Cpt’ The Future Is Working Together.e 1 Introduction WELL TESTING ‘A well test is the measurement, under controlled conditions, of all factors relating to the produc- tion of oil, gas, and water from a well. Acquired well test data is used to determine reservoir capa- bilities. Important decisions, such as production methods, well production improvement, and devel- ‘opmental drilling are made from this information, Regulatory bodies may use the test results to establish withdrawal allocations and tax bases. Well testers have a responsibility to provide com- plete, accurate data of the reservoir performance. Since the purpose of well testing is to gather information, well test equipment provides the ‘means to obtain essential data such as: 1. Pressures 2. Temperatures 3. Production Volumes @ 4, Gas, Oil and Water Rates 5. Samples of Produced Fluids Surface well test equipment provides well control, data measurement, well effluent processing, disposal and analysis. The exact combination of the components necessary to achieve these goals is dependent upon well conditions and test requirements. ‘The following page is a simplified schematic of surface equipment standard elements. Well production begins a controlled surface flow at the surface tree and concludes with disposal at the burners. Descriptions of the main individual pieces of equipment and their specific functions will follow in Section 2, Surface Well Testing Page 1-1abit WOuvuaas u¥ STNHWS ‘aasn waauocay sunivaaeaL ONY SuNSS 38a OWSHTEIM nam vaiens waisat LMOLRA va omva1ant aanivssaal nose alan 30LMO. shhanys 34049 angarn ana WoInaHo Anas sovuns 0193130 SNS AIRS Surface Equipment Package Page 1-7 Surface Well TestingSURFACE WELL TESTING COURSE e@ A variety of topics will be presented throughout the Surface Well Testing course. The course will cover the process by which a welt is flowed, controlled and monitored to gain insight to the resetvoit's capabilities. The class will cover the surface equipment used in the well testing process as well as the theoretical and practical principles on which the process works. The course seeks to combine learning with practical hands-on training. ‘The course’s manual is designed to be a study guide for learning many of the aspects of surface well testing. The Surface Well Testing manual consists of: Section Subject Page 1 Inuoduction 2 Surface Equipment 3 Surface Test Trees 21 Surface Safety Valves 2-13 Piping & Elastomers 2-21 ‘Choke Manifold 2-33 e Heaters 2-40 Separators 2-55 Disposal Equipment 2-86 3 Production Problems 4 Hydrocarbons 5 Data Recordings & Measurements Gas Flow Measurement Test Procedures Test Types Glossary Conversion Factors Dep ear. Rate Calculation Tables Surface Well Testing Page 1-3 aEUNITEST Surface Test Tree ‘The function of the UNITEST surface test tree is to control surface pressures during formation testing. The UNITEST is a component-style tree, allowing maximum versatility in arrangements of control assemblies. Another advantage of the design is to permit field personnel and customers to order only those components they need. Fluid can be pumped through UNITEST equipment for sub-surface pressure control. ‘Swabbing operations can also be done through this equipment. ‘Components include: Lift Nipple Bar Drop Sub Flow Tee Swivel Master Valve Access Valve Remote Controlled Safety Valve All UNITEST surface control subassemblies have a 4 3/8"-6 Stub Acme thread (male or fe- male) so interchangeability of components pre- sents no problem, ‘The flow tee and master valve are separate components; thus, a master valve can be run with or without a swivel, and master valves ccan be stacked in tandem. AU master valves are basically LO TORC plug valves. A remote controlled safety valve can be installed in place of or in tandem with the flow tee, and can provide a way to close in a well atthe surface from a remote location, UNITEST components can be provided for the standard service (S) applications (15,000 psi working pressure) and for sour service (SG) (10,000 psi WP). Litt Bar Drop Flow Nipple Device UNITEST Components Suryace Well Testing Page 2-1}—_ UFT NIPPLE BAR DROP SUB FLOW TEE MASTER VALVE, REMOTE CONTROL ‘SAFETY VALVE, FLOW LINE HYDRAULIC CONTROL UNE ‘20 SWIVEL MASTER VALVE ACCESS VALVE NIPPLE }-—_—— DILL PIPE Control Head and Component Descriptions cee eee ee ee lene nena ieininanan nines atatssiasasassinininintestastntntstt= ttt tsa tats] ‘The Lift Nipple, used instead of a pup joint, provides a latching point for tubing or drill pipe elevators. ‘The Bar Drop Device allows a bar to be dropped down the test string to operate a revers- ing valve without breaking any surface connec- tions. ‘The Flow Tee contains a side port that allows flow to exit from the surface control equipment. At the top it contains a plus which can be replaced with a check valve or can be completely removed if the tee is located below the bar drop device. The Double Ported Flow Tee is an optional flow tee with two 1.62 in. ID flow outlets. One of the outlets can be used for direct connection of a kill line. The Remote Controlled Safety Valve is used when the surface equipment is too high above the rig floar for the safe manual operation or when it is desireable to control a well from a remote location when testing. The valve is normally closed but can be opened with the application of fluid or gas pressure and will remain open as long as external pressure is maintained. Where high flow is expected the optional Double Ported Remote Controlled Safety Valve with a 1.62 in. ID flow is avail- able. ‘The Master Valve provides a means for surface closures and pressure control. The LO TORC plug valve design allows pressure control in harsh conditions. The master valve is de- signed to operate with string weight hanging through the valve. One quarter tum is all that is required to operate the valve. The Access Valve is used to introduce hydrate inhibitors into the flow stream to prevent freezing. Surface Well Testing Page 2-2Bar Drop Device Uft Nipple 3-7/8 in. 6 Stub Acme 3-7/8 in, 6 Stub Acme 3. Master Valve: -7/8 In. 6 Stub Acme ST Pressure Balanced Swivel 3-7/8 in. 6 Stub Acme oT Modular Compact Test Tree Surface Equipment Assembly Page 2-3 Surface Well TestingStiff Joint A stiff joint is a heavy walled joint of tubing that is placed in the upper section of the test string. This joint replaces thin wall tubing sections which run through the rotary table and below the surface test tree. These joints provide extra support, safety and stability to the control head if the elevators are removed. SPECIFICATIONS -Meets requirements of NACE MR-01-75. NOTE: Other sizes and configurations are available w meet most applications. Stiff Joint Surface Test Tree ‘The basic designed Surface Test Tree incor- porates four valves - waster, swab, kill, and. flowline (hydraulic actuator). ‘The assembly also has a swivel to-allow pipe rotation for manipulat- ing downhole tools without turning the test head. Er Stiff Joint Specifications A lifting sub is supplied with the tree to allow rig elevators to raise and lower the tee in the derrick. Some designs may incorporate a hydraulically actuated kill valve, lower master valve, and/or chemical injection sub. Two distinct styles of test trees exist: (1) component aud (2) solid block. Surface WellTesting Page 2-4UFT SUB SOLID BLOCK CONTROL HEAD CHECK VALVE ‘SURFACE CHEMICAL INJECTION VALVE FROM KILL LINE CONNECTION Surface Test Tree ats EMERGENCY SHUT DOWN ACTUATED WING VALVE HYORAULIC ACTUATOR ‘VALVE FLOWLINE D FLEXIBLE TEST LINE Lower MASTER VALVE STIFF JOINT AC TO STIFF JOINT ya hae CONNECTION Surface Well Testing Page 2-5SPECIFICATIONS (683.0020 683,00300 683.0500 Cameron Type FC ‘Cameron Type FC ‘Cameron Type FC 29/16 in 18K 31/16 in 10K 31/16 in 15K Service HS’ Hs! Bs" Size 2-9/16 in 3-1/16 in 3-1/16 in ‘Working 115,000 psi. 10,000 psi ‘15,000 psi Pressure End 5.75 in - 4 Stub Acme Box | 5.75 in - 4 Stub Acme Box | 5.75 in - 4 Stub Acme Box Connections Flanges +2-9/16 API 6 Bx 15K 3-1/16 API 6 Bx 15K 3-1/16 API 6 Bx 15K Studs A320 GRL7 A320 GRL7 4320 GR L7 NACE Class II NACE Class If NACE Class II el I Wing Tee WLead-filed target W/Lead-filled target W/Lead-filled target Cross Overs | 2-9/16 APL6 Bx x Weco | 3-1/16 APL6BxxWeco | 3-1/16 API6 Bx x Weco Fig 2202 Union Fig 1502 Union Fig 2202 Union One wing ‘One wing half, One wing half. half, one thread half ‘one thread half ‘one thread half e@ whbull plugs woul plugs whoull plugs Lint Eye 3 in Dia Hole x 1.5 thick x | 3 in Dia Hole x 1.5 thick x | 3 in Dia Hole x 1.5 thick x pin thread pin thread pin thread Lift Sub 61771021 617.7101 617.7101 Operating. -20°F Ambient temperature | -20°F Ambient temperature | -20°F Ambient temperature ‘Temperatures | 250°F Maximum fluid 250°F Maximum fluid 250°F Maximum fluid temperature temperature. temperature “Meets requirements of NACE MR.01-75. NOTE: Other sizes, configurations, and pressure ratings are available to meet most applications. Surface Test Tree Specifications Test tree flowheads are installed on the DST _They also provide an exit through a flow string to give a means of entry into the DST wing valve for the well stream fluids. Since tubing by: they are a complicated piece of equipment they should only be operated and maintained by LKill, circulating, or stimulation fluids ‘competent personnel. 2.Wireline or Coil Tubing ‘To operate the valves with the tree installed on e a floater, takes considerable skill and dexterity, ‘Surface Well Testing Page 2-6Eee A Check Vaive .:istaller! or the side cf the Surface Test ites) Te vaive s designed to prevent we i c# vet from flowing back Ihrough the ke, Wie °. 708 ke BUMPS. Use of the Check Valve allows the kill valve on the Surface Test Tree to be left ‘open and enables the kill pump to be left ‘on-iine at all times. This action enhances emergency kill operation response since Bersonne| are not required to ascend the ina riding belt to manipulate valves Prior to commencing operations. The Check Valve is designed with a lock- out pin to be used during pressure tes ‘operations. When the pin is screwed in, wil keep the check vatve flapper off seat, Gliowing the test liquid to flow back through the Check Valve. This allows pressure to be bled off the the kill pump ‘manifold rather than the choke manifold immediately before testing is to begin. SPECIFICATIONS Part Number 683.20500 683,20501 683,20502 Working Pressure | 10,000 psi 15,000 psi 15,000 psi Service HS" HS" HS Size 3-1/16 in 2.9/16 in 3-116 in End Connections | API 6 Bx Flange | API 6 Bx Flange | API 6 Bx Flange “Meets requirements of NACE MR-01-75. | NOTE: Other sizes und configurations are available ro meet most applications. ‘Check Valve and Specifications Surface Well Testing Page 2-7SPECIFICATIONS 0533 5.00100 oosa, BS op 1025 in 3a 10000 psi 444.000 80 pat 540000 80 psi 421300 5.000 pa | Max WP 477.000 th5.000 psi 358,700 1/10.000 ps 415,000 Ws10.000 pa 352.00 5,000 psi 352.000 15.000 psi ‘Connections a3 6 5738-4 4375 9-6 ‘Sub Acne Sub Acne ‘Sub Acme Pin x Box Pin Bor Pin X Box * Meets requirements of NACE MR-OI-75 NOTE: Otter sizes and configurations are avaiable 1 mest mos applications. Surface Test Tree Swivel and Specifications Surface Well Testing Page 2-8 He eee eee a en ee TERED EEE UBER GEER REESE Eee EEE Ena{Ihe lower master valve 1s an optional item which can be run below the swivel. This valve provides added security because it can be closed manually or by emote control should a leak develop in the swivel assembly or STT assembly. The lower master valve can also be used when pressure testing the above rotary table installation; this prevents test fluid and pressure from entering the test string. SPECIFICATIONS Part Number 4073720 | _683,00600 640.73449 683.0601 Valve Type ‘Manual Hydraulic Pneumatic Hydraulic Service Hs” HS” HS HS” D 2.68 in 3.0625 in Bin 3in Working 10,000 psi 10,000 psi 15.000 psi 15,000 psi Pressure Tensile 358,000 Ib 400,000 tb 400,000 Ib 400,000 Ib Strength Wire Cutter No Yes No Yes Connections | 4.375in-6S.A. | 5.75 in-4 S.A. 5.75 in -4 5.75 in -4 S.A. Pin x Box Pin x Box Box x Pin Box x Pin “Meets requirements of NACE MR-D1-75. NOTE: Other sizes and configurations are available to meet most applications. Lower Master Valve and Specifications Surface Well Testing Page 2.9Tn some well tests, chemical injection is required in the q@ surface tet tre, The chemical injection aub is designed to allow chemicals to be injected into the vertical upper ‘test string. When the well is flowing, the chemicals mix with the well effluent and flow through the surface equipment. When the well is shut-in, the chemicals fall own the test string. SPECIFICATIONS 358,000 Ib Connections | 4.375 in-6S.A. | 5.75in-4 S.A. ‘Pin X Box Pin X Box * Meets requirements of NACE MR-01-75, NOTE: Other sizes and configurations are available to meet most applications. ‘Surface Chemical Injection Sub and Specifications Surface Well Testing Page 2-10 ————— — —— rr — — — — —————Generai Rules 1, Always wear a safety hamess (in good condition). 2. Do not ascend to the tee on the tugger by using the DST tubing as an aid to ascent. Always ascend on the tugger away from the tree, then once above the tree swing over and come down on the tree, otherwise there is a danger of being caught under the tree when the rig heaves. 3. When hoisting subassemblies such as wireline BOP’s etc. to the top connection ensure that it is properly slung with a certi- fied lifting strap. Stendaré Operating Practices 1, Ensure that the test tree is rated in excess of the maximum anticipated shut-in wellhead pressure, 2. The tree is suitable for sour service if the well is of sour nature. 3. Visually inspect the main body for signs of structural damage likely to affect integrity of assembly. Check threads and sealing sur- faces for damage. Check lead targets (if installed) for signs of erosion. 4, Oneach of the manual valves ensure that the number of turns to open/close the valve are noted (18 turns to fully open Cameron/Foley type valves, 13 turns for McEvoy type valves). 5. Function the hydraulic actuator mechanism ensuring that it travels freely the full travel without internal pressure. With the valve in the closed position measure the protrusion of the stem and note. Check the operation of the ESD panel supplying the hydraulic fluid to the actuator. Pressure Testing Prior to the Surface Test Tree being taken to the drill floor and rigged up onto the test string the assembly will be pressure tested to ensure the integrity of the Tree body, valves and flanged connections. Please refer to schematic on page 2-5. In initial tests pressure applied via D with needle valves in test caps in postions A, B and C. The Barton surface pressure recorder should be used to record these tests. The test pressure and test period are usually dictated by our clients requirements. 1. Prior to pressure testing: a. Erect warming barriers around the test area, b. Announce over P.A. system that pressure testing is about to commence. c. Ensure all non-essential personnel are clear of test area. 2. Open valves 1 through 4 and A through D. (3000 psi control line pressure required to open Actuator Valve (4)). 3, Fill assembly with water. 4, Close needle valves A,B and C and com- mence pumping to test pressure. Visually inspect all connections for sign of leaks. Note: Do not attempt any remedial action while there is pressure applied. 5. Once at test pressure isolate pump and monitor for test period. (Test one - full internal). 6. Close valves 2,3, and 4 (control line pressure 2210). 7. Bleed pressure slowly via needle valves A,B, and C to zero. 8. Monitor for test period. (Test two against Kill, swab and flowline valves internally). 9. Close valve 1, open valve 2 (kill ine) slowly bleeding pressure above master valve, monitor for test period. (Test three - master valve from below). 10. Bleed pressure via pump vent to zero. 11. Rig-up onto a (kill line) with test equipment, 12. Open valve 2. (Valves 1,3 and 4 closed). 13. Commence pumping to test pressure. Surface Well Testing Page 2-1114, Once at test pressure isolate pump and pressure testing of the test string. There are monitor for test period. (Test four - master _various permutations employed by our clients to valve from above). achieve this, one such approach is outlined q below. 15, Close Valve 2 and monitor for test period. (Test five - kill valve). Valve configuration as follows: 16. Bleed pressure via pump vent to zero. i, Kill valve open. Actuator valve open, Note: Repairs and maintenace undertaken at iii, Swab valve closed. this point should follow recommended iv. Master valve closed (or fluid will be maintenace procedures. pumped downhole). y. Choke manifold valves open. Moving Surface Test Tree torig floor: ‘1. Commence pumping slowly flush lines. (Utilizing rig pump via kill line). 1, While in the process of moving tee to die rig floor ensure that all personnel are aware 2. Close front valves on choke manifold and and avoid being trapped under the tree commence pumping to working pressure. should the rig heave. 3. Once at test pressure, isolate pump and 2. Remove and store the shipping slings before monitor for test period. Test one against the tree is hoisted by the rig elevators. master and swab valves also checks integrity of co-flexip, data header and choke connec- 3. Before the tre is made up to the handling tions. joint to be made up to the DST string ensure that the swivel is free to turn and that either 4, Bleed pressure via pump vent to zero. e the upper or lower master valve is closed. 5. Close flowline actuator valve, 4, While the wee is being made up to the DST string ensure the lock out cap is on. This 6. Commence pumping slowly to test pressure. will avoid damage to the actuator stem. Be careful of grease nipples and their web 7. Once at test pressure isolate pump and Protectors. monitor for test period. Test two against flowline actuator valve. 5. After the tree is made up to the DST string ensure that the lock out cap is removed and 8. Bleed pressure via pump vent to zero. excessive weight from the flow lines (Coflexip or metal hoses) is not being sup- 9. Open master valve and flowline actuator ported by the tree connections (use tuggers, valve. if necessary). 10. Close kill valve. 6. Before pressure testing check the swivel. It is good practice when working on a floating 11. Commence pumping slowly to test pressure. rig to paint a white line down across the joints on the STT to be able to observe if any 12. Once at test pressure isolate pump and of them are backing out. monitor for test period. Test duce against kill valve. Once the surface test tree has been rigged up onto the test string there will be further pressure 13, Bleed pressure via pump vent to zero. e@ tests to ensure the assembly's integrity prior to the test program commencing. These tests will normally be performed in conjunction with Surface Well Testing Page 2-12Considerable problems are caused by at- tempting to open the valves with pressure locked in between the gates and seats. This may occur uring pressure testing. This pressure must be relieved by either: 1. “Stinging” the valve through the body filer port using a tool specially supplied by McEvoy. NOTE: This must be done with extreme caution. 2. Bleeding off the pressure through a port in the bonnet of the valve (if available). Once the pressure testing is complete the tree should be left in the following condition prior to the opening of the downhole tools. a) Swab valve closed b) Kill valve closed (unless otherwise di- sted) rect ©) Flowline valve open 4) Master valve(s) open Maintenance and Repair ‘The removal of worm seats must be done with a seat extraction tool and not with a bar, etc. If the seats are removed improperly, the counter bores which receives the seats may be distorted “oval”. ‘This will cause further problems when the new seats are pressed home. ‘The size of the counter bore can be found stamped under the bonnet of the valves. If any machining is done, these sizes must be updated. ‘The sealing compound chambers in the seats must be filled. “This is done by closing the valves 4-5 tums and then injecting the sealing compound. through the appropriate grease injection ports. Each time the valve is funtioned the displacement of the stem and seat helps to inject a small amount of sealing compound onto the face of the valve to aid in sealing. Grease the valve stem bearings through the ‘grease nipples in the valve bonnets. ‘When shipping put protectors over the union connections to prevent damage (i. other half of union complete with bull plug for pressure testing). A fill inspection of assembly should be made between test periods. Any maintenance and repair should be carried out using recom- mended maintenance procedures. ‘An end of job status report must be submit- ted to Maintenace Supervisor. Surface Safety Valve Since the consequences of uncontrolled flow are so severe, especially offshore, well safety systems are important enough that they are sometimes mandated by law. Safety systems must be failsafe. Failure of the energy source or any component must cause the system to shut in the well at one or more points. Safety systems sense conditions and shut in the well or wells when conditions deviate from the preset limits. Shutting in the well averts further danger due to: 1) Uncontrolled flow from ruptured pressure vessel 2) Fueling any fire that has started or may start 3) Overfilling vessels with fluid and/or pressure STANDARD LOCKOUT Cal RiaLe CaP OPTIONAL) ‘UPPER STEW Surface Safety Valve ‘Surface Well Testing Page 2-13Most surface safety valves are reverse-acting gate valves with piston-type actuators. Valve body pressure against the lower stem area moves the gate to the up/closed position. Control pressure applied to the piston pushes tie gute the down/open position. Usually a spring is used to close the valve if valve body pressure is not present. Valve body pressure and piston/stem area ratio determine the control pressure re- quired. The larger the area ratio the less control pressure needed to maintain the valve open, A hydraulic actuator valve is normally Jocated on the flow wing of the HRS Surface Test Tree. However, when a non HRS tree is being used or test conditons dictate, a hydraulic or pneumatic actuated valve can be located on the flowline upstream of the choke manifold near the wellhead. SSV usually have an actuator stem protrud- ing from a threaded boss on the actuator cylinder head for several reasons. ‘© Stem position gives a visual position indica- tion. © A manually operated jack can be attached to open a closed valve. © Alockoute.y 9r Sc sop vam keep the valve open during # weli 1: : jerations or when the control system is dc wn. The power required by most pilots and safety valves is pneumatic or hydraulic. Most systems are pneumatically powered because compressed air or gas is readily available. Power is con- sumed only when a valve is being opened; most of the time the system is static. ‘Valve control is performed by hydraulic/ pneumatic or pneumatic/pnenmatic relays. These relays permit the use of either bleed (two- way) or block and bleed (three-way) sensors. Relays are reset manually to put the system back in service after a closure. This safety feature ensures that personnel are present to determine that the cause for closure has been corrected and that reopening will not be hazardous. Conditions that are possibly monitored include: 1) Pressure - high or low 2) Levels - high or low 3) Fire 4) Toxic or flammable gas mixtures 5) Manual controls at exits and critical locations 6) Erosion Probes HYDRAUUC PRESSURE NET PRESSURE TOCrEN) Gate Vaive with Hydraulic Actuator Surface Well Testing Page 2-14Tn addition, the system can be adapted to Visual inspection of unions for damage. land or offshore operations incorporating subsur- These unions may be Weco connections, face safety devices. Graylock connections or flanged connec- tions. Ensure threads are clean and undam- Inspection aged, inspect sealing surfaces. On receipt of equipment on location a gen- if : : eral inspection of the actuator valve should be ® Visual check on main body for signs of made. This inspection should include: es damage likely to affect integrity of ° assembly. OPEN—Uoper stem practically flush with cylinder. indicating valve is open. (1) Control pressure on actuator piston holds valve ‘open: (2) Large piston area permits use of low-pressure contro! system: (3)Stem packing section reduces contamination of act ator worning parts) Flowine pressure. ‘CLOSING—() Loss of control pressure on piston permits piston tomove outward. Valve Doay pressure, acting on area of the lower stom. is designed to move the gate to the closed cosition: 2) Spring helns to close valve. especially where low tlowiine pres- Sure exists; Nonrotating, vertical movement of stem minimizes ‘wear on packing ‘CLOSED—} Extended stam inaicates valve is closed: (2) Metal ometal seat between actuator bonnet and lower stem nas Served.as a Secondary seal when high temperatures have meited br alstorted lower stem packing: (3) Unstream vale body pres- Sure nelps to noid gate closed unt trouble ts corrected Pneumatic Safety Vaive, Operating Surface Well Testing Page 2-15Emergency Shutdown System ‘The HRS Emergency Shutdown System consists of a hydraulic control manifold that supplies hydraulic pressure to the actuated flow valve on the Surface Test Tree and air or nitrogen to a “pilot” sensing system. Pressure sensing pilots are located at strategic locations throughout the surface equipment. If any of these pilots sense au “upset” condition (either high or low pressure), the well will be automatically shut in at the ‘surface test tree via a hydraulic/pneumatic relay in the control manifold. In addition to the dial pilots, manual shutdown valves and fusible plugs can be strategically placed around the test area and rig. If required, high and low liquid sensors can also be incorporated. Hydraulic/Pneumatic Well Test Safety System Surface Well Testing Page 2-16‘The BRS surface hydraulic control manifold is designed to provide the hydraulic pressure required tn hold open varius safety valves, such as the hydraulic surface safety valve, and to sense the pilot pressure of the system. Any loss of pressure in either the pilot ine or hydraulic line allows the safety valve (or valves) to close automatically. HRS Surface Controt Equipment OVAM ee =n Bag gtevensen- Surface Well Testing Page 2-17200¥ FLAPPER SEAL SPRING GUIDE, VALVE SPRING RETAINER O-ING CONTROL LINE PRESSURE exHausT EXWAUST BACK TO. RESERVOIR In Service Operates Hydraulic Quick Exhaust Operating Principle The operating principle is based upon pressure differential. When backflow occurs in the control line Isading to the Quick Exhaust Vaive, upward movement of diaphragm Is desioned to pull non-extrusion vaive offseat. With valve offseat, an unobstructed path is created for exhausting of control ine pressure. Control line presstire will then retum fo hydraulic fluidt reservoir FROM PILOT ROLLING ee sonrace une gourmet pressure Frow ars SEING Bxraustes math SouRce. ‘TeROuEH PLOT vawe SensusT PORT (n Service Pneumatic Quick Exhaust Operating Principle When In service, contro! pressure is admitted to and flows through the Quick Exhaust Valve to ‘the safety valve. When the control pressure is exhausted from the control line, the pressure differential should cause the diaphragm in the Quick Exhaust Valve ta move. The valves exhaust port is then opened and is designed to allow quick exhaust of the control pressure from the safety valve. ‘Quick Exhaust Valves a ia Surface Well Testing Page 2-183-Way Block and Bieed Relay vatve sa ‘diophragm/spring-operated valve that is designed to block and bleed control Pressure to operate safety valves automatically Design Principle Vaives large flow area is Gesigned to bleed off control pressure quickly to speed closi of safety valves. 7 Valve can be used in most safely systerns ‘with low-pressure control ine. Valve closes automatically. A deliberate manual effort must be made to open valve. This positive action is dsigned to prevent accidentally reaciivaling the sysiem. Manual overtide allows the shuttingin of the safety system or putting system back in service, contro. UNE — Fhow vow omessune GisoRaIRsouRcE outer SFeowT ROL er Shutdown Valve is is designed !o be used re it can be operated manually to shut down the safety system in on emergency of for routine maintenance. Such locations inciude separators. rig floor, tanks, exits, etc. The valves are located in the pilot Control ine and are normally used witn G relay valve. By pling up the handle, control pressure Is released 16 the atmosphere from the contro! line, which is designed to activate the relay valve, bleed off control pressure from the safety vaive and allow the safety vaive to close. sano PISTON Presoune wanoue mare contro. tnero Operating Principle Control pressure is acimittec to the 3-Way Block and Bleed Relay Valve, and f flows through the vaive body to one or more safety valves, Pressure also flows down the 3-Way Valve stem through an orifice where it gqucizes above and below a diaphragm. Control pressure continues on to monitor pilots in the flowiine. Should any monitor pilot sense gan abnormal change in flowline pressure beyond the preset limit, itis designed to ‘exhaust pressurefrom the control line by the Bilot. This is dosigned to create a pressure Siferential across the dlophragm (assshed by spring) to move inward, blocking incoming control pressure from the safety valve chamber, permitting the safety valve to close. Control pressure is exhausted quickey through a snap-cigture slement Ground the 3- Way Valve stem. 3-Way Valve handle must be pulled out manually to put valve back into service. Ne 4 + Sonnet Live pressure In Service Operated INSTRUCTION, Pneumatic ESD Valves Surface Well Testing Page 2-19the supply pressure ports. 2 cap SPRING High-Only Moge OF Operation The capis screwed down to compress the spring which pushes the inner vaive stem and Pressure assembly all the way down. This cllows supply gas to enter through the "HIGH Port and exit "he port marked “OUT.” Fiowine Pressure increases will bush up the inner valve stem, blocking and bleeding supply pressure ‘and aliowing The safety valve fo close. nici por ve - HIGH’ PORT 7 INNER en vv out ANE sren Low roar Low post c wenn { PRESSURE. I~ pressure e SENEING Senso : sSSeMaty AD) setwawe =H genseo 3/4) ~ eevee 3. 7p BSc g pressure ao - In Service Operated 2 Ladhnshit Otis BB HI-Only or LO-Only Monitor Pitot is c spring-loaded, pressure sensing plunger pilot, The pllot is designed fo block and bleed control pressure whenever sensed pressure rises of fals eyona the preset limit, it can be converted to high or low sensing by proper connection of cae SPRING Low Only Mode Of Operation The cap i adlusted to alow towne pressure to override spring pressure. ‘This pushes the inner valve stem and pressure assembly all the way up and allows the passage of supply gas from the "LOW" entry port to tne “OUT” ox port, ‘Upon loss or decrease of flowline pressure, the soring wil push the inner valve stem down, blocking and ceeding supply Pressure and allowing the safety valve to close. Pressure Pilots Tix ase ~ Pressume z—reonae | FF icontaaccne on y= C _(snosion 2 Sonne: SPanaee Erosion Probe Operating Principle The housing of the pilot is cylindrical and is Ported to provide G means of connecting the safety system control lines. The pilot is designed to operate only when erosion penerates the thin wall of the probe, When the probe is penelrated, pressure within me vessel § ollowed To act against the lower end of the 3/4" piston, This pressure forces the piston and plunger upward until the valve containing system control pressure is allowed to exhaust to tmosphere around the plunger and is designed to cause the satety system to activate. Surface Well Testing Page 2-20Pressure Testing Prior to the test program commencing the actuator valve assembly will be pressure tested to censure the integrity of the valve body, valve and connections. See procedures headed ‘HRS Sur- face Test Tree’ for guidelines on pressure testing actuator valve when part of the ST assembly. ‘The procedure for testing an actuator valve on a flowline is as follows. This test will normally be conducted in conjunction with tests on the choke manifold, 1. Prior to all pressure testing: a. Erect warning barriers around test area. b. Announce over P.A. system that pressure testing is about to commence. ©. Ensure all non-essential personnel are clear of test area. 2. Open hydraulic actuator valve. Control line pressure 3,000 psi. (Choke valves open). » . Commence pumping slowly to flush lines. S . Stop pumping. w . Close actuator valve. Control line pressure zero. 6. Commence pumping slowly to test pressure. ‘Visually inspect all Connections for sign of leaks. Note: Report leaks immediately, Do not attempt any remedial action while there is pres- sure applied. 7. Once at test pressure isolate pump, if possible, and monitor for test period. . Bleed pressure via pump vent to zero, 9. Open hydraulic actuator valve. Control line pressure 3,000 psi. Operational Procedures The flowline actuator valve is normally in the open position for the duration of the well test. A pressure of 3,000 psi will be required in the control line between the actuator and the ESD (Emergency Shut Down) Control Panel. ‘Care should therefore be taken in the running of this line. The Actuator valve is the primary clement in the HRS ESD system. A full inspection of the assembly should be made between test periods. Any maintenance and repair should be carried out using recom- mended maintenance procedures. An end of job status report must be submit- ted to the Maintenance Supervisor. Coflexip Hose Coflexip hoses are generally used for 10,000 and 15,000 psi applications to replace hard piping. Their primary uses are as kill and flow lines from the surface test tree. By using 40 foot Jong flexible hoses instead of hard piping, many connections are eliminated and no sharp comers are present which could be subjected to flow cutting. A typical Coflexip line is composed of: A) A length of flexible pipe B) Twoend-fittings complete with lifting/ handling collars. ‘The end-fitting consists of: 1) The termination which ensures the seal and the mechanical attachment of the end-fitting to the flexible pipe. To move the line use a shackled sling through the eyes of thevifting collar. 2) The connector to allow the connection of the end-fitting to any other connector. All types of connectors can be supplied with any end- fittings, the most frequent being API hubs, hammer unions and flanges. ‘The termination bears permanent markings indicating: Manufacturer * Test pressure Serial number Length of line Tntemal diameter Date of factory pressure test Application* Stamp of certifying authority working pressure * Optional before mid-1990 ‘Surface Well Testing Page 2-21Available line applications and limits: C/K: Choke and Kill (temporary H,S; not vented) DST/ACD: Dual Service Line (temporary sour service limit of 72 hours; vented) PTL: Production Test Line (permanent sour services vented) ACD: Acidizing/Fracturing (150°F limit) ROT: Rotary (150°F limit) ‘The whole surface, both inside and outside of a standard end-fitting is protected against corrosion, wear, abrasion and handling by a protective coating of Ni-Kanigen. If the inner coating is damaged or cracked, traces of corro- sion and rust may be visible and an inspection should be completed. CONNECTOR LIFTING / HANDLING COLLAR ‘TERMINATION | FLEXIBLE PIPE fetes =n TL experrnscs 4 — End Fittings Cronund nl armor Invermediate psu nr Flat ste! spiral | TARR intemal Structure ‘The construction of the Coflexip consists of a “non bonded” structure of seven layers. 1) The thermoplastic inner liner makes the pipe leakproof. This layer limits the upper tem- perature and the chemical compatibility of the line, Standard lines are rated from -20°C to 100°C with a Rilsan material liner. The inner liner of high temperature lines is ‘Coflon and good between -20°C and 130°C. 2) The zeta spiral layer takes the hoop stress due to the internal pressure and external Joads. ‘This layer limits the minimum bend- ing radius of the line (roughly 12x ID). If the limit is exceeded, irreversible damage to the line will occur leading to perforation of the inner tube when under pressure. Overbending generally occurs during han- dling of the line near the end-fitting. Due to the heavy nature of the line, never allow the Coflexip to support its own weight, Thus insure that while manipulating the Coflexip during installation, a length of about 3 feet behind the termination is not bent. 3) The flat steel layer reinforces the zeta layer ‘under high pressure. 4) The intermediate thermoplastic sheath improves the dynamic behavior of the line with its anti-friction material. This layer is not leakproof. 5) The double crosswound steel armour wires resist axial load caused by intemal pressure or external axial loads. This layer also provides the line with its resistance to tor- sion. 6) The thermoplastic outer sheath is leakproof and therefore protects the armour wires against corrosion and the line against hydro- static external pressure. 7) The stainless steel outerwrap protects the plastic outer sheath against mechanical damage caused by impacts, wear, handling, etc. Note: A flexible stee! line is a mixed con- struction of steels and thermoplastics. Heat diffusion which occurs during welding may cause irreversible damage leading to a danger- ous line. Surface Well Testing Page 2-22WRONG RIGHT f \ Hales & OC) ° OF a 7 | i MINIMUM : ' js BEND | : RADIUS | | i g 7 7 SB LONG LENGTHS = Srixon MINIMUM OT OF piri i BENDING : RADIUS Coflexip Handling installation Guide 4 _ Surface Well Testing Page 2-23PRODUCT COMPATIBILITY OF STANDARD TEMPERATURE RATED LINES e CORROSION RESISTANCE OF RILSAN INNER LINING CONCENTRATION TEMPERATURE DESIGNATION OR OF ) 150°F | 20°F | 250°F EXPOSURE TIME | _Yg°¢ eete-tosecdsice Hydrochloric acid 13% F Fo. F F HCL 30% F F F F Hydrofluoric acid 3% F Fo. oF F HF 75% F F F F Xylene 100 % 1s 8 3 s | MR C6 Hy (CH3)2 24H s s | 5s NR eae 100 % s | xR | xr | nr 5 | oem saturated F F F F F en al saturated el] eg Bye L foo saturated 8 s wip L e Toul 100 % s s 8 8 1 Diesel 100 % s s i $s i Ss L Crude oil 100 % Ss Ss $s Ss eNO 30% s L | xR | NR | ONR Beton soe | <20% siti s 8 L 2 | | S: Satisfactory NR : Not Recommended Le Limited use Fs Farhidden Procuct Compatibilty of Standard Temperature Rated Lines Surface Well Testing Page 2-24@ PRODUCT COMPATIBILITY OF HIGH TEMPERATURE RATED LINES CORROSION RESISTANCE OF COFLON INNER LINING CONCENTRATION | TEMPERATURE | DESIGNATION OR | 9° 75° 50° yo tia oer | 75°F | 150°F | 200°F j EXPOSURE TIME "| gee} a4 | 66°C | 93°C ! Hydrochloric acid 15% s s s $ $ HCL 30% s s s $ 8 Hydrofluoric acid 3% $ $ s $ 2 HF 15% 8 s s 8 ? Xylene 00% | 15° 8 $s s 8 s Co Hy (CHaig | 24H 8 s s s s anon 100 % $ s $ s Arent saturated $ 3 3 s ? Sannin saturated |S $ s s | e sae Cateium enloride saturated s s {os s 2 Methane | $ | | cH, | 100% $ 8 s $ s Diesel | 100 % 8 s | s 8 Crude oil | 100 % Vs Tos |] os 3s | Sodium hydroxide 7 a Lil Y ! ha 50% Ss $s L NRO} NR j NaOH | | ! i | Hydrogen sulfide i / i | ¥ <20% los jos s s Sj Hy | | - i 3: Satisfactory NR: Not Recommended Li: Limited use F Forbidden Product Compatibility of High Temperature Rated Lines Surface WellTesting Page 2-25jyrgRecedved from mRS.nENAB (214) 418-3020 05/14/92 e 14.51 -> HS.721899 HS NIGERIA/TELEX TELEX cc: Mike Jenrette -> HS.T45529 HE COLOMBIA/TELEX TELEX cc: F. Suarez -> HRS.GLENG GLEN GIBLING/MANAGER STE ENG -> HRS.BNM BN MURALI/TECHNICAL MANAGER ADMIN -> HRS.GREGL GREG LOYACANO/MGR SVC LINE DEV ADMIN Date: May 14, 1992 te: Area Managers Regional Eng. Managers From: Robin Jackson Subject: Coflexip Hose Failure In July of 1991, Colflexip issued Technical Bulletin GG/N91/179 to all U.K. North Sea users cf high tomperature drill stem and production test lines. This was the result of a failure on such a line. e ‘They have determined certain operating conditions were seen as the main source of failure. The three main parameters are exposure of relatively long periods to : a) High Temperature b) High Pressure ¢) High C02 concentratins with H2S present Coflexip has new suspended supply of ET/HP test lines until an alternative design becomes available. For those HT/HP test lines (Coflon) which remain in use, the following limitations on use therefore appiy + PRESSURE ‘TEMP FLUID CONDITIONS 35,000 ps 130 deg.c 02 > #28 less than 108 10,000 psi 130 deg. C C02 + HAS less than 30% 10,000 110 deg. C C02 + H2S less than 50% In the event that any such line is known to have been exposed e to conditions above these limits tor a period over 48 hours, the line should be removed from service and returned together with full details of the exposure to Coflexip for inspection. Soo S So ST ee === nee eeePiping Ensure enough of correct size and pressure _errosion in the flow system: target elbows, rating pipe is available for surface rig-up. block trees, lead targets and erosion probes. 6 Check supply of any crossovers required. Piping may consist of straight lengths, Grease swivels, check unions and seals, Pres- swivels and crossovers. Additional assemblies sure test to working pressure prior to sending on may be needed to reduce flow cutting and a job. m= j i § i Colborne Rearend ang | Surface Well Testing Page 2-26SYSTEMS ENGINEERING BULLETIN Report No.: $90-01 SURFACE Date: 19 September 1990 L_Averovais [¥¢E [Hee | Pressure Ratings for 1502 Weco Unions Purpose ‘Tho purpose of this bulletin is toinform you of the limitations of 1502 Woco style unions. Pressure Limitations It is esesential to know beforchand if the flow pipe you are putting into service was fabricated for sweet or sour service: When fabricated from standard service materials, the 1502 style union is approved for use in pressures of up to 15,000 psi. @ When fabricated from sour service materials, the 1502 univu is good for use in pressures of up to 10,000 psi. Consequently, a flow pipe with 1502 unions that has been built for sour service should not be used in any application (sweet or sour) above 10,000 psi. This is because the material used to build the sour service flow pipe has a much lower yield strength than if the pipe were built to be used for standard service. Note: The HRS quality program QP1433 requires flow pipe to be striped to indicate pressure rating and type of service. H,S serviceis identified by a 4-in. green band. The presence of that band on a piece of flow pipe with 1502 unions means that it should not be used in conditions that exceed 10,000 psi. Page 1 of 1 Robert Pahmiver —————————Production Systems e P.O.Box 819052 Dallas, ‘'X 75381-9052 2601 Beltline Rd. Carrollton, TX 75006 Ph. 214-418-4412, Fax 214-418-3010 HALLIBURTON pn. Ao [ Approvals | ffs £ Se Dili To: Surface Well Test Equipment Personnel From: Production Systems Engineering - Dallas Date: October 28, 1993 Subject: Threaded Line Pipe Bulletin Introduction The purpose of this bulletin is to specify the Halliburton surface well test equipment threaded piping requirements. This document applies to all surface taper-threaded piping and connections where the threaded joint serves as a seal. This document supersedes HRS engineering bulletin 89-02 Halliburton Production Systems Engineering Standards conform to ASME/ANSI B31.3 Chemical Plant and Petroleum Piping. Threaded Pipe Standards Minimum Thickness of Male Steel Threaded Components Fluid Service Nominal Pipe Size Range Min. Wall Thickuess Category "M" sis" Schedule 80 2" Schedule 40 >2" Not PermittedPressure Rating The depth of the threads must be considered in establishing the pressure rating of threaded pipe. Prior to calculating the allowable working pressure, thread depth must be subtracted from the pipe wall thickness much in the same manner as a corrosion allowance, The thread depth of NPT thread is 0.0571" for 1/2" & 3/4” NPS, 0.0696" for 1"-2" NPS, and 0.100" for pipe greater than 2” NPS. If you have questions regarding this bulletin, please feel free to contact Joe Kangan via MEMO ID HRSW611 or at (214) 418-4412dian 5S }10S} 10 | LW] 20} 30} STD] 40s} 40 | 60 | 80S] 80 | 100/120} 140] 160] Xs | xx ie eK] 085 iS 8 Sal Ta Be 2% Bish 3 ice ssoal Sn eel BP Sef B55 3% Ren Al 2a36|i238% Tc 288 30) Le satizoe 7 sof 7aqhiiseohr$i0 rs; o|11 Sof ioecet osaol Ors rseea [rstocks Sissel a stan hsagahist cigs peat gaye 18 beste Gal nerolireaalincohnso x a8Sal2aosc 2a [race Tan : 20 [nse ‘infiséee| Sea] 9s0q)1950 200% ‘apealsozschsooe 5 30 is hs 32 In 24 Pisce, oa ial aa 36 sie oa ARE af pal sérstiszsohrs 3izshe a S05ef S39) 37 Pssahh Hee rahiassshres 7 x37shi2)2 alir2so] i i 1925019006) :625} Ta 7API Flanges z Ee oe oe ne ne = = 2 et ae ne eee aa $20 cinecreme ae tae ae ae Roma 12 Ve be axe ii nes oe p ze zene ia i a aE : ae iene = H za EE na ae , Lees te a 4 Epes HE she $2 enema oo or ns se ae Hada ee Eee H om ) SEE 3 u aoe ee ii Ses Sa enemas ie oo SANSTCEEEEEEEEEEEE EERE EEE EEE PE Pressure-Temperature Ratings - Material Group 1.1 MAWP (psi) Based on Class of Flange Temperature (°F) -20 100 200 300 400 500 600 650 700 750 800 850 900 950 2000 150 285 260 300 740 675 655, 635 600 550 535, 535 505, 410 270 170 105 50 400 990 900 875 845 800 730 15 710 670 550 355, 230 140 70 600 1480 1350 1315 1270 1200 1095 1075 1065 1010 825 535 345 205 105 900 2220 2025 1970 1900 1795 1640 1610 1600 1510 1235 805 515 310 185Paint Specifications Each HRS assembly shall include painted identification bands to identify pressure rating and service, An assembly should have a 12” band of the proper color for the working pres- sure of that particular piece. H,S service is identified by a four inch wide green band with four inch wide bands of the pressure rating bordered on each side. The pressure rating color code to use is: Working Pressure (PSI) 1,440 @ 2,000 3.000 4,000 5,000 10,000 15,000 Color Silver Blue Black Brown Gray \ Yellow Orange Note: Band width may vary according to size or configuration of assembly Paint Specs HS CODE (IF APPLICABLE) PRESSURE CODE 12° —= Surface Well Testing Pave 2-27tro-:-:;----;----—-'‘(('|_——_——_—_———— HALUBURTON ELASTOMERIC MATERIALS GUIDE Chemicai 70 XXXXX 600 XXX 601.3XXXX e Environment P.C. Nitrile Fluorocarton Aflas (FEM) (TFEP) HS x aA A Hydrocarbons A A A (Sweet Crude) CH, B-EX B-EX A-EX (Methane) Sweils Slightly Salt Water A a A Steam x Devends on Type B co, B-EX A-EX B-EX Sweils N, B-EX ALEX B-EX Weak Acids B A a (15% HCD Amine B x A Inhibitors | ® Alcaiois A C. Sweils Diesei B A Acidic Compietion DIC B A Fluids Rapid Hardening Aromatic C - Softens B c ‘drocarbons and Mechamicai Property Loss Solvents x B x camnie-Xviene) Exceijent - Recommended Good - Little or No Efect Conditionai Attacks Not Recommended Exposure at High P: jease May Cause ture and Rapid Pressure Re- olosive Decompression | Hallipurton Elastomeric Materials Guide Surface Well Testing Page 2-28 ee ___{ant 96) #24 coos pus (o. cy Vv v aN 7) @ cI we «| <} <} 5} 5] <| gs] < g ag Otis Guidelines for Seals Page 2-29 Surface Well Testingepwauwore! IN -YN —ex2eHY-G —_PaHe ov 10 eI POELION-IN — sHIMg 9 ‘homasnes: y we uN wr wy v 3 v v ¥ vy ¥ ww tN ws v v v v v Y v ¥ v 2 3 v v v v v v ¥ ¥ v v v v v v v v v v v v @ é v ¥ 3 7 v v sre Gen 008 onost ea oy war Baader see on eonies Pr end on wen | gions [epee | ygpumoduog Otis Guideline for Seals Page 2-30 Surface Well TestingData Header The data header is an assembly normally e@ mounted in the flow path upstream of the surface choke manifold. The header is designed with four to eight lateral fittings providing access to measure certain well flow parameters. The access points may be used for pressure, tempera- ture, sand monitoring, sampling, chemical injection, etc. If transducers or gauges are to be used, care must be taken not to shock them when making up unions etc, e SPECIFICATIONS Size 2in | 2in 3in 3in 3in Working Pressure | 10,000 psi_| 15.000 psi | 10,000 psi | 15,000 psi | 15,000 psi Service HS" as’ |S" HS? HS" End Connections | Fig 1502_| Fig 2202 | Fig 1502 | Fig 2202 | API6 Bx Fig Length 37 in Din Win 20 in 21 in Weight (56 Ib 225 Ib 140 Ib I 225 Ib 225 Ib “Meets requirements of NACE MR-01-75 Data Headers and Specifications Surface Well Testing Page 2-31 PERSRESRERREREEeInspection On receipt of equipment at location a general inspection of the data header should be made. This inspection should include: ¢ Inlet female Weco connection (Hub-Clamp connection for 15K equipment). Check threads are clean undamaged. Inspect seal ring and replace if necessary. ‘© Outlet male Weco connection (Hub-Clamp connection for 15K equipment). Check sealing surface for damage. Check condition of wing nut threads. © Removal of 1/2" NPT plugs (SNO-Trik HP fittings for 15K equipment). Check condi- tion of threaded connections. Replace plugs. Rig Up The general procedure on a four port data header is to install needle valves in three of the 1/2" NPT threaded connections with a thermowell in the fourth. Use thread (teflon) tape on all NPT connections. Pressure Testing Prior to the well test program commencing the data header will be pressure tested to ensure the integrity of the connections. This will be done in conjunction with the pressure tests on the choke manifold. Note: Report leaks immediately. Do not ‘attempt any remedial action while there is pressure applied. Deadweight Tester Deadweight Testers are used where accurate pressure measurement or pressure calibration is required. Their operation depends on balancing known weights against the force exerted by an unknown pressure acting on a piston of precisely known area. The weights are applied manually until the piston is floating with no net vertical movement. ‘When the weights are applied to the piston, the entire assembly is rotated clockwise slowly. This rotation minimizes frictional effects and permits vertical motion of the piston with ex- tremely small variations in pressure. Deadweight testers have a manually con- trolled pump which can generate the pressure needed to calibrate spring and strain gauges. Valves permit rapid, convenient switching between functions. Testers have an oil reservoir to provide the pressure medium needed for purging lines and calibrating purposes. Typical Deadweight Tester Surface Well Testing Page 2-32Chemical Injection Pump Chemical injection pumps are provided to inject the following chemicals: a) Hydnue formation inhibitor (medanol or glycol) ») Corrosion inhibitor ©) Demulsifying agents d) Foam inhibitors ) Dewaxing agents Chemical Injection Pumps Choke Manifold ‘The choke manifold is the primary means of controling the flow of the well and should be monitored and operated by competent personnel. ‘The assemblies normally contain two chokes: 1) an adjustable choke used generally in well clean up operations and 2) a positive choke which allows more accurate control for pre-determined choke sizes. Alternatives of dual fixed or adjust- able chokes are also possible. Manifolds offer the option of directing flow through either choke while isolating the other for choke changes, maintenance or repair. Five valve configura- tions also allow an unrestricted flowpath through, the manifold with a total bypass of choke con- tral. Inspection On receipt of equipment on location a gen- ral inspection of the manifold assembly should be made. This inspection should include: a. The choke manifold must be rated to the maximum expected shut-in pressure. It should be sour service rated if H2S is ex- pected. b. Inleoutlet Weco connections (Hub Clamp connections for 15K equipment). Ensure threads are free of dirt and have no indica- tion of damage. Inspect seal rings and replace if necessary. Ensure thread protector replaced after inspection. Surface Well Testing Page 2-33 a. Always prior to operation count and note the number of tums to fully open and close each valve. Valves should open and close freely (18 turns to fully open Cameron/Foley type valves, 13 turns for McEvoy type valves). Also inspect condition of Stem Adaptor, Bearing Cap and Bonnet. 4d. Visual check on main body for signs of structural damage likely to affect integrity of assembly. Rreak om 60" nut on vovitive side of chrke manifold. Checi. itu: size of choke bean installed. Ensure thot i» rhreads are in good condition and the inner as; "iy is free of dirt and other deposits. Checs sal 31. ving nut. Replace and make-up wing nut. Break-out wing nut on adjustable side of choke manifold. Ensure inner assembly free of dirt and other deposits. check valve scat for signs of wear or damage. Check seal on wing nut. Replace and make-up wing nut. |__ Positive Choke ‘Choke Manifold Surface Well Testing Page 2-34MANIFOLD ASSY. 5 VALVE c A B CHOKE MANIFOLD ASSY. 4 VALVE FIXED CHOKE INLET VARIABLE CHOKE Surface Well Testing Page 2-35 Choke Manifold AssembliesValve repairs and maintenance undertaken at this point should follow recommended mainte- nance procedures. Pressure testing of the assem- bly may be required before placement in its well test position. this should be done following the ‘guidelines laid down for workshop pressure testing of choke manifold, SO 1416. Rigup Installation of adjustable choke, positive choke, sample points and pressure gauges should only be undertaken once manifold is located in its well test position. a, Adjustable choke - installed as per manufac- turers recommended procedures. s )._ Positive choke - if information is available of the well’s performance it may be possible at this point to install a positive choke. If so it should be installed as per manufacturers recommended procedures. If not, install a thread protector (large choke size bean). ¢. Sample points - 1/2" NPT threaded connec- tions (SNO-TRIK HP fittings for 15K equipment) are located on the manifold assembly. One directly behind each of the chokes and one at the junction prior to the outlet. Needle valves should be installed in each of these connections. Sample/Bleed hoses can then be installed behind each of the chokes. d._ Pressure gauge - Downstream choke pressure is monitored throughout the testing program. ‘The gauge may be installed in the needle valve at the outlet junction, Pressure Testing Prior to the test program commencing the choke manifold will be pressure sted w ensure the integrity of the choke body, choke valves and Weco connections. The tests should be monitored via the data header on a Barton Pressure Recorder and a suitably rated pressure gauge (€.g. 5,000 psi test use 10,000 psi gauge). ‘The recommended procedure for the four valve (non-bypass) configuration is as follows:- 1. Prior to all pressure testing: a. Erect waming barriers around test area. b. Announce over P.A. system that pressure testing is about to commence. ¢. Ensure all non-essential personnel are clear of test area. 2. Ensure alll needle valves with the exception of those to the Barton recorder and pressure gauge are closed. 3. Open all 4 valves on the manifold. = Back-out the adjustable choke. 5. Commence pumping slowly to flush lines and choke manifold: 6. Stop pumping, 7. Close both back valves on manifold. 8. Commence pumping slowly to test pressure. Visually inspect all connections for sign of leaks. Note: Report leaks immediately. Do not aitempt any remedial action while there is pressure applied. 9. Once at test pressure isolate pump, if pos- sible, and monitor for test period. 10. Bleed pressure via pump vent to zero. 11, Close both front valves on manifold. 12. Open both back valves on manifold. 13. Commence pumping slowly to test pressure. Visually inspect all connections for signs of Teaks. 14, Once at test pressure isolate pump, if pos- sible, and monitor for test period. 15. Bleed pressure via pump vent to zero, 16. Open both front valves on manifold. Surface Well Testing Page 2-36Procedure for the 5 valve by-pass configura- tion is similar and is outlined below. ..As above. -Open all 5 valves on manifold. -As above. ..Close both back valves and by- pass valve on manifold. As above. ..Open both front valves and by- pass valve on manifold. Valve repairs and maintenance undertaken at this point should follow recommended mainte- nance procedures. General Rules Manipulations of the chokes should be done in conjunction with the company representative. It is essential that perfect understanding and ‘communication exists between ourselves and our client. Never flow through the manifold without either the adjustable choke seat or fixed choke bean in place to protect the body threads. Never use the valves as chokes as this will damage the gates and seats. Note: Before operation of the choke mani- fold, while in service or in testing, the entire installation should be grounded by means of a cable which allows the static electricity to dispense and avoid flashes. The cable should have a maximum resistance of 1 ohm per three ‘feet. It should be connected to a place where there is no paint, either on the vessel or on the rig. In the case of onshore testing, the ground should be a copper earth electrode at least three ‘feet long, driven into the ground and watered regularly to keep the earth wet and provide good contact. Operation Adjustable chokes are not highly accurate. ‘Therefore, avoid using adjustable chokes for extended periods. Where conditions permit use fixed chokes with the the adjustable used as a bypass system to allow fixed choke changes. Note: Careful monitoring of upstream and downstream pressures must be made during any choke change; bearing in mind the rating of the downstream equipment. When installing choke beans/scats use the appropriate wrench and check that the metal sealing gasket is in place. The seal will help prevent damage to the body and choke seat threads due to flow cutting. With the seat installed correctly the adjust- able choke stem can be made up to the manifold. Back out the stem before offering it up to the choke body. Make up the hammer union tight insuring the indicator notch is centered on the top. Screw the adjustable stem all the way in until it butts with the seat. Zero the indicator. Rack the choke out halfway then re-check the. zero setting. The accuracy of adjustable chokes is affected by the amount of backlash in the threads. Con- siderable choke size variation can occur due to the thread movement between stem and body. Pressure may drive the stem to seat or away from the seat depending upon the force applied and the area of the stem. Due to the aforementioned reason, whenever a well is first opened to the adjustable choke, the stem must be backed off its seat to prevent a pressure lock. If a pressure lock occurs, do not force an unseating with excessive torque or damage may result. Ensure provisions are made to bleed off pressure when changing chokes both upstream and downstream of the choke. Be particularly careful of pressure trapped upstream of choke, caused by mud, plugs, hydrates, etc. Check for wear and damage of chokes and body threads. Surface Well Testing Page 2-37Check that an adequate supply of chokes/ seats and correct choke indicators arc available. Ensure adjustable choke is zeroed correctly. Always remove positive chokes after test and replace in carrying box. Always carry spare adjustable choke stems and seats. 1. Initial Opening The choke configuration prior to initial opening of the well is generally as follows:- Both front valves closed. Both back valves open. Sample point needle valves closed. Needle valve to downstream gauge open. ;. Adjustable choke set off zero. Positive choke installed, choice depen- dent on well performance. peeoge On initial opening a low adjustable choke size may be selected. ‘The front valve is then opened and the well flowed through the adjust- able side. The downstream pressure is carefully monitored to ensure the working pressure of the downstream configuration is not exceeded. The adjustable choke size is then manipulated up or down depending on well response. Well effluent samples can be taken duting this period. Itis good practice to take these samples at a point directly in the flow path i.e. in this case from the adjustable side sampling point. Samples should be taken throughout the flowing periods and results recorded. 2. Positive Choke For accuracy af results it is good practice ta flow the well, once clean-up achieved, on a positive choke. The choice of positive choke bean will be predetermined by the adjustable choke size, ‘The procedure for installation of a positive choke bean is as follows: a Ensure front and rear valves on positive choke side are closed. b. Bleed pressure to zero via the bleed valve at the rear of the manifold, Avoid discharge of well effluent onto floor or work area as this may present a safety hazard. c. Leaving bleed line open break-out and remove wing nut. 4. Install choke bean as per manufacturers recommended procedures. €. Replace and make-up wing nut. f. Close bleed needle valve. ‘The choke bean is now installed on the positive side. The flow path must now be switched from the adjustable to the positive side. (Note: two operators may be required). The procedure is as follows: a. Open rear valve on positive side. b. Begin to slowly close front valve on adjust- able side while simultaneously opening slowly the front positive side valve; observe the downstream pressure gauge. Note: Itis essential the working pressure of the downstream configuration is not exceeded. e c. Generally a pressure ‘kick’ is observed on the downstream gauge indicating flow through both sides of choke, at this point smoothly close front adjustable valve while opening front positive valve. The adjustable side may be isolated at this point and the adjustable choke removed, cleaned and inspected. Post Test Inspection A fill inspection of the assembly should be made in between test periods. Any maintenance and repair should be carried out using recom mended maintenance procedures. End of Job Status An end of job status report must be submit- ted to the Maintenace Supervisor. Surface Well Testing Page 2-38Chokes Chokes are throttling valves whose design enables progressive manual, powered or fixed control of the wellstream by opening, closing or selecting an orifice. They are capable of with- standing erosion due to the very high stream velocities occurring at, and immediately down- stream, from the orifice. In order to understand the flow controlling ability of a choke, two essentially different flow conditions across the choke must be reviewed. These are called critical and noncritical flow conditions. Critical flow occurs when the pressure downstream of the choke is one-half or less than the pressure upstream from the choke. In this case, the flow rate through the choke depends only on variations of the upstream pressure, flnid character and on choke settings. Changes in the separator pressure within the critical flow range does not affect the rate of flow through the choke. Flow rates can be estimated from choke coefficient tables in the critical flow condition Tange. Non-critical flow occurs when the down- stream pressure is more than half of the up- stream pressure. In this case, changing the separator pressure downstream from the choke will affect the flow rate through the choke. In the non-critical flow condition, estimation of flow rate cannot be made from choke coefficient tables. Assumptions of Choke Nipple Flow Esti- mates: 1) Dry gas 2) Positive choke bean (6" long) 3 Critical flow 4) Gas is ideal (compressibility constant) 5) Qmefi Gravity x Temperature Absolute Choke coefficient is based on the following : Coane D?9" x 26.616 x 18 Note: Moderate and changing amounts of liquid content will invalidate flow rates esti- mated by this method. CHOKE COEFFICIENT SHOKE SIZES MCF / DAY * 2/64 0.324 3/64 0.918 4/64 1.638 5/64 2-610 6/64 3.690 7/64 5.166 8/64 6.250 9/64 7.992 10/64 9.954 11/64 12.132 12/64 14.440 13/64 17.208 14/64 20.088 15/64 23.184 16/64 26.510 17/64 30.006 18/64 33.930 19/64 37-980 20/64 43.640 21/64 46.818 22/64 51.588 23/64 56.592 24/64 61.210 25/64 67.320 26/64 73.134 27/64 79.092 28/64 85.130 29/64 91.818 30/64 98.532 31/64 105.516 32/64 112.720 36/64 144.180 40/64 179.740 44/64 219.168 48/64 260.990 * Calculated from data appearing in Bureau of Mines Monograph 7. Choke Flow Rafe Estimate for Gas —_ Oil Flow Estimate: Qe Rowrr P= Wellhead Pressure (psig) D= Choke (64ths) Surface Well Testing Page 2-39Wellstream Heater Itis frequently necessary to heat the pro- Guced wellstream above the wellhead flowing temperature in order to: 1. Prevent hydrating at the separators. 2. Compensate for heat loss through a flow control throttling device (choke) which drops a large amount of wellstream heat through free expansion at the end. 3. Assist in separation of water in oil or oil in water emulsions. 4, Aid in separation of foamy oil. 5. Lower the oil viscosity to promote better flow and atomization at the burners. 6. Prevent waxes from coming out of solution in wax bearing oils, which could foul the separator. Wellstream Refridgerator Option Heaters are on occasions used to cool the well fluid. To achieve this cooling, a water medium is pumped into the shell to puil heat out of the well effluent. Baffle plates made up, alternately top and bottom, ensure the water makes a tortuous flow path to eliminate stagnant hat spats. A phenomenon requiring consideration is the Joule-Thomson effect. When natural gas ex- pands from a high pressure to a lower pressure without heat added there is a coincident tempera- ture drop or refrigeration effect which is nor- mally referred to as the Joule-Thomson effect. Possible separation economic advantage can be gained. Benefit is achieved by using the pres- sure drop to lower the separation temperature of the hydrocarbon mixture, causing more liquid condensation of the natural gas. ered is the formation of hydrates of natural gas. Hydrates are unstable, solid chemical com- pounds of natural gas and water which exist in snowlike form at temperatures above 32°F under pressure but decompose at atmospheric pressure. ‘They appear to be hydrates of 2 mixture of the component gases and not 2 mixture of the hy- drates of the individual gases. Thus these hydrates form at a temperature for a given gas mixture rather than at the hydrate temperature for the individual pure components in the mix- ture, It is also a known fact that the presence of liquid water is generally considered necessary for the formation of hydrates. Turbulence accelerates the formation of hydrates and freez- ing occurs frequently downstream from valves, regulators, chokes, sharp bends, etc. Until the first hydrate crystal forms, there exists no nucleus for further formation; but once started, hydrates form rapidly from the available free water, When testing high pressure gas wells at low rates itis especially important to have the heater at operating temperature before the well is passed through it. This set of conditions, high pressure drop at the choke and possible low temperatures, is conducive to the formation of hydrates with its resulting problems. Flowing wells at higher flow rates usually increases the flowing wellhead temperature because the formation heat comes to the surface. Due to the higher temperatures and less pressure drop at the choke there is less likelihood of hydrates and the heater’s use may be reduced or even eliminated. Designs There are two basic designs of wellstream heaters in general use with production testing equipment. One is the indirect heater; the other is the steam heat exchanger. Both designs usually incorporate a choke or chokes located downstream of the midpoint on the heating piping (coils). Three types of indirect, fired, (water bath) heaters available are: 1) Gas fired 2) Diesel fired 3) Electrical Indirect gas or diesel fired heaters consist of a large, low pressure tank which contains a large volume of water or glycol mixture heated by a burner nozzle inside a fire tube. The well fluid Surface Well Testing Page 2-40passes through high pressure flow tubes or coils which are installed in the tank and emersed in the water, The coils make numerous passes to provide the largest amount of surface area possible for heat transfer. Note: Heaters may have a high pressure side upstream of choke and a low pressure side downstream. Care musi be exercised when testing to ensure low pressure coils are not subjected to excess pressure. When the heaters are opened for inspection a small hole will be seen in the end of each coil’s 180° bend. Erosion will be at its worst on the crown of the bend. If erosion takes place, the “ell tale” hole should allow a release of flow to the shell of the vessel at a controlled rate provid- ing sufficient time to remedy. Do not flow the well through the heater during the clean up period, since any entrained solids could damage the coils and necessitate expensive repairs. The heater should have a direct bypass manifold such that the flow tubes can be isolated during well cleaning up opera- tions or depressurized to check/change the choke. Because of the length of the coils and the number of bends, the heater can exhibit a con- siderable back pressure. At low rates this may not be a problem but at high rates this can present a considerable problem. For this reason modifications have been made to some heaters that include larger coil IDs and elimination of chokes. While this has reduced the back pres- sure exhibited, there is a compromise in that the effective surface area for fluid heat transfer has. been reduced. Unfortunately, all the heat put into any heater vessel is not 100% efficiently exchanged to the well fluids flowing through. Heat loss is always present. Diesel fired heaters use a diesel burner assembly which incorporates a diesel pump for pressure and an electrical fan to supply forced air for good burning. Generally, diesel units have more efficient BTU ratings than the gas fired. Electrical heaters consist of two clectrical elements replacing the fire tube arrangement. The heated water/glycol allows heat transfer to the coils and thus the well effluent. Electrical supply of 220/480 volts is required for the electrical control system. This unit was de- signed to meet stringent environmental safety guidelines for offshore California. Gas fired bumers may use 1) natural gas obtained from the separator at a point down- stream of the gas orifice meter or 2) gas from an external source such as a propane tank. The piped separator or external gas usually makes one pass through the heater bath to prevent possible hydrate formation and then is regulated down to 15 psi for burning. The bummer has a gas-air mixing arrangement with air being Controlled by an adjustable shutter. A thermo- stat controls the heater bath temperature. A pilot light with 3-5 psi gas burns constantly to ignite the main burner when necessary. Note: Extreme care should be taken during attempts to light the burner. Only remote igni- tion of pilot is advisable. Allow system to purge with fresh air before attempting to light a gas saturated fire tube. During the clean up period separator gas can be obtained by cracking the inlet valve with the separator’s downstream valves closed and trapping a sufficient supply of natural gas. On any well with HS an external supply of gas is required. Be aware that the heater stack’s spark arrestor may suffer from soot blockage due to the inefficient buming of rich liquid gases such as bottled LPG. Poor burner air drafting may result unless a clean bum is maintained or modifications tu the spark arrestor are made. Check working pressure and pressure test. If the heater is indirect fired (using diesel or separator gas) check operation of pilot main burner and safety shut down controls. Ensure bath is filled with fresh water (do not use salt water) and that the thermostat operates correctly. Check that the regulators are set to give correct, pilot and burner gas pressure. Surface Well Testing Page 2-41Internal View of Indirect Gas Fired Heater Surface Well Testing Page 2-42Heat Exchanger Heat exchangers consist of an outer shell into which is passed a series of coils. The coils are subdivided into HP and LP coils. The pressure drop from HP to LP coils being usually made through twin parallel long nose chokes. To determine and note the appropriate choke size when flowing through the twin parallel chokes use the following formula: D,=\D7+D;_ Example Flowing through 20/64 and 24/64 parallel chokes, the equivalent choke size would be: Dye Nae D= 31/64 ‘The chokes are secured by unibolt fittings. ‘The bleed screw must be removed and any pressure bled off before attempting to release the securing bolt. Once the securing bolt is loosened a sharp tap on the lugs of the connection should break the connection. The bolt should then be removed and the choke withdrawn carefully to prevent damage. To replace the choke, reverse the procedure but ensure the choke stem is backed out before you start. Once the securing bolt is made up tight, zero the choke. and replace. the hleed screw with a new gasket in place. The outer shell is rated at 250 psi and are fitted with relief valves. The coils are usually 5- 10,000 psi HP and 2000 psi LP. Each heater must be checked and the respective ratings determined. ‘The vessel is supplied by heat from an external source - rig steam or HRS boiler unit. The steam, once used, is either dumped to a drain or fed back to the boiler via a fluid trap to remove the hydrocarbons, Inspection On receipt of equipment on location, a general inspection of the heat exchanger should be made. This should include: a. Inspect all inlet and outlet connections. Check threads are clean and undamaged. Replace seals where necessary. b. Visually check for signs of structural damage which may affect the integrity of the equip- ment. ¢. Visually check all piping and valve assem- blies. Function test all valves. Note: Before operation of a steam heat exchanger, while in service or in testing, the entire installation should be grounded by means of a cable which allows the static electricity to disperse and avoid flashes. The cable should have maximurn of 1/3 olen per foot. It should be connected to a place where there is no paint, either on the vessel or on the rig. In the case of onshore testing, the ground should be an iron stake at least three feet long, driven into the ground and watered regularly to keep the earth wet and provide good contact. Pressure Testing ‘The pressure test should be done in conjunc- tion with the complete rig up and should com- prise of 1. LP coil test 2. BP coil test 3. InleV/bypass manifold test Note: Once the pressure test is completed it is imperative that the outlet valve be open to prevent water trapped in the coils from expand- ing when steam is applied. Surface Well Testing Page 2-43Steam Boilers erat ‘The quality of the water used in the boiler will ‘The boiler must be sited ina safe area. ete nd the prorranceof tba. 6 Tee feed wuermastmeet he folowing specifies, Checks shoud be made on he quality of he ons: feed waters and the water treated with chemicals as necessary. At regular intervals open 1. Total dissolved solids -2,000 ppm maximum the boiler steam valves by lifting the relief lever. 2: Total alkalinity - 300 ppm maximam 3. PH value - 9-11 trols under pening Condi oy en controls under operating conditions by interupting Boilers may be gas fired or oil fired. When the feed water sipply. starting an oil fred boiler, care must be taken to censure thatthe fuel pump is properly primed Check the operation of the flame failure otherwise the pump could be severely damaged. device by withdrawing it and covering its “eye”. Exar al seam oes arin good coon and properly made up. Always ensure before applying steam to the heat exchanger that the inlet and outlets to the coils are open. Steam Heat Exchanger Surface Well Testing Page 2-44SPECIFISATIONS ‘Capacity Imm 2mm 2 um BTU/ir 3mm 3 mm BTU/hr BTU BTUMr Brune @ Pressure 5.000 psi | 5000psi | 10,000psi | 5,000 psi 5,000 psi Rating Preheat 12-3xxH_ 14-3xxH 445x25 18-3xxH 184.5225 Coils Rating 5,000 psi 5,000 psi 10,000 psi 5,000 psi 10,000 psi Postheat 63H e-3ut 83uH 3x 6-308 Coils Rating 2,000 2,000 $,000 2,000 5,000 ‘Choke 2in~ $000 | 2in- 5,000 2 in - 5,000 2 in - 5,000 2 in - 5,000 Service HS’ HS” HS" HS” HS’ Heater OD 48 in in 60 in in 60 in Skid Length | __192 in 288 in 288 in 288 in 288 in Skid Width 60 in 90 in 90 in 90 in in Skid Height 72 in 120 in 120 in 120 in 120 in ‘Skid Weigot 15,000 in 20,000 in 23,000 in 25,000 in 25,000 — e Size 6mm (BTU) 6mm (BTU) Working Pressure 10,000 psi 5,000 psi Vessel Pressure 350 psi 150 psi Preheat Coils 224.5" OD x 2.25" ID 223"xxH Pressure 10,000 psi 5,900 psi Postheat Coils 2x 4-3xxH 2x 4-3"xH Psi 5,900 2,300 Choke 2-2 in Mox Oriface 2+1 in Mox Oriface 10,000 psi 5,000 psi Service HS" HS" Heater 60 0D 60 OD Skid Length 294 in 294 in Skid Width 84 in 84 in Skid Height 108 in 108 in Skid Weight 25,000 Ib 20,000 1b e “Meets requirements of NACE MR-01-75 Heater Specs ‘Surface Well Testing Page 2-45“NI OS W3d SONNOd - 3uNSS3ud 3ONvD 0008 oo0y 0008 9002 ° —= = ‘Janseaus Svo Jonadu:azuinoau | on Tews Tor “ ‘LIBHNBSHYS '§934930 on ¢ JO! SV9 U9 dS Z NO GaSvE BAND NOILONGSY AW3L—NOISNYdXd SVD WYNLWN Page 2-46 ‘Surface Well Testing Natural Gas €xpansion/Temperature Reduction Curves180 160 140, 120 3 3 & Tomporoture drop, °F a 8 40) 20 ° 9 sa9 i000 isco t200 280 30ca 2500 000 4300 50c@ 5500 6000 fninet pressure, 9319 Temperature Drop Accompanying a Given Pressure Drop 6000 4000 3000 1500 1000 ‘800 400 300 130 z 3 t00 20 60 40. ramperature, °F Pramure Temperature ‘Curves for Predicting Hydrate Formation Surface Well Testing Page 2-47LAA eT Ae ATA Nid Pamnissibia Expansion of 0.7-Gravily Natural Gas Without Hydrate Formation Surface Well Testing Page 2-48aT 0 7 Ed & OSs B00 eee 7300 2000" Permissible Expansion of .08-Gravity Natural Gas Without Hydrate Formation Permissible Expansion of 0.9-Gravity Natural Gas Without Hydrate Formation Surface Well Testing Page 2-49MAG ST i TEMPERATURE I lrinal pense, oe Permissibie Expansion of 1.0-Gravity Natural Gas Without Hydrate Formation Surface Well Testing Page 2-50Theoretical Heater Performance Below are outlet temperatures versus flow rate calculations and curves for the following heaters: Water Bath Heaters: 5,000 psi 2 mm BTU/HR Gas Steam Heat Exchangers: 6mm BTU/HR Description Four programs have been developed to provide the outlet temperatures versus flow rate calculations and curves for water bath heaters and steam heat exchangers: LIQHTR For water bath heaters flowing liquids. The required input data is: © Inlet temperature, © Water bath: temperature, thermal conductiv- ity, temperature of volume expansion, specific sravity, viscosity and prand! num. er. © Well fluid (iquid): specific heat, specific gravity, viscosity and thermal conductivity. GASHTR For water bath heaters flowing gas. In addition to the input data required for LIGHTR, the following is also required: Inlet pressure Gas critical temperature and pressure, spe- cific heat, specific gravity and thermal conductivity. LIQHTR.STM For steam heat exchangers flowing liquids. ‘The required input data for the well fluid is the same as that for LIOHTR. For the steam bath, the input data is: © Steam temperature, pressure, thermal con- ductivity, density of saturated liquid and vapor, latent heat of vaporizadon, saturated liquid viscosity and specific heat. GASHTRSTM For steam heat exchangers flowing gas. In addition to the data required for LIQHTR.STM, the following are also required: © Inlet pressure. © Gas critical temperature and pressure, spe- cific heat, specific gravity and thermal conductivity. Example curves follow for typical condi- tions. Surface Well Testing Page 2-51OOO! X dd - 3LVv¥ MOTs ainoIn coos osz oz 8330930; OE +... §338030:0L0 3330930:09 7 ova! ASINI vacua $a3u030: osa 4 Set = due, weg Bisd 000s = sseug 19)U SOUBUOLad Je}e9} jeONWe100UN) 00580 = DITDS enh Oe! oe 00"! 060 08'0 Opt 001 Xx wal L310 3 930 - 5,000 2mm BIU/HR Gas Fired (Liquid Flow) Page 2-52 Surface Well Testing0000000! X g3oS - 3LvY MO14s SVD rc StL: LSC Se@z@—sNs SL @N3L LBW! EvaHadd 4 $8. = dwa, weg SAINI NG +... 5338930:0L0 S33uO3d!09 Bazvoad‘oso } isd 00S = Sseld 19]U] QOUPLUIOPOd 19]89}] [BDNe100U os‘! ser 6€ss'0 = SVD OS oso 060 z oc ov O01 X 4 930 - dN3L L371NO 5.000 2mm BTU/HR Gos Fired (Gas Flow) Page 2-53 Surface Well TestingO1 XxX e QS9SWW - 3Lby MD14 suo ess 00°35 esh eern ese 9a°s ese e272 esl SdH3L LBINI LW3H3d, corsster Beal St Nur “184 x? hh +e Eh wet ota A otey =dwet weg Sisd 000s = said 191UI 00s9°0 = svD DS eoueuoped JaBueyoxy jeoy weal jeonesooyL os Steam Heat Exchanger (Gas Flow) 54 Page 2. Surface Well TestingSeparators A separator is a pressure vessel used for separating well fluids produced from oil and gas wells into gaseous and liquid components. An oil and gas separator generally includes the following essential components and features. 1) A vessel that includes: a. primary separation device and/ar section b. secondary “gravity” settling section c. mist extractor to remove small liquid particles from the gas d. gas outlet €. liquid settling section to remove gas from oil and/or separate oil and warer f. oiloutlet 8 water outlet 2) Adequate volumetric liquid capacity to handle liquid surges 3) Adequate vessel diameter and length to allow most of the liquid to separate from the gas without carryover 4) A means to control oil and water levels - liquid controller and diaphragm cantral valve 5) A back pressure controller and valve on the gas outlet to maintain a steady pressure in the vessel 6) Pressure relief devices Oil and gas separators can operate at pressures ranging from a high vacuum to 5,000 psi. Most separators operate in the pressure range of 20 to 1,500 psi. Separators may be referred to as low, intermediate, and high pressure. Low-pressure vessels usually operate at pressures ranging from 10 to 225 psi. Medium-pressure separators usually operate at pressure ranges of 230 to 700 psi. High-pressure vessels generally operate in the pressure range from 750 to 1,500 psi. Oil and gas separators can have three general configurations: horizontal, vertical, and spherical. ‘The different configurations are available for two- and three-phase operation. In the two-phase units, gas is sega)! trom ths liquid werh the gas and liquid being sii "sargec! separately. tn three-phase separators, well fi! is separate imu gas, oil, and water with the thre2 2:7 discherged seztécstelv, Some units may be two s vr “cnsistin: of a hight pressure two-phase vessel and a lus rs, :supe three-phase vessel used in conjunction. Variations of Separators and Functions: 1) Separator - Conventional, handles highest instantaneous flow 2) Trap - same as separator 3) Knockout vessel - removes one component (H20, liquid, sand) 4) Flash chamber - low pressure, second or third stage 5) Expansion vessel - first stage on low-temp separator unit ©) Scrubber - similar w separator, handles Quid w/ less liquid 7) Filter - dry type scrubber, removes dust, scale, rust Surface Well Testing Page 2-55‘The table below shows a comparison of the “absolute” guide but affords a relative compari- advantages and disadvantages of horizontal, son of the various features of the different types vertical spherical oil and gas separators, two- _of separators over the full range of types, sizes and three-phase. This table is not intended as an and working pressures. Comparison of Horizontal, Vertical, and Spherical Separators CONSIDERATIONS HORIZONAL* VERTICAL SPERICAL, MONOTUBE MONOTUBE ONE COMPARTMENT 1, Efficiency of Separation 1 2 3 2. Stabilization of Separated 1 2 3 Liquids 3, Adaptabitity o varying 1 2 3 conditions (such as “heading” Now) 4, Flexibility of operation 2 1 3 (such as adjustment of liquid level ‘3. Capacity (Same diameter) 1 2 3 6. Cost per unit capacity 1 2 3 7 Ability to handle foreign 3 1 2 e material 8. Ability to handle foaming 1 2 3 oi 9. Adaptability to portable 1 3 2 use 10. Space for installation 1 3 2 Vertical plane Horizontal piant 3 1 2 11. Base of installation 2 3 1 12, Ease of inspection and 1 3 2 maintenance 13, Handling low API gravity 3 1 2 and LP oil 14, Handling gas/condensate 2 3 1 production 1 - Most favorable, 2- Intermediate, 3 - Least favorable. For overall operations, the comparison favors the horizontal separator, but separator performance depends vn lke e internals, associated accessories, plus the type well to be tested. *Table from Petroleum Production Handbook, Vol. 1, Thomas C. Frick, Editor-in-Chief, Society of Petroleum Engi- neers of AIME, Dallas, Texas. Surface Well Testing Page 2.56Main Functions of Oil and Gas Separators Removal of Liquid from Gas Separation of liquid from gas begins as the fluid flows to lower pressures through the formation into the wellbore and progressively increases through the tubing, flow lines, and surface handling equipment. Under certain conditions the fluid may be completely separated into liquid and gas before the oil and gas separa- tor is reached. In such cases, the separator affords only an ‘enlargement’ to permit gas ascent to one outlet and liquid descent to another for sampling and measurement. In other words, the oil and gas separator may perform only the function of providing space in which final separation is accomplished by density difference of the liquid and gas. Mist Extractors Residual liquid in the form of mist can be effectively removed from the gas stream in an oil and gas separator by a well-designed mist extractor. However, condensible vapors in the gas cannot be removed by mist extractors. Condensation of these vapors due to reduction of temperature, may occur after the gas has been discharged from the separator. This existence of condensed liquid in the gas effluent from an oil and gas separator, in many instances, does not necessarily reflect upon the efficiency of the separator. Since condensible vapors may have the characteristics of natural gas when at separa- tor tcmperature and pressure, condensation of these vapors into liquid between liquid and gas may accomplish separation of liquid droplets from a gas stream where the velocity of the stream is slow enough and sufficient time is Oll.ana Gas Separator Difference in densities of the liquid and gaseous hydrocarbons may accomplish accept- able separation in an oil and gas separator However, it is usually necessary to use mechani- cal devices commonly referred to as ‘mist extractors’ to remove liquid mist from the gas before it is discharged from the separator. Also, it may be desirable or necessary to use some means to remove nonsolution gas from the oil before it is discharged from the separator. allowed to accomplish separation. Limiting the gas velocity in a separator may obtain satisfac- tory separation without a mist extractor. How- ever, mist extractors are generally installed in conventional oil and gas separators, to assist in separation and to minimize the amount of liquid (mist) carried out with the gas. Mist extractors can be of many different designs, utilizing one or more of the principles of 1) impingement, 2) change of flow direction, 3) change of velocity, 4) centrifngai force, 5) coalescing packs, and 6) filters. Surface Weil Testing Page £-3/PRESSURE \VANE MIST ‘SHRINKAGE TESTER WATER OUTLET Separator Piping Schematic Surface Well Testing Page 2-58a SL-L0-ML SOVN Jo suswarnba s29jy_ SL10-WW ADV Jo stuawaynbar sayy, ] (009 - UZ oo-uz | wyeaq | 00 = HZ 009 = Uz ureaq Ost Uy ost-uy | PUPA Ost - Up Ost - Up PUT I (009 = WZ ooo-uz | FING are AL OE = UZ 009 = UZ WUMO 4978 A, 109 - ure oo-me | THRO WO oor - Ee N70 10 009-49 ooo-ur | PEN sep O0E = UF WIN sey | 009 - Uy oo- | vaquy | O0E - Uy fort 1 000'8E amo | TA PPIS ‘1 000" TW3PAL PPIS UL FIT Ur pT [ 13H PPS wt zor TBH PPIs U1 96 1 96 WIPIAA PPS: 1 96 UIPEAA PIS: ‘Ur OOE UL OPT | w8uay pris UL OFT wauay pris I SH SH Ee SH ‘@]A9g I ‘ads 000'07 ada 00's! =| Apedea pmbrT dad 00°01 dad 000'0r Aygedeg pinbry 2 (Gps) ww on (QDs) ww og | Aypedeg sep GDS 87 Gas €¢ pede sey I 18d OFT dot | sanssoug Buyeaedg 18d 009 sd OFT danssoig Bunesado I Tewozoy aseyd ¢ | jewozucy aseyd ¢ | wondyssaq Tewvozpoy eseyd ¢ Feiuocuoy aseud ¢ y ustxarurey [ worxaiursy | aZIS (RS89A BOI X GT Urge Wor € ar urge ! SNOILVOISIO3dS SNOILVOISIOadS Well Testing Separator Specifications Page 2-59 Sus face Well TestingSPECIFICATIONS ] Service HS” Cold Temperature Heater Rating 1,000,000 BTU he Description Working Pressure (coil) 5,000 psi —| Proheat Coils 123yxH. 115.4 sq ft area Postheat Coils 6-3nHl, 79.2 sq ft Separator Gas Volume 25 MMSCE/D Description oi 3,000 BPD Water 2,000 BPD Vessel Dimensions 24 in Dx DHSS Operating Pressure 140 pai Overall Length a 19 6 in Dimensions Width 9ROin Height 99 in Weight 29.000 tb Applicable Separator ASME Sec. VII Div 1 Codes Piping ANSLB313 Overall NACE MR.O1-75 Units DNY. ABS. Lloyds Separator Combination and Specifications Surface Well Testing Page 2-60Impingement If a flowing stream of gas containing liquid mist is impinged against a surface, the liquid ‘mist may adhere to, and coalesce on, the surface. After the mist coalesces into larger droplets the liquid will gravitate to the liquid section of the vessel. If the liquid content of the gas is high, or the mist particles are extremely fine, several successive impingement surfaces may be re- quired to effect satisfactory removal of the mist. Change of Flow Direction When the direction of flow of a gas stream containing liquid mist is changed abruptly, inertia causes the liquid to continue in the origi- nal direction of flow. Separation of liquid mist from the gas is thus effected, since the gas will more readily assume the change of flow direc- tion and continue to flow away from the liquid mist particles. The liquid thus removed may cualesce on a surface, or it may fall directly into the liquid section below. Change of Velocity Separation of liquid and gas is also effected with either a sudden increase or decrease in velocity. Both conditions utilize the difference in inertia of gas and liquid. With a decrease in the velocity of gas, the higher inertia of the liquid mist carries it forward and away from the gas. The liquid may then coalesce upon some surface and gravitate to the liquid section of the separator. With an increase in gas velocity, the higher inertia of the liquid causes the gas to move away from the liquid, and the liquid may fall to the liquid section of the vessel, which shows one version of a vane-type mist extractor used in oil and gas separators to remove liquid from gas. Centrifugal Force If a gas stream carrying liquid mist flows in a circular motion at sufficiently high velocity, centrifugal force throws the liquid mist outward against the walls of the container or element. Here it coalesces into progressively larger droplets and finally gravitates to the liquid section below. Centrifugal force is one of the most effective methods of separating liquid mist from gas. Efficiency of this method increases as the velocity of the gas stream increases. The figure on 2-55 contains a centrifugal- type mist extractor used in vertical oil and gas separators. The radial vanes cause a circular motion of the gas, and the resulting centrifugal force throws heavier liquid particles to the wall of the vessel where they coalesce into drops large enough to drain from the mist extractor element. ‘Small centrifugal-force-type mist extractors have been inserted in small-diameter (4 to 12 in.) vessels, and these “separators” have handled relatively large volumes of gas. This type of separator (or scrubber) is used in scrubbing gas in gas gathering transmission, and distribution systems. However, a small-diameter vessel usually is not practical for use on oil and gas producing wells as the primary separator because of the possibility that the small vessel may be filled with a “slug” or “head” of liquid and cause the liquid to flow out the gas line. ‘Therefore, a larger conventional separator vessel should be used to separate well fluids because miniature vessels may cause trouble by “overloading” with liquid. Coalescing Packs Coalescing packs afford an effective means of separating and removing liquid mist from a stream of gas. One of their most appropriate uses is the removal of liquid mist from gas in transmission and distribution systems. Coalescing packs can be made of Berl saddles, Raschig rings, knitted wire mesh, and other such materials. The packs imply a combi- nation of impingement, change of direction, change of velocity, and centrifugal force in separating and removing liquid mist from gas. ‘These. packs provide a large surface area for collection an coalescence of the liquid mist. A word of caution is appropriate concerning the use of coalescing packs in oil and gas separa- tors for general field use. Coalescing packs may be made of fragile material which can be dam- aged during transit or installation if they are Surface Well Testing Page 2-6?