01A - SWT Equipment Introduction

Surface Testing Equipment
Introduction
Schlumberger Private
Testing Services - Fluid Sampling Specialists
• WELL TESTING OVERVIEW
• SAFETY & POM
• WELL TEST TYPE & SEQUENCE
• CLEAN UP
• WELL TEST DATA
• SURFACE TESTING EQUIPMENT
2 FS
The FLOWHEAD is the primary well pressure control equipment
3 FS
Flowhead
5K, 10K, 15K WP All equipped with:
Flow valve actuator
Swivel
4 FS
Riser or Lubricator
BOP Typical Flowhead
(Kill (Flow valve)
valve)
(BOX)
5 FS
Principal functions:
•Control the pressure.
•Support the weight of the Test String.
•Allow up-and-down & rotation movement of Test
String.
•Allow flow out of the well through a flow valve.
•Allow to pump fluid into the well through a kill valve.
•Allow tools to be introduced into the well through a
swab or crown valve. 6 FS
Flow valve
hydraulic
actuator
“Fail Safe”
7 FS
PIPING
PIPING is generally flexible between the FH & CM to allow
FH up-and-down movements. It is rigid elsewhere.
Hammer weco union
with rubber lip seal
Graylock with
metal seal
8 FS
40 or 60 feet long
FLEXIBLE PIPING
- High Pressure flexible hose ended with weco-

union or graylock connections, used between
FH & CM : COFLEXIP
- Low Pressure flexible rubber hoses, ended
with weco union, used generally for air, water
lines
2 or 3m long
FLEXIBLE PIPING
- High Pressure flexible hose used between FH
& CM : COFLEXIP , to allow up an down
movement of the string (DST tools operations),
keeping the flow line connected to the burner via
the CM.
-(Compulsory on all floaters)
- Long length available (40ft, 60ft, etc.)=
less number of seals and risks of rupture or leak.
- Coflexip hoses are heavy and the use of a
crane is mandatory to rig up it safely.
- To respect the MBR, a couple of elbows,
may be used both end of the Coflexip hose.
RIGID PIPING
•Rigid Piping with “weco-union” connections or “graylock” for HP.

- straight piping, often 1m or 3m or 5m long
- elbows, often 90 degree
WECO-UNION CONNECTIONS
Wing
Pin
Male Thread
Box
Female
Ex: Weco Hammer Union Fig

1002
12 FS
PIPING
• To see POM (Appendix B)
• Mainly defined by : - Nominal diameter (wall mid point), O.D ? I.D. ?

- Schedule (Sch.80, XXS, SP) ?
- Grade ?
•Working Pressure of the pipe (WP) is determined by the Wall Thickness.
Wall Thickness, measured with : - ultrasonic tester.

- X-ray.
- Manual Caliper.
13 FS
PIPING
• Regular inspection of wall thickness to :
- check the WP of pipe.

- find effect of erosion/corrosion.
- prevent accident.
• No down rating of pipework allowed.
• All H2S rated / must conform to NACE MR 01-75.
Note: Thickness inspection does not replace pressure testing,

BOTH are required.
14 FS
PIPING
Line sizing:
• gas/fluid velocities limitations to maximum :
- 80 ft/sec if solids (sand) or 2-phase flow.
- 160 ft/sec for dry gas.
•if higher velocity expected, a full HAZOP is required as :
- increase pipe ID, flare tip ID.
- divers flow through more than one pipe.
- reduce as much as practical the line length and number of
bends
- reduce the choke size.
See FOH 1, Section 11 page 13 for gas velocity chart.

15 FS
VALVES
•Valves or taps are devices
fitted to piping or equipment
and designed to control the flow
of fluids.
•ex: a 3” gate, ball or butterfly
valve, means a 3” ID
GATE Valves
•Used for shut off, (on/off function)
•High pressure (5, 10, 15, 20Kpsi)
•ex: FH, CM, Steam-exchanger, Sand-
trap
•Sealing method:
-metal/metal for WOM valve
-grease sealing compound for
McEvoy valve
•Standard sizes= 3 1/16” to 4 1/16”
Surface
GATE Testing
Valves
McEvoy (pressure trapped)
Sealing done with Grease fittings for

the special grease
Special sealing
compound grease
Grease fitting for

standard grease
VALVE CLOSED
NEEDLE Valves
•Used for shut off, (on/off) + Flow
control (bleed off part of flow)
•High pressure (5, 10, 15, 20Kpsi)
•ex: instrumentation on FH, CM,
Steam-exchanger, Sand-trap
•Kerotest (up to 10Kpsi)
•Autoclave Engineers (10, 15, 20K) (~sizes= ¼”, ½”, ¾”)
•Sealing method: metal/metal

BALL/PLUG Valves
•Used for shut off, (on/off)
•¼ turn
•Medium pressure (~1500 psi)
•ex: separator, burners, pumps,
etc.
•Sealing method:
-PTFE (Teflon) seal ring or
seat
Standard sizes= 1” to 4”
BALL/PLUG Valves)
Mapegaz
•Sealing= (white teflon
ring)
white teflon
(Spherical)
ring seal
Cross Section of a Mapegaz valve

BALL/PLUG Valves
Gachot
•Medium pressure
•Sampling / bleed-off
points
•Sealing= white
teflon seal ring
•Standard sizes=
¼”, ½”, ¾”, 1”
BUTTERFLY
Valves
Weco
•Used for shut off, (on/off)
•Low pressure
•Tanks
•Sealing= rubber seal
•Standard sizes= 1”, 2” 3”
Automatic
Control Valves
Fisher
•Used for flow control + throttle
action
•Medium pressure
•Separator, Surge tank
•Sealing (not 100%)=
metal/metal
•Standard sizes= 1”, 2”, 3”,4”
Swing Check Flow through valve
Valves
•To allow flow in one direction
only
•High/Medium/Low pressure
•Separator inlet, pump outlet Flow ceases or fails below back pressure
•Sealing= metal/metal
CHECK
valves
RELIEF Valves
Farris
•Spring loaded and set to open at a
given pressure to protect systems from
over pressure
•Separator, flowlines, Steam-
exchanger, Surge-tank
RELIEF Valves
Anderson Greewood
•Piloted safety relief valves
•New Separator and Surge-tank
•Standard sizes= 3”,4”, 6”
ESD system layout
•ESD stations
•HI pilot: Ds/s CM
•LO pilot: Up/s CM
28 FS
ESD schematic
Hydraulic &
air circuits
29 FS
Pilots
Basically located:
• Hi-pilot, downstream
choke manifold, to
protect low pressure
equipment.
• Lo-pilot, upstream
choke manifold, to
protect against a line
rupture.
Pressure increasing: Hi-pilot activated
30 FS
Hydraulic valves:
Actuator on the flow valve or/and SSV independent on the
flowline. Hydraulic oil maximum circuit pressure: 6000 psi
(normal operating oil pressure= 1500 to 3000 psi)
ESD panel:
Hydraulic pump Quick exhaust valve
Hydraulic oil tank Reset valve
Interface valve Bypass valve
Check valve Pilots Lo / Hi (around 30psi)
Air spare vessel (old model) Stations ESD (around 30psi)
31 FS
Surface safety valve
5K, 10K, 15K WP
to Shut In the flow
upstream of the
choke manifold
Operated by ESD
32 FS
Data header to connect
instruments & sensors
with sandec probe mounted in side

view (top) and schematic (bottom)
33 FS
Dual-pot sand filter 5K and/or 10K WP
The dual-pot sand filter
removes sand and other solid
particles
from well effluent. It is usually
located upstream of the choke
manifold.
•Two 46 L filter ports
•Bypass between filter & drain
34 FS
Cyclonic Desander, 5K WP
Max Liquid: 4500 B/D
Max Gas: 35 MMSCFD
•Single cyclone insert

•Sand accumulator vessel
35 FS
The CHOKE
MANIFOLD
controls
the flow
36 FS
Choke Manifold (5K, 10K, 15K), controls the fluid from the well
37 FS
•Control the Flowrate (allow different choke sizes).
•Control the Well Head Pressure or Shut In at surface
(CM WP selection = 1.2 x MWHP expected)
•Ensure Critical Flow = pressure fluctuations D/S choke
do not affect downhole Pressure & Flowrate of the well.
38 FS
Choke Manifold
Fixed choke
Located
up/s choke
39 FS
Choke Manifold
Adjustable choke
inlet
40 FS
outlet
Choke Manifold
& Buble hose
“Weak blow”
41 FS
The HEATER (or STEAM EXCHANGER) is used to raise
the effluent temperature above hydrate formation point,
to reduce viscosity (heavy crude oil) or to break the emulsion.
42 FS
Indirect-fired heater, •Vessel for water bath at atmospheric
5Kpsi WP pressure
(diesel burner) •Heating capacity: 2 MMBtu/hr
43 FS
•Hydrates prevention
•Viscosity reduction
•Foam reduction
•Emulsion breaking
•Increase burning efficiency
44 FS
Indirect-fired heater,
description
45 FS
Steam-heat exchanger, 5K, 10K, 15K WP
•Steam-heat exchangers
have almost completely
replaced indirect-fired
heaters for offshore work
•A steam-heat exchanger is
virtually free of fire risk.
•Third-party companies
provide steam generator
service.
46 FS
Steam-heat exchanger
47 FS
The SEPARATOR is the main surface testing piece of equipment.
It separates the three phases of the effluent which can then be
metered and sampled individually.
48 FS
Test separator, 600psi, 720 psi, 1440 psi WP
49 FS
Separator vessel
50 FS
Test separator
Capacities
51 FS
Separator capacity
52 FS
Test separator Pressure Controller Valve
Daniel orifice gas meter

PSV
Oil Level
Controller
valve
2” & 3” oil meter 53 FS

Test separator
ACV
Liquid lines Gas lines
54 FS
Test separator
Gas pressure
controller
55 FS
Test separator
Oil level
controller
56 FS
57 FS
Test separator
Test separator
Liquid meter
Floco 2” oil meter
100-2200 bbls/d
(3400 intermittent)
58 FS
Test separator
Liquid meter
Rotron 3” oil meter
3400/22000 bbls/d
Rotron 2”oil meter

1700/8500 bbls/d
59 FS
Test separator
Gas orifice meter
DANIEL gas orifice meter

It is composed of a dual chamber that allows orifice
plates to be changed safely under pressure, and
without interruption of the flow
60 FS
Test separator
Gas orifice meter
61 FS
Test separator
Differential
pressure
recorder
Barton
62 FS
Test separator
Shrinkage Tester 1 2 3
To measure the oil volume
63 FS
changed between
sep. cond. & atmospheric cond. (P & T)
Test separator,1440 psi WP,
with cyclone cluster
Maximum
Gas: 60MMSCFD
Oil: 14400 Bbls/d
64 FS
Vertical gas separator (2200 psi WP)
Max Gas capacity: 100 MMSCFD
Max. Liquid capacity: 1500 Bbls/D
- cyclone cluster separating unit
- 8-in. orifice meter
- optional flow measuring system for
oil
- optional flow measuring system for
water
- 4-in. gas control valve
- 2-in. oil/water control valves
- two 3-in. pilot-operated safety
valves. 65 FS
The ATMOSPHERIC GAUGE TANK and the SURGE TANK are used
to calibrate the separator liquid flow measurement,
and to measure the flow in case of low oil flow rates.
66 FS
Principal functions of Gauge & Surge Tanks:
•Storing liquids when large samples are required
•Metering liquids when flowrate is low
•Storing liquids when pressure is low
•Measuring the Shrinkage Factor (1-shr)
TANK reading
•Calibrating the separator’s liquid meter f=METER
reading
67 FS
Atmospheric gauge tank
•To measure low flow
•To calibrate meter
•To measure shrinkage
•To store liquid
•No H2S
•2 x 50 bbls
or
•2 x 100 bbls
68 FS
Atmospheric
gauge tank
69 FS
Vertical surge tank
•To measure low flow
•To calibrate meter
•To measure shrinkage
Single Compartment vessel:
H2S Services, 50 psi WP, 80 bbls
Dual Compartment vessel:

H2S Services, 150 psi, 2x50 bbls
70 FS
Surge Tank description: Gas outlet
(ended with Flame arrestor)
High-level alarm Safety relief valves (2)
(horn)
Sight-glass (2)
Man-hole (2)
Oil inlet 3” 602 F Automatic PCV
Oil outlet 3” 602 M Gas outlet*
4” 602 Male
Safety outlet
71 FS Grounding strap
Vertical surge tank
72 FS
Oil manifold, 1440 psi WP
73 FS
Transfer pump
•Empty one tank compartment

while the other is being filled
•Reinject oil into an existing
flowline
•Pressure boosting when there
is insufficient pressure to
achieve atomization at burner
74 FS
Transfer pump
Most are electric powered
Centrifugal Transfer pump
•H2S
•From 2000 to 10000 bbls/day at about 400psi discharge pressure
Screw-type Transfer pump
•Not H2S
•From 4000 to 5000 bbls/day at about 300psi discharge pressure
Gear-type Transfer pump
•Not H2S
•2000 bbls/day at about 200psi discharge pressure
75 FS
Gas manifold, 1440 psi WP
76 FS
Boom
•Boom length can be extended from 60 to
85ft, to reduce heat radiation and the risk of
fire.
•Oil is disposed off through BURNER located
at the extremity of the BOOM.
•Gas is burned separately through a Gas
FLARE located on the BOOM
77 FS
BURNERS
• Principle: Atomization of well effluent -> reduction in fine
droplets
• Needs: -propane for pilots
-electricity for lodge boxes (spark plug)
-Schlumberger air compressors (do not use rig air)
-water mainly to prevent heat radiation
• Classified by number of combustion heads: determines
maximum oil flow rate
78 FS
79 FS
BOOMS RIG UP - Adjusting
The boom axis should

should be placed slightly
above the horizontal axis
80 FS
BOOM FORCES (FOH)
81 FS
SLB:
Boom Hanging Procedure (FOH)
SLB:approximately
approximately35m
35m
x 7 m) for laying the boom
out with enough additional
space for personnel to
manoeuvre around and guide
the sections into place
without becoming trapped
required
• Attach Fish Plate and Guy-Ropes to King Post
required
82 FS
SLB:
Boom Hanging Rigging
SLB:approximately
approximately35m
35m
• Saddle must be close to the size of the cable
• Spacing between clamps is equal to 6 to 8 times the
required
required
diameter of cable
• Remember “Never Saddle a Dead Horse”
• Bolts must be equally tight
83 FS
Green dragon burner
•Pneumatic actuators on oil & air valves
•Pneumatic control panel for rotation
control & high-efficiency burning
•3 heads: 7000 bbls/d
•4 heads: 9000 bbls/d
84 FS
Green dragon
burner 3-heads
85 FS
Green dragon
Oil atomizer
86 FS
EverGreen burner
-No water injection
into the flame is
required
–Most efficient,
cleanest burner used
today. Winner of
2000 Chairman’s
Award
87 FS
EverGreen burner
– 1 Head with 12 nozzles
– Service: H2S
– Capacity: maximum 15000 bopd at
240 psi (High flowrate kit)
– Up to 30% Water Cut
– Eliminates liquid fall out
88 FS
BURNERS – Fluid Circuits
– Pneumatic (air) atomization & Nozzle schematic
enhanced air induction due to
Sunflower shape.
– No water injection into the flame is
required
– Oil flows along centre of barrel, air
along the outside – mix at nozzle
– Pressure Test using 12 plugs or
using shuttle system in barrel
89 FS
EverGreen Burner Head
Shut-off valve
CLOSED
OPEN
Air
Oil
90 FS
No more
91 FS
92 FS
93 FS
Have a Safe Test …

01A - SWT Equipment Introduction

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01A - SWT Equipment Introduction

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Surface Testing Equipment

BOP Typical Flowhead

- High Pressure flexible hose ended with weco-

•Rigid Piping with “weco-union” connections or “graylock” for HP.

Ex: Weco Hammer Union Fig

• Mainly defined by : - Nominal diameter (wall mid point), O.D ? I.D. ?

•Working Pressure of the pipe (WP) is determined by the Wall Thickness.

Wall Thickness, measured with : - ultrasonic tester.

- check the WP of pipe.

• No down rating of pipework allowed.

• All H2S rated / must conform to NACE MR 01-75.

Note: Thickness inspection does not replace pressure testing,

See FOH 1, Section 11 page 13 for gas velocity chart.

•Valves or taps are devices

Sealing done with Grease fittings for

Grease fitting for

•Sealing method: metal/metal

Cross Section of a Mapegaz valve

to Shut In the flow

with sandec probe mounted in side

•Single cyclone insert

Daniel orifice gas meter

2” & 3” oil meter 53 FS

Floco 2” oil meter

Rotron 2”oil meter

DANIEL gas orifice meter

Oil: 14400 Bbls/d

Dual Compartment vessel:

•Empty one tank compartment

The boom axis should

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