9 Conduct Test 4-2

Well Test 1 Course
Global Training Course

Conducting a Well Test
Safe Operations.
It is everyone’s responsibility to conduct operations in a

safe and professional manner. Should you be in any doubt
about an operation then this must be reported immediately
to a higher authority and this operation will be
delayed/cancelled until such time as the situation is
remedied.
You may find that the client’s representative may put you
under pressure to complete the operation, but you must
use you judgment and offer an explanation on the delay.
®Copyright Expro 2007 WELL FLOW MANAGEMENT

Here are some of the conditions that might lead to suspension or

cessation of flowing operations.
• Any component of the flow system between the wellhead and the heater choke having a
rated working pressure below the maximum possible wellhead shut-in pressure.
• Any leak in the complete flow system found during initial static pressure testing with water,
or developing later during the flowing operations.
• Insufficient heater capacity resulting in hydrating at the choke or at the back pressure
valve.
• Malfunction, freezing, or seizing up of a back pressure valve.
• Insufficient venting capacity of storage or metering tanks.
• Separator burst disc stamped rating of more than 1.05 the equipment's rated working
pressure.
• Separator's safety relief valve setting at pressure above the equipment rated pressure.
• Plugging from hydrates, waxes, or solid in any part of the flow system.
• Danger of or noticeable erosion of the flow system from sand production.
• Insufficient distances between wellhead, heater, storage tanks, and flare stack burner,
resulting in fire hazard.
• Working on a H2S well without proper equipment and trained personnel.
• Night time operations without sufficient lighting for the work area.

Job Safety.
There is no such thing as a routine pressure job and

nothing is more important than safety.
Company safety regulations must be strictly observed on
all well testing operations with particular regard given to
this aspect when wildcat and/or sour gas H2S wells are
involved.

Safety Practices.
• Work clothes- Coveralls, hard hat, gloves, steel toed boots worn. Safety goggles
should be on hand and worn when necessary.
• Hold a spot safety meeting. Include client and rig crew if possible.
• Emphasize the emergency duties assigned to each crew member for the operative
period.
• Be aware of the dangers of working with high pressure. No line, valve or equipment
should be worked on until all pressure is relieved. Watch for trapped pressure.
• When possible use spark resistant tools.
• Do not smoke around the well or equipment at any time. Leave all matches, lighters
and cigarettes outside the work area.
• When opening a valve under pressure, open the valve gradually but do not ‘throttle’.
Gate valves should be fully open or fully closed.
• Wear safety harness when working on high structures.
• Wear life vest when working above water.
• Secure all flow lines, relief lines, hoses, etc...
• Use common sense and proper safety procedures.

SAFETY is everyone's
responsibility and a good
pressure job is a SAFE one.

What do we mean by a Hazardous Area?
The term refers exclusively to the danger arising from

ignition, but it must be remembered that a dangerous
condition also exists where the atmosphere contains toxic gas or
vapour in such a concentration as to be a danger to life.
These fall into three groups:

Zone 0
Zone 1
Zone 2

Gases, vapours and mists

For gases, vapours and mists the zone classifications are:
Zone 0
A place in which an explosive atmosphere consisting of a
mixture with air of dangerous substances in the form of gas,
vapour or mist is present continuously or for long periods or
frequently.
Zone 1
vapour or mist is likely to occur in normal operation occasionally.
Zone 2
vapour or mist is not likely to occur in normal operation but, if it
does occur, will persist for a short period only.

Zone 1.
• An open area within a radius of 15 metres (50 ft.) from an open

discharge or petroleum-bearing fluid or any other point where
emission of a dangerous atmosphere is likely to arise.
• An area within a radius of 15 metres (50 ft.) from well-pulling and
other such well-servicing operations unless regular tests with an
explosimeter show that no dangerous atmosphere is present in
which case this area may be classified as Zone 2.
• Any enclosed premises containing a source of hazard which may
give rise to a dangerous atmosphere under normal operating
conditions. The extent of the Zone 1 area within a radius of 15
metres (50 ft.) from any point of exit from the building.

Zone 2.
• An area within a radius of 1.5 metres (5ft) of any production plant or other oil
process installation in open premises or in the open air, operated as a
closed system to prevent in normal circumstances the emission or
accumulation in the area of a dangerous atmosphere.
• Any enclosed premises containing a source of hazard, which may give rise
to a dangerous atmosphere under abnormal operating conditions. The
interior of the building should be classified as Zone 1 but surrounding area
in the open air within a radius of 1.5 metres (5ft.) must be classified as Zone
2.
• Any enclosed premises not containing a source of hazard but located in a
Zone 2 area should be classified as Zone 1, but if the entry of a dangerous
atmosphere is continuously prevented by the provision of fire walls,
ventilation or other means, the premises may be classified as a safe area.
When mechanical ventilation is employed and it is not possible to guarantee
the source and reliability of a safe atmosphere, the premises should be
classified as Zone 2.

There is also a vertical limit for Zone 1 and 2 areas. This is

normally 3 meters (10 feet) upwards from the highest
source of hazard.
This can vary somewhat dependant on obstructions and
ventilation. Downward the hazardous area would be to the
water surface.
These are only guidelines and the area can be much
larger.

Operating Procedures.
• The test program is normally directed by an operating

company representative. It is therefore essential that
good communication and understanding exits between
us and our client.
• Well test equipment must only be installed, operated and
maintained by trained personnel adhering to standard
procedures.
• In cases of emergency actions to be taken must be
defined beforehand, in particular, under what
circumstances the EXPRO supervisor (or shift
supervisor) must stop operations.

Preparation – before opening the well.
• Hold a Toolbox talk/Safety Huddle prior to performing any work. through the
Separator covering:
• This procedure, do not walk close to a leaking fitting, do not tighten a
leaking fitting under pressure and Housekeeping
• Barrier off Welltest testing area.
• Spill Kits.
• Fire Extinguisher.
• Clear Routes of escape.
• All PPE to be worn at all times.
• Only qualified competent personnel will operate the Separator.
• Communication – Good clear and precise.

Well Clean Up.
Normally the first procedure to take place on any job. It is

important that the well is conditioned prior to any flowback
measurements.
Safetywise it is most important that extra care is taken
during this flowback as there is no indication as to how the
well will perform. Also solids and other extraneous
materials could be returned causing problems with
equipment and flaring.

When opening the well for the first time.
• The Client representative must be present.

• Communication must be checked before starting.
• Flow should be directed straight to the burners by-
passing, heater, and separators. (Local rules may apply)
• Flow should be through the adjustable side of the Choke
Manifold.
• Personnel should be placed at the Burners and
Compressors, to make sure that ignition and burning
takes place.

Preparing the Separator for flowing into.

• Prior to any entry into the separator confirm the flow path route is correct
and lined up to the oil and gas flares line on, the appropriate burner.
Confirm wind direction with control Room. Unless the operations are only
tank related.
• Make sure that orifice plate carrier with orifice plate moves up and down
within the Daniels senior. Leave the holder, carrier and plates ready and
visible close by the Box.
• Check that all instrumentation on Separator is open and ready to operate.
• Function Test the controllers on the oil, water and gas lines.
• The Oil and Water controllers set at 5 with a proportional band setting of
2.5. The pressure controller to be set at 0 with proportional band set at 2.5.
• Sensing line to BPV controller is clear and needle valve is open.
• Make sure that any sample point needle valves are closed.
• Check all other needle valves, sight glass drains etc are closed.
• ESD system should have been checked prior to this stage.

• Low pressure pilots must be isolated until pressure reaches level over set
pressure. The same must be done with low level pilots.
• Fit Differential chart in Recorder, Clock is wound up/battery fitted and
switched on to 24 hour clock.
• Check pens in the differential recorder are marking.
• All sight glasses are open and clean.
• Line up preferred oil line and zero meter if applicable and inform scan of this
data.
• Line up water line.
• Read number 1 again then again check process line up and diverter
manifolds to make sure that they are lined up to the required burner boom.
• Have some buckets hand for any sampling, draining etc.
• Burners lit and a Pre-flaring checklist complete.
• Confirm all of the above with a second person.

Diverting flow into the Separator.
• Have 2 people for this operation.

• Check downstream pressure on choke before starting.
• Normally it is very important to be within Critical flow when flowing
on production but customer sometimes do not require this specific
criteria. Confirm this with the test engineer on location
• Slowly open inlet valve on separator.
• Open outlet valve
• Commence closing the selected separator Oil or Gas bypass valve.
• Keep a close eye on liquid levels and ensure control valves open on
rising liquid level
• Set Separator Pressure to the desired figure. Do not rush this, small
movements of the dial makes big differences in the separator
pressure.

• Once the pressure is around area required do not keep adjusting. Monitor
and adjust as required but also give it time to stabilize.
• With the oil and water level controllers set at five, the level should be
automatically set to control at that point. Adjust levels accordingly but also
give it time to stabilize.
• Confirm with operator at burner boom to make sure that good burn is taking
place.
• Check to make sure that static pressure is steady and confirms with vessel
gauge and Data Acquisition.
• Activate Pilot systems
• Once separator is stable, inform scan that you are about to lower orifice
plate in chamber. Lower orifice plate slowly noting differential pressure.
Inform Data Acquisition of orifice plate size.
• CLOSE EQUALISING MANIFOLD
• Continue general operating procedures.

Shutting in the Well.
• Inform the drill floor of the intent to close in the well surface.
• Ensure that all of the test crew are at the delegated workstations.
• The Well Test Crew should liaise with the Petroleum Engineer to
confirm shut-in requirements and time.
• Ensure that any final pressure/temperatures are recorded prior to
shut-in.
• Ensure that any final sampling requirements are met prior to shut-in.
• The Well Test Crew Chief should close in the well at the agreed
time, in line with the procedure below.
• Ensure the shut-in recording equipment is operational and recording
at the required scan rate (if applicable).
• Inform the drill floor of the actual well shut-in time.

Procedure for shut-in.
• Ensure that all relevant personnel are present prior to shut-in.

• Ensure that the pressure recording devices are of suitable range to
record the build up.
• Ensure that all recording devices are operational and open to the
well conditions.
• Ensure that all of the sample points are isolated.
• Close in the relevant upstream choke manifold valve.
• Close in the downstream choke manifold valves.
• Bypass and isolate the downstream equipment to ensure that flow
(in the event of a leak or similar problem) is directed to the flare.
• Monitor any pressure between the upstream and downstream
valves on the choke manifold in an effort to determine any leak
through the valves.

If it is a downhole shut-in the same procedures to be used,

but clear communication must be kept with the Downhole
Tool Supervisor, he will be completing the downhole shut
in.
It is not necessary to monitor any Surface Pressure at this
time.

• What readings should you Take during the test and what is
• the timescale?

How do you take a BS&W?
A sample from the flow stream is taken in a

centrifuge tube like the one Right.
You must take a full sample up to the 100ml point.
This would be balanced against the same size
sample on opposing sides of the centrifuge. You
would then spin this in the centrifuge for 5 mins at
which time you would allow the centrifuge to stop
turning, before removing. By looking at the
separation of the different materials you would then
make note of how much solids and water there is
showing on the glass.
The Centrifuge can either be hand, electric or air
operated.
The same method is used for both the Choke
Manifold sample and the Oil Line Sample.

How do you do an H2S and

CO2?
By using the hand pumps shown

on the right.
The ends of ampoules are
removed and inserted into the
pump.
Insert ampoule into stream of gas
and pump required number of
times.
Read off the discoloration of
paper inside ampoule.

How do you measure Water Salinity (salt in water).
We would use a refractometer.

Apply a small sample of distilled water to the
prism end of the refractometer. Close lid.
While viewing towards a light source, use the
zero adjustment wrench to line up the base
line with the 0 scale.
Apply a small sample of produced water to
the prism end of the refractometer. Close lid.
While viewing towards a light source,
determine the point on the scale that a color
change occurs.
Using the refractometer's calibration table,
determine the NaCl content. To determine
chloride content divide by 1.65.
How to do a shrinkage?
Use a shrinkage tester.

• Close liquid inlet valve.
• Open liquid bleed valve.
• Close gas decompression valve.
• Open gas inlet valve slowly, purge shrinkage
tester by allowing gas to flow out oil bleed valve.
• Close oil bleed valve and allow shrinkage tester
to reach separator pressure.
• Open oil inlet valve and allow oil level to reach
zero on graduated scale.
• Close oil inlet and gas inlet valves.
• Record tester pressure and temperature.
• Allow tester to decompress by opening
decompression valve (this should have a 1/64th
calibrated orifice in the valve).
• Leave it 30 minutes to decompress.
• Read the shrinkage percentage and temperature.
• Close decompression valve and drain oil.

How to determine a Oil Gravity.
• The sample to be tested for gravity is poured into a

clean clear graduated cylinder without splashing.
This is to avoid the formation of air bubbles and to
reduce to a minimum the evaporation of the lighter
oils. The cylinder should be placed in a vertical
position in a place free from air currents.
• The hydrometer is carefully lowered into the sample
to a level two smallest scale divisions below that at
which it will float and then released. When the
hydrometer has come to rest, floating freely away
from the walls and bottom of the cylinder, the gravity
is read at the point the surface of the sample cuts the
hydrometer scale. The reading obtained is corrected
by an arbitrary deduction of 0.1o API.
• The thermometer is read at approximately the same
time as the hydrometer and the temperature
determined to the nearest 1oF.
• The observed gravity and observed temperature
obtained is corrected to the API gravity at 60oF.
Tables are available for the necessary correction.

How to find a PH Value.
• A sample of water coming from the

formation is separated from the oil and a
PH paper is dipped into the fluid. By the
change in colour reaction on the paper and
measuring against the PH scale on the
packet that comes with the paper you can
determine roughly what the ph is.
• 7 on the ph scale is neutral.
• Anything below 7 is acidic and anything
above 7 is alkali.

pH Scale

How to take a Gas Gravity.
This is only an introduction.

We would use a Ranarex, (Gas
Gravitometric method.)
It is measured against a reference,
which is dry air. (Air is 1, anything
below is low gas and anything above 1
is heavy gas).
Dry air is also used to calibrate the
Ranarex.

Procedure for taking a Gas Gravity.

• The silica gel crystals used in the air drier should be in an active state (deep blue). If
the crystals are pink they should be dried in an oven at 250oF for two hours or until
the dark blue color returns.
• Check that the pointer and lock knob are in a "lock" position.
• Put selector valve in "O" position.
• The instrument should be connected to 110 volt 60 Hz or with an inverter to a 12 volt
source and operated on air only (selector on "O" setting) for at least few minutes
before conducting a specific gravity determination.
• Unlock the pointer and check the zero position (1.000 SG) at the beginning and end
of this warm up period.
• If the gas gravity is known to be less than 1.0, gas will be admitted to the upper
chamber and reference air to the lower chamber. If the gas gravity is known to be
above 1.0 gas will be admitted to the lower chamber and reference air at the upper
chamber. If gas gravity is not known to be above or below 1.0, it can be determined
by admitting gas either way and view the indicator scale for proper movement.
Generally, the "LG" selection (upper chamber) will be acceptable for most
applications.
• Connect a gas vent hose to the appropriate outlet. This is especially important when
dealing with H2S or confined spaces.

Now introduce the Gas Sample.

• Connect gas hose to flowmeter inlet. Turn selector valve to "LG" or "HG" position.
• Adjust inlet flow valve so float rises to approximate specific gravity of gas. With the
instrument in operation the source gas flow should be approximately 12 CF/Hour at a
pressure not exceeding 15 psig. (Just barely audible flow out of 1/4 inch rubber
tubing produces an ideal flow rate).
• Allow the instrument to operate on this gas for 20-30 seconds or until the pointer
reaches a steady reading.
• Read the specific gravity on the lower (red) scale when the gas is admitted at the
"LG" inlet and read the upper (black) scale when the gas is admitted at the "HG" inlet.
Note that the gravity decreases from right to left on the red scale and from left to right
on the black scale.
Purge the Instrument with Fresh Air
• When the specific gravity determination is complete, shut off the source gas flow,
disconnect the gas sample hose, turn to "O" setting on inlet selector valve, and allow
the instrument to purge free of gas until pointer returns to 1.000. This will prevent
corrosion and leave the instrument ready for the next test.

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9 Conduct Test 4-2

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Well Test 1 Course

Global Training Course

It is everyone’s responsibility to conduct operations in a

®Copyright Expro 2007 WELL FLOW MANAGEMENT

Here are some of the conditions that might lead to suspension or

®Copyright Expro 2007 WELL FLOW MANAGEMENT

There is no such thing as a routine pressure job and

®Copyright Expro 2007 WELL FLOW MANAGEMENT

®Copyright Expro 2007 WELL FLOW MANAGEMENT

®Copyright Expro 2007 WELL FLOW MANAGEMENT

What do we mean by a Hazardous Area?

The term refers exclusively to the danger arising from

These fall into three groups:

®Copyright Expro 2007 WELL FLOW MANAGEMENT

Gases, vapours and mists

®Copyright Expro 2007 WELL FLOW MANAGEMENT

• An open area within a radius of 15 metres (50 ft.) from an open

®Copyright Expro 2007 WELL FLOW MANAGEMENT

®Copyright Expro 2007 WELL FLOW MANAGEMENT

There is also a vertical limit for Zone 1 and 2 areas. This is

®Copyright Expro 2007 WELL FLOW MANAGEMENT

• The test program is normally directed by an operating

®Copyright Expro 2007 WELL FLOW MANAGEMENT

Preparation – before opening the well.

®Copyright Expro 2007 WELL FLOW MANAGEMENT

Well Clean Up.

Normally the first procedure to take place on any job. It is

®Copyright Expro 2007 WELL FLOW MANAGEMENT

When opening the well for the first time.

• The Client representative must be present.

®Copyright Expro 2007 WELL FLOW MANAGEMENT

Preparing the Separator for flowing into.

®Copyright Expro 2007 WELL FLOW MANAGEMENT

®Copyright Expro 2007 WELL FLOW MANAGEMENT

Diverting flow into the Separator.

• Have 2 people for this operation.

®Copyright Expro 2007 WELL FLOW MANAGEMENT

®Copyright Expro 2007 WELL FLOW MANAGEMENT

Shutting in the Well.

®Copyright Expro 2007 WELL FLOW MANAGEMENT

Procedure for shut-in.

• Ensure that all relevant personnel are present prior to shut-in.

®Copyright Expro 2007 WELL FLOW MANAGEMENT

If it is a downhole shut-in the same procedures to be used,

®Copyright Expro 2007 WELL FLOW MANAGEMENT

®Copyright Expro 2007 WELL FLOW MANAGEMENT

How do you take a BS&W?

A sample from the flow stream is taken in a

®Copyright Expro 2007 WELL FLOW MANAGEMENT

How do you do an H2S and

By using the hand pumps shown

®Copyright Expro 2007 WELL FLOW MANAGEMENT

How do you measure Water Salinity (salt in water).

We would use a refractometer.

Use a shrinkage tester.

®Copyright Expro 2007 WELL FLOW MANAGEMENT

How to determine a Oil Gravity.

• The sample to be tested for gravity is poured into a

®Copyright Expro 2007 WELL FLOW MANAGEMENT

How to find a PH Value.

• A sample of water coming from the

®Copyright Expro 2007 WELL FLOW MANAGEMENT

®Copyright Expro 2007 WELL FLOW MANAGEMENT

How to take a Gas Gravity.