple and tighten.
Repeat system or vessel pressure test.
Successful test - Replace impulse/sensor system and continue pressure testing as per procedures.
Unsuccessful test - Proceed with the following.
Ensure pressure in system or vessel is bled off.
Close rupture disc isolation valve.
Disconnect impulse system/sensor line as above and open MSRV.
Operate test pump and pump slowly through open valve to wash around ball seat and seat ring surfaces.
Apply hydraulic pressure and close MSRV through closure port as above.
Repeat system or vessel pressure test.
Successful test - Replace impulse/sensor system and continue pressure testing as per procedures.
Unsuccessful test - remove valve from system and inspect.

SECTION 7
MSRV
Page 2 of 3
7.9.2 WELL OPERATIONS - VALVE ACTIVATED
If activated the valve remains open until reset closed. Only when the well has been secured and the relief
system is depressurised should the valve be closed.
Ensure in-line system pressure or vessel is bled to zero.
Check rupture disc isolation valve is still open.

(This is to ensure that the fluid in the operating chamber is not compressed within a closed system when the
inner mandrel and piston travel from open to closed position.)
Close MSRV through closure port.

Remove 1/4" JIC cap with care, checking for any pressure build up.
NOTE: The loading pistons will retreat into the mandrel recess after being level with the piston retainers as
an indication of the valve closing. Once the mandrel has travelled to the fully closed position the air
pressure within the air chamber will increase and cause the loading pistons to again rise. This does
not signify the valve has opened, depressuring of the pressure within the chamber will cause the
pistons to retreat and clarify the valve is infact closed.
Bleed off pressure and drain fluid in closure system.

Install 1/4" JIC Cap onto closure port nipple and tighten.
Close impulse system isolation valve and remove rupture head assembly.
Dis-assemble rupture head by removing upper gland from body.

Remove spent rupture disc and hold down ring. Inspect inside of rupture head and hold down ring, ensure any
debris from previous spent rupture disc is removed.
Install replacement rupture disc of desired setting into head as per procedures. Assemble upper gland and
body and tighten to recommended torque.
Install rupture head assembly into impulse system. Tighten all coupling connections and open rupture head
isolation valve.
Pressure test through system against closed MSRV and as per rupture disc procedures.
"Ready for Operation"

SECTION 7
MSRV
Page 3 of 3
WORK INSTRUCTION
INSPECTION/VERIFICATION OF MULTI SENSOR RELIEF VALVE
WI/AB2068

WELLTEST OPERATIONAL GUIDELINES SECTION 7
MSRV
Appendix 7
Figure 7.1
Page 1 of 2
EXPRO ABAD No. 1002B.13A Job No. :

Unit No. :
JOB CARD 10K M.S.R.V
Client Location Date of Issue Contract No. Maint / INSP No.

WI/AB/2002
Date of Next Annual Survey : Major Survey :

Maintenance Level : 1 2 3
Lift Equipment Valid Till (WI/AB 2060) : VIS: MPI: PROOF:
Relief Valve Valid Till HRS INIT WIS WTOG
1 External Damage Inspection WI/AB 2805
2 Clean/Flush External/Internal WI/AB 2006
3 Inspect Internal WI/AB 2806
4 Hold Point, Damage Report WI/AB2803
5 Address Faults on Operations Report 7.2
6 Disassemble relief valve 7.2
7 Remove all elastomers 7.2
8 Steam clean all components 7.2
9 Inspect all components WI/AB 2806 7.2
10 Repair or replace as required 7.2
11 Assemble relief valve 7.3
12 Cycle MSRV & Function test hydraulics WI/AB 2068 7.5/6
13 Pressure test M.S.R.V body WI/AB 2068 7.5/6
14 Pressure/function test ball WI/AB 2068 7.5/6
15 Pressure test closed ball WI/AB 2068 7.5/6
16 Set pressure set point 7.7
17 Install sensor line, ensure all connections are tight 7.7
18 Ensure remaining 9/16 AESL sensor ports are plugged tight 7.3/7.8.1
19 Pressure test sensor line 7.7
20 Check & complete spares box inventory.Include with MSRV. App7 fig 7.2
21 Prepare for shipping WI/AB2809/
2811/2812
PRINT NAME:
OTHER WORK - REMARKS (Cont. over)
PRESSURE SET POINT:
EQUIVALENT CHOKE ORIFICE SIZE:
INLET/OUTLET X-OVERS, SIZES, CONFIGURATION:
JOB COMPLETED : Yes No DATE COMPLETED : R/HRS

FOREMAN : HR/HRS
SUPERVISOR : TOTAL
JOB CARD CONTINUED
QUANTITY MATERIALS/CONTRACTORS PURCHASE VALVE RECHARGE
ORDER
OTHER WORK - REMARKS (Cont.)

SECTION 7
FIG 7.2
Page 1 of 2
MSRV (MULTI SENSOR RELIEF VALVE)

SPARE PARTS LIST
CLIENT: RIG:
DATE: SIGNATURE:
SHEET 1 OF 2
DESCRIPTION 1) DRAWING NO. QUANTITY

2) PART NO.
3) MANUFACTURE PT NO.
SEAL RING ASSEMBLY TOOL 1) TED180125 1
MANDREL CHOKE ASSEMBLY TOOL 1) TED180124 1 (IF CHOKE INSTALLED)
BALL CAGE ASSEMBLY TOOL 1) TED180122 1
BALL SEAT RING ASSEMBLY TOOL ALLEN KEY 2)MR02-048 1
LOADING PISTON RETAINER ASSEMBLY TOOL TED180123 1
DESCRIPTION 1) DRAWING NO. CAST NO. QUANTITY

2) EXPRO PART NO.
MSRV COMPONENT PARTS
MAIN HOUSING 1) TED180102
END SUB A 1) TED180103
END SUB B 1) TED180104
INNER MANDREL 1) TED180105
END CAP 1) TED180106
SPLIT RING 1) TED180107
BALL SEAT* 1) TED180108 1
BALL CAGE 1) TED180109
BALL RETAINER 1) TED180110
BALL RETAINER SEGMENT 1) TED180111
BALL SEAT RING* 1) TED180112 1
LOADING PISTON 1) TED180113
PISTON RETAINER 1) TED180114
MANDREL SEALING RING 1) TED180115
MANDREL CHOKE* (IF REQUIRED) 1) TED180116
SEAL RETAINING RING 1) TED180117
BALL* 1) TED180118 1
BALL DIE SPRING* 2) MR02-056 6
LOADING PISTON BALL* 2) MR02-082 6
AMOUNT REQ. QUANTITY

(PER SET)
MSRV REDRESS KIT (T-SEALS)
END SUB B (EXTERNAL T-SEAL, SLIM) 2) MR02-026 3) 427 EXT.1 1 3
MAIN HSG. (INTERNAL T-SEAL, SLIM) 2) MR02 -024 3) 335 INT.2 1 3
INNER MANDREL (EXTERNAL T-SEAL, WIDE) 2) MR02-020 3) 332 EXT.2 1 3
MANDREL SEALING RING
(INTERNAL T-SEAL, SLIM) 2) MR02-022 3) 335 INT.1 1 3
(EXTERNAL T-SEAL, WIDE) 2) MR02-0283) 427 EXT.2 1 3
BALL SEAT (INTERNAL T-SEAL, SLIM) 2) MR02-0223) 335 INT. 1 1 3
MSRV REDRESS KIT (O-RINGS)
MAIN HOUSING (O-RING) 2) MR02-030 3) BS 436 1 3
MANDREL CHOKE 2) MR02-016 3) BS 222 1 3
LOADING PISTON 2) MR02- 014 3) BS 020 6 12
NOTE: * All indicated are to be included as a minimum within the Spare Parts Box

SECTION 7
FIG 7.2
Page 2 of 2
MSRV (MULTI SENSOR RELIEF VALVE)

SPARE PARTS LIST
CLIENT RIG:
DATE: SIGNATURE:
SHEET 2 OF 2
DESCRIPTION 1) DRAWING NO. AMOUNT REQUIRED QUANTITY

2) EXPRO PART NO.
MSRV CROSS OVER SEALS/GASKETS
3 FIG 602 WECO SEALS** 2) AN16-024
4 FIG 206 O-RINGS** 2) OR04-044
3 C-25 SEAL RINGS** 2) TG80-004
3 ANSI 600 METALFLEX GASKETS** 2) TG14-008
MAWP QTY QTY

REQD
SENSOR SYSTEM ADAPTERS / FITTINGS
9/16 AEHP SAFETY HEAD C/W 2) MR02-054 3) CS9600-1/4-SOG* 10K 1
9/16 AEHP FEMALE x 3/8 NPT MALE 2) MR02-032 3) 6M69N3-SOG
9/16 AEHP TUBING 3) T3-143/80/21 10K 22
9/16 AEHP GLANDS 2) MR02-070 3) MU3-10-SG 10K 4
9/16 AEHP COLLARS 2) MR02-072 3) MU3-11-SG 10K 4
9/16 AEHP NEEDLE VALVES 2) MR02-084 3) VU3 - 1 - 21 15K 1
9/16 AEHP PLUGS 3) ML3-13-SG 10K 1
9/16 AEHP T-BLOCKS 2) MR02-062 3) FU3-3-21-SG 10K 1
9/16 AESL PLUGS 2) MR02-052 3) ML3-13-SG 10K 2
9/16 AESL GLANDS 3) ML3-10-SG 10K 2
9/16 AEHP (F) x 1/2 NPT (M) 3) F3 - CMT - 07 10K 1
9/16 AESL (M) x AEHP (F) 3) ML3 - FU3 - SG 10K 1
SENSOR SYSTEM ASSEMBLY TOOLS QTY REQD QUANTITY

9/16 AEHP TUBING CONING / THREADING TOOL 1
TORQUE WRENCH (20 - 100 Nm RANGE) 3) GEODORE 4550-10 1
1 3/8 WRENCH SOCKET 1
SAFETY HEAD COMPONENTS QTY REQD QUANTITY

1/4 ANGLED RUPTURE DISCS @ 1300 PSI 2) MR02-010 4
1/4 ANGLED RUPTURE DISCS @ 4500 PSI 2) MR02-012 4
HOLD DOWN RINGS 2) MR02-002 2
MANUFACTURERS RUPTURE DISC TAGS 4
ADDITIONAL COMPONENTS QTY REQD QUANTITY

DISC SETTING BRASS IDENTIFICATION TAGS 2) MR02-046 2
LEAD / COPPER SEALS 2) MR02-044 4
5/8 BSP SENSOR HOSE (6Ft) (MULTI SENSING 2) MR02-086 2
APP. ONLY) 3) 4012 ST
5/8 BSP (M) x 5/8 BSP (M) (SENSOR HOSE 2) MR02-006 1
CONN. ONLY) 3) 1212-10-10
5/8 BSP (M) x 9/16 AEHP (M) (MULTI-SENSING 2) MR02-074 2
APP. ONLY) 3) MU3-5/8MSH
9/16 AESL (M) x 1/2 NPT (F) 2) MR02-066 1
(ESD PILOT X-OVER) 3) ML3-CFT-SG
Note: All AEHP fittings are RESATO manufacture apart from ( * ) MARKED which are Autoclave.
** Dependent on x-over selection.

SECTION 7
Fig 7.3
Page 1 of 4
APPENDIX 7: DRAWING INDEX
DRAWING TITLE DRAWING No.
Multi Sensor Relief Valve General Assembly TED180101

MSRV Sensor System Application (Standard) TED180121
MSRV Downstream Sensor Installation (Heater to Separator) TED180126

SECTION 7
Fig 7.3
Page 2 of 4

DATE:
9/16" RESATO HP
9/16" RESATO HP 9/16" RESATO HP PLUG
PLUG TUBING SPOOL
9/16" RESATO HP 9/16" RESATO HP

TEE BLOCK TEE BLOCK
9/16" RESATO HP
TUBING SPOOL 9/16" HP FEMALE 9/16" AE RUPTURE
OCTOBER 1999
STRAIGHT RESATO DISC SAFETY HEAD
VALVE
9/16" RESATO HP 9/16" RESATO HP
TUBING SPOOL TUBING SPOOL
9/16" RESATO HP - FEMALE

9/16" RESATO HP - FEMALE INLET X OUTLET
X
9/16" RESATO SL - MALE
1/2" NPT - MALE ADAPTER
X-OVER / ADAPTER
9/16" RESATO SL
SENSOR PORT
1/4" NPTF
9/16" RESATO SL CLOSURE PORT
1/2" NPT FEMALE PORT SENSOR PORT
ISSUE
2
MSRV
9/16" RESATO SL
SENSOR PORT
90 ELBOW X - OVER
3.0" 25 HD TECHLOK OR EQUIVALENT 3.0" 25 HD TECHLOK OR EQUIVALENT
x 3.0" 25 HD TECHLOK OR EQUIVALENT x CLIENT SPECIFICATION
TEE PIECE
3.0" 25 HD TECHLOK OR EQUIVALENT
x M x F CLIENT SPECIFICATION
REVISION
O
Fig 7.3
APPENDIX 7
Page 3 of 4
SECTION 7
SECTION 7
Fig 7.3
Page 4 of 4

SECTION 7
Fig 7.4
Page 1 of 1
APPENDIX 7 AMENDMENT/ADDITION PROPOSAL FORM
DOCUMENT CHANGE REQUEST
Procedure Change Controlled Document Change
Procedure/ Document Number:

Page Number: Section: Base:
DCR Number: Requested By: Date:
Reason for Application:
Details of Request :
1.
2.
3.
4.
Above details as on attached sheets.

Request granted subject to conditions and limitations below:-
Signed: Quality Assurance Dept Date

(Procedure & Controlled Document Change)
Signed (Engineering) Date

(Engineering Procedure Change Only)
Signed (Region Director) Date

(Main Procedure Change Only)
Signed (Department Manager) Date

(Department Procedure)
Signed (IBIS Administrator) Date
(Inputted onto IBIS)
Conditions and limitations applying to this request:-
AB/AD 0501 B Rev. 2

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EXPRO

WELL TEST OPERATIONAL GUIDELINES

THIS MANUAL IS CONTROLLED

CONTROLLED COPY NO: _____

WELL TEST OPERATIONAL GUIDELINES

TITLE BASE NAME REF

OPERATIONS MANAGER HOUSTON T PARKIN 001

AREA MANAGER YARMOUTH W OWEN 008

REGION DIRECTOR HOLLAND A KITCHENER 017

REGION DIRECTOR AUSTRALIA S ASHTON 021

GENERAL MANAGER NORWAY J MACBEATH 005

OPERATIONS SUPERVISOR TUNISIA S DRAKE 009

OPERATIONS MANAGER VIETNAM S MOLLOY 022 & 023

GROUP MANAGER NIGERIA P STYLES 025

AREA MANAGER CHINA K CRAWFORD 007

BUSINESS DEVELOPMENT MANAGER AMERICA J LOAFMAN 029

CLIENT ACCOUNT MANAGER P GHEZ 033

OPERATIONS LIBYA S DRAKE 031

OPERATIONS ABERDEEN G MACDONALD 050 to 059

OPERATIONS YARMOUTH A ROSS 070 to 079

OPERATIONS HOLLAND N TIELENS 090 to 099

OPERATIONS VIETNAM S MOLLOY 110 to 119

OPERATIONS AFRICA/FSU D WOODEN 140 to 143

DATE: OCTOBER 1999 ISSUE 2 REVISION O

WELL TEST OPERATIONAL GUIDELINES

Surface & Environmental Systems Business Stream

DATE: OCTOBER 1999 ISSUE 2 REVISION O

WELL TEST OPERATIONAL GUIDELINES

AMENDMENTS AND RE-ISSUES

DATE: OCTOBER 1999 ISSUE 2 REVISION O

WELL TEST OPERATIONAL GUIDELINES

REV No. DATE SUB-SECTION BY APPROVED SUMMARY OF CHANGE

DATE: OCTOBER 1999 ISSUE 2 REVISION O

WELL TEST OPERATIONAL GUIDELINES

1.0 GENERAL OPERATING GUIDELINES

1-1 Toxicity of Hydrogen Sulphide Gas

Fig. 1.1 Sour Gas Systems

DATE: OCTOBER 1999 ISSUE 2 REVISION O

WELL TEST OPERATIONAL GUIDELINES

2.0 PRESSURE TESTING GUIDELINES

Fig. 2.1 Line Up for Flushing System

3.0 EQUIPMENT OPERATING GUIDELINES

DATE: OCTOBER 1999 ISSUE 2 REVISION O

WELL TEST OPERATIONAL GUIDELINES

3.2 Lower Master Valve

DATE: OCTOBER 1999 ISSUE 2 REVISION O

WELL TEST OPERATIONAL GUIDELINES

3-1 Required Number of Turns to Fully Open/Close a McEvoy Valve

Fig. 3.1 Actuator Lock-Open Cap and Disc

DATE: OCTOBER 1999 ISSUE 2 REVISION O

WELL TEST OPERATIONAL GUIDELINES

Fig. 3.25 Liquid Meters Set-up

Fig 1- EXPRO 2" Supergreen Atomiser head Assembly - TED090101

4.0 SURFACE SAMPLING GUIDELINES

Fig. 4.1 Gas PVT Sampling Hook-up

5.0 SAFETY GUIDELINES

6.0 CONTINGENCY GUIDELINES

6-1 Freezing Points of Glycol/Freshwater Mixes

DATE: OCTOBER 1999 ISSUE 2 REVISION O

WELL TEST OPERATIONAL GUIDELINES

7.0 MULTI SENSOR RELIEF VALVE (MSRV)

Fig 7.1 10K MSRV Job Card

Fig 7.3 Drawing Index