Book3 Surface Testing
Book3 Surface Testing
Services
Schlumberger 2000
Schlumberger
225 Schlumberger Drive
Sugar Land, Texas 77478
All rights reserved. No part of this book may be reproduced,
stored in a retrieval system, or transcribed in any form or
by any means, electronic or mechanical, including photocopying and recording, without prior written permission
of the publisher.
SMP-7086-3B
An asterisk (*) is used throughout this document to denote a mark of Schlumberger.
Barton is a registered trademark of Barton Instrument Systems, LLC.
Daniel is a registered trademark of Daniel Industries, Inc.
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surface testing equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard set of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Classified zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Zone 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Zone 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Zone 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety standards for equipment layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H2S service requirements and safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Advanced Well Test Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Well test design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment safety barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surface safety systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency shutdown system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surface safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flowhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
218-in. lightweight flowhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
214-in. flowhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
318- and 3116-in. flowheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
618-in. flowhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sand-Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dual-pot sand filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sand separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cyclonic desander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Choke Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater types and applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrate prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Viscosity reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emulsion breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steam-heat exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indirect-fired heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate-steam exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Separator vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
1
1
2
2
3
3
3
4
4
4
4
9
10
10
11
12
12
15
15
17
21
22
23
26
29
31
33
35
37
39
43
43
46
49
53
55
55
55
55
55
56
61
65
69
70
iii
iv
Introduction
This second section of the third book in the Schlumberger Testing Services set describes well test
design, safety considerations and the features and selection of surface well testing equipment.
When performing well tests, the following items must be addressed:
requirements of dynamic conditions
type and layout of surface testing equipment
equipment needed to collect samples at the surface
safety requirements.
A reservoir test can be performed only under dynamic conditions, which means that the reservoir must be exposed to a disturbance that will cause the reservoir pressure to change. The
pressure change is recorded and interpreted in conjunction with the measured flow rates to yield
information about the parameters and geometry of the well and reservoir.
Creation of a pressure disturbance depends on whether the reservoir is producing or
shut in:
If the well has been shut in for a long time, the best way creates a pressure disturbance is to
flow the reservoir; this is called drawdown.
If the well has been flowing for a long time, shutting in the well to create a pressure disturbance; this is called buildup. A pressure disturbance can also be created in a flowing well by
either increasing or decreasing the flow rate.
quickly control pressure and flow rates at the surface and shut in the well (applicable to both
exploration well testing and development testing, such as cleanup)
separate the resulting effluent into three separate fluids (oil, gas and water), accurately
meter the fluids and collect and separate solids as applicable
collect surface samples
dispose of the resulting fluids in an environmentally safe manner.
Introduction
flowhead
safety valve
sand filters
choke manifold
emergency shutdown (ESD) system
heat exchanger
separator
gauge or surge tank
transfer pump
oil and gas manifolds
burners and booms.
Equipment layout
The surface equipment and its layout for performing well tests vary considerably depending on
the environment, well conditions and test objectives. Considerations dictating the equipment
layout include the following:
location
land or offshore operation
well conditions
flow rate and pressure
effluent properties (oil properties and hydrate formation)
sand production
presence of corrosive fluids (H2S, CO2, acid).
Safety
Safety is a major factor in designing and conducting a well test. Schlumberger general safety
considerations that pertain to the type and layout of surface testing equipment are as follows:
Classified zones
This section describes why classified zones were established, defines classified zones and identifies the surface testing equipment associated with each zone.
A wellsite is classified into zones or areas based upon the probability that flammable gases or
vapors may be present around a specific piece of equipment. For safety purposes, both the
American Petroleum Institute (API) and French Association of Oil and Gas Explorers and
Producers have defined zones.
The following classified zones are listed in order from most to least hazardous. Schlumberger
safety procedures recommend no overlap of classified zones within a well testing layout. Zone
restrictions do not dictate the placement of all well test equipment. For example, the ESD
system and oil and gas manifolds, although usually placed in Zone 2, are not restricted to that
specific zone. However, the location of other well test equipment defines certain zones. For further information on the zone classifications, see API publication 64B.
Zone 0
Zone 0 is defined as an area or enclosed space where any flammable or explosive substance (gas,
vapor or volatile liquid) is continuously present in a concentration within the flammable limits
of the substance. Thus, the borehole and the well below the wellhead are classified as Zone 0.
Safety
Zone 1
Zone 1 is defined as an area where any flammable or explosive substance (gas, vapor or volatile
liquid) is processed, handled or stored, and where, during normal operations, an explosive or
ignitable concentration of the substance is likely to occur in sufficient quantity to produce a
hazard.
The location of the gauge tank is classified as Zone 1 because the presence of flammable gases in the immediate vicinity of the gauge tank vent is normal.
Most of the electric-driven transfer pumps are designed for use in Zone 2; however, their use
in Zone 2 may be subject to geographical restrictions or client approval.
At the choke manifold, samples of well effluent are taken, typically at the beginning of a test.
Because sampling causes some gas release to the atmosphere, the choke manifold is designated as Zone 1.
Because the flowhead is used as a means of introducing tools into the well during a well test,
the area around the flowhead is classified as Zone 1; when tool introductions are not being
made, the area around the flowhead is classified as Zone 2.
Zone 2
Zone 2 is defined as an area where any flammable or explosive substance (gas, vapor or volatile
liquid) is processed and stored under controlled conditions, but the production of an explosive
or ignitable concentration in sufficient quantity to constitute a hazard is likely to occur only
during abnormal conditions.
The separator is designated as Zone 2 because it releases flammable gases or vapors only
under abnormal conditions, such as a leak.
Diesel-driven transfer pumps are classified as Zone 2 if they are equipped with automatic shutdown devices, spark arrestors, inertia starters or special electric starters.
The indirect-fired heater is classified as Zone 2 because it uses a naked flame to heat well
effluent. The steam exchanger is also Zone 2 because its surfaces can reach high
temperatures.
Piping is defined as a Zone 2 area.
Clean zone
A clean zone is an area where no flammable or explosive substances are processed, handled or
stored. Clean zones are also referred to as nonhazardous or safe areas. An example of a clean
zone is the living quarters of an offshore drilling rig.
The area around the flowhead is classified as Zone 2 with a radius onshore of 45 ft [15 m] and
a radius offshore of 30 ft [10 m].
If a separator vessel becomes overpressured, the rupture disc will burst and release effluent
to the atmosphere. Because of this risk, the top area around the separator rupture disc pipe
is classified as Zone 1 with a radius of 15 ft [5 m] and Zone 2 with a radius from 15 to 30 ft
[5 to 10 m]. For both offshore and onshore layouts, the area within 15 ft above the roof of the
gauge tank is classified as Zone 1.
Recommended distances among equipment pieces also affect onshore and offshore surface
testing layouts (Figs. 3 and 4, respectively).
Zone 2
Safety
Zone 2
a
b
e
d
a = 90 ft [30 m]
b = 90 ft [30 m]
c = 75 ft [25 m]
d = 90 ft [30 m]
e = 90 ft [30 m]
f = 75 ft [25 m]
Safety
f
d
a = 30 ft [10 m]
b = 75 ft [25 m]
c = 45 ft [15 m]
d = 10 ft [3 m]
e = 45 ft [15 m]
f = 40 ft [13 m]
Description
Color
None
Odor
Density
Explosive limits
4.3% to 46%
Ignition temperature
500F [260C]
Water solubility
Toxic Effects
1 ppm [0.0001%]
H2S can be smelled. Caution: If H2S concentration exceeds 1 ppm, immediately leave the area
or use personal protective equipment (breathing apparatus).
10 ppm [0.001%]
Odor disappears in 3 to 15 min as sense of smell is deadened; eyes and throat burn.
Sense of reasoning and balance lost; respiratory problems develop within 2 to 15 min; prompt
resuscitation required.
Loss of consciousness occurs quickly and breathing stops; death occurs unless the affected
person is removed and immediately resuscitated.
Safety
Operation guidance
When you are working in conditions in which H2S can be encountered, always follow these
guidelines:
Equipment safety
In addition to its adverse health effects, H2S is highly corrosive to metals. Service requirements
vary by system.
Gas-only system
Below 65 psia [4.5 bar], no H2S requirements
Above 65 psia [4.5 bar], H2S requirements.
All components upstream of the tanks should be rated for H2S service. Basic rules for H2S
service are as follows:
Equipment not positively identified as H2S service must be assumed to be not rated for H2S
service.
Welding performed outside a qualified shop on H2S equipment invalidates the H2S rating, and
the equipment must be used in non-H2S service only.
Piping with threaded connections is not rated for H2S service.
Use only a surge tank offshore; never use an atmospheric gauge tank offshore.
10
Heat radiation
Problems associated with heat radiation arise primarily during burning operations and are a
serious concern, particularly offshore for both personnel and equipment. The data in Table 3
demonstrate how critical it is to compute radiated heat before burning and to identify appropriate actions for avoiding excess heat. Table 3 must be available onsite for the testing crew to use
to estimate the radiated heat in consideration of variables such as the wind direction and
strength, type of boom and burners, and quantity of hydrocarbons to be burned.
Table 3. Heat Radiation
Quantity
Description
330 Btu/hr/ft2
440 Btu/hr/ft2
1500 Btu/hr/ft2
API RP 521 recommended upper limit for an oilfield worker wearing work clothes and intermittently
sheltered or sprayed with water
3000 Btu/hr/ft2
Upper limit for unprotected structures and equipment; personnel may escape harm by leaving
quickly
4000 Btu/hr/ft2
Radiates 93 MMBtu/hr
1 MMscf/D
Radiates 13 MMBtu/hr
Safety
11
Noise
Ear protection is critical for all personnel exposed to noise during well test operations.
International Standards Organization (ISO) recommendations for permissible noise exposure for
humans (not wearing hearing protection) are listed in Table 4.
Table 4. ISO Noise Exposure Recommendations
Noise Level (dBA)
Permissible Exposure
90
8 hr/D
95
4 hr/D
100
2 hr/D
105
1 hr/D
110
115
10 min/D
2 hr/D
For example, a separator flowing 4000 BOPD with a gas/oil ratio (GOR) of 300 generates a
noise level of 62 dBA. For a listener 100 ft from the flowline, a 10-MMscf/D flow in a 6-in. gas line
generates a noise level of 96 dBA and a 35-MMscf/D flow generates a noise level of 107 dBA.
Electrical safety
Electrical equipment located in hazardous areas must meet protection standards defined by
Comit Europen de Normalisation Electrotechnique (CENELEC) or International Electrotechnical Commission (IEC). In North America, equipment must meet Commission for Environmental
Cooperation (CEC) and National Electrical Code (NEC) standards. The standards define
protection methods
temperature classes
classification of hazardous areas (different designations for CENELEC and IEC and for CEC in
Canada and NEC in the United States)
classification of gases.
Only equipment certified by an authorized certification body and that carries the appropriate
marking may be used in hazardous areas. The most commonly used means of protection are
intrinsic safety (EEx ia or EEx ib): EN50014 and EN50020 or IEC 79-0 and 79-11
explosion proof (EEx d): EN50014 and EN50018 or IEC 79-0 and 79-1.
12
Table 5 indicates which method of protection may generally be used in various hazardous areas
according to European standards (EN) and IEC standards. Further consideration must be made
of the temperature marking of the electrical apparatus versus the classified gas type present or
expected in the hazardous area.
Table 5. Hazardous Area Electrical Protection
EN or IEC Zone
0
EEx ia
Yes
Yes
Yes
EEx ib
No
Yes
Yes
EEx d
No
Yes
Yes
Safety
13
Advanced Well
Test Design
All Schlumberger testing operations, together with all Schlumberger-manufactured surface testing equipment, obey a set of recognized standards (Fig. 5) and internal guidelines. The general
standards and Schlumberger specifications are described in this section. Additional regulatory
requirements issued by local authorities that relate to well testing operations are
Det Norske Veritas (DNV) rules for mobile offshore units Pt. 6 Drill (N)
UK Statutory Instruments No. 289 and HSE Guidance Notes
Norwegian Petroleum Directorate (NPD) regulations for drilling, etc., for petroleum in
Norwegian internal waters.
General standards
Surface testing equipment used by Schlumberger must comply with the following general
standards:
API Specification 6A, Wellhead and Christmas Tree Equipment, for flowheads, surface safety
valves, choke manifolds and high-pressure flowlines
API RP 14E, Design and Installation of Offshore Production Platform Piping Systems, or
American Society of Mechanical Enginerrs (ASME) B31.3, Process Piping, for low-pressure
flowlines downstream of heat exchangers
API Specification 12K, Indirect-Type Oil Field Heaters, for heaters and steam exchangers
API RP 14C, Analysis, Design, Installation and Testing of Basic Surface Safety Systems on
Offshore Production Platforms, for surface safety systems
API Specification 14A, Subsurface Safety Valve Equipment, and 14D, Specification for
Wellhead Surface Safety Valves and Underwater Safety Valves for Offshore Service, for surface
safety shutdown valves and ESD systems
API Specification 16A, Drill Through Equipment, for API hubs
ASME boiler and pressure vessel code Section VIII for pressure vessels
National Association of Corrosion Engineers (NACE) MR-01-75 for all H2S service equipment.
15
16
Safety redundancy at every stage, with sufficient segregation of operations to prevent system
failure because of a component breakdown
Total protection at the surface
Semisubmersible rigs should incorporate the subsea tree into the ESD system.
Jackup and land rigs should run an E-Z Valve* well control valve linked to the ESD system.
Automatic ESD controls should be bypassed for the previous two configurations whenever
wireline or coiled tubing is in the well to make only manual actuation possible.
Wellhead valves are closed and test equipment shut down if the well parameters exceed
the operating envelope, pilots are actuated, or surface equipment essential to well control
fails and creates a safety or environmental hazard. In case of a catastrophic failure, the
subsea safety valve is closed.
Operating time of the safety system commensurate with the well and reservoir characteristics,
with less than 10 s for full closure of the surface safety valves operated manually or by the
slowest pilot device.
17
Figure 6 shows a sample HAZOP analysis chart, which logs the various levels of alarms and protection by operational segment or equipment. The information is derived from the general safety
system philosophy (Fig. 7) and Safety Analysis Table (S.A.T.) (Fig. 8) for each segment.
API 14 C
SAFETY ANALYSIS
FUNCTION EVALUATION CHART
(S.A.F.E.)
14th DEC 1993
PROCESS COMPONENT
IDENT.
SERVICE
DEVICE
I.D.
SHUT DOWN
FLOWLINE
INTERNAL PLC
TIME
FLOWLINE
VALVE
Preliminary REV 1.
SD PROTECTION
ALT.
SAC NO. ALTERN.
V
001
SDV
002
HORN
ON
CONTROL
PANEL
AUDIBLE
ALARM
MESSAGE
ON
CONTROL
PANEL
MESSAGE
RECOMMENDED
SET POINT
CONTROL
PANEL
PLC OPERATOR
INTERFACE
PANEL
PRESSURE
RELIEF
REMARKS
FLOWLINE
UPSTREAM
HEAT EXCH.
PRESSURE
PSL-001
N/A
H-001
HEAT
EXCHANGER
EROSION
OF COIL
ERP-001
5 SEC
VESSEL
PRESSURE
PSH-301
PSV-001
FLOWLINE
UPSTREAM
CHOKE
PRESSURE
PT-201
PSHH-201
PSL-201
PSLL-201
LOOP
(4-20mA SIGNAL TO CPU IN CONTROL ROOM) THIS INSTRUMENT PERFORMS THE PSHH, PSL & PSLL PRESSURE FUNCTIONS.
1 SEC
X
X
X
X
100% WP
1 SEC
X
X
500 PSIG
1 SEC
X
X
X
X
200 PSIG
X
FLOWLINE
TO HEAT
EXCHANGER
DOWNSTREAM
CHOKE
PRESSURE
PT-202
PSHH-202
PSH-202
PSLL-202
LOOP
(4-20mA SIGNAL TO CPU IN CONTROL ROOM) THIS INSTRUMENT PERFORMS THE PSHH, PSL & PSLL PRESSURE FUNCTIONS.
1 SEC
X
X
X
X
100% WP
1 SEC
X
X
60% WP
1 SEC
X
X
X
X
100 PSIG
X
H-002
HEAT
EXCHANGER
PRESSURE
OIL LINE
FROM
HEATER TO
SEPARATOR
PT-301
PSHH-301
PSH-301
PSLL301
PSV-003
LOOP
(4-20mA SIGNAL TO CPU IN CONTROL ROOM) THIS INSTRUMENT PERFORMS THE PSHH, PSL & PSLL PRESSURE FUNCTIONS.
1 SEC
X
X
X
X
100% WP
1 SEC
X
X
80 % WP
1 SEC
X
X
X
X
100 PSIG
1260 PSIG
X
X
H-002
HEAT
EXCHANGER
PRESSURE
VESSEL
PT-322
PSHH-322
PSH-322
PSLL322
PSV-002
LOOP
(4-20mA SIGNAL TO CPU IN CONTROL ROOM) THIS INSTRUMENT PERFORMS THE PSHH, PSL & PSLL PRESSURE FUNCTIONS.
1 SEC
X
X
X
X
145 PSIG
1 SEC
X
X
120 PSIG
1 SEC
X
X
30 PSIG
220 PSIG
X
SET POINT AT AMBIENT TEMP
X
D-001
SEPARATOR
PRESSURE
PT-101
PSHH-101
PSH-101
PSL-101
PSLL-101
PSV-004
PSV-005
LOOP
LT-111
LSHH-111
LSH-111
LSL-111
LSLL-111
LOOP
(4-20mA SIGNAL TO CPU IN CONTROL ROOM) THIS INSTRUMENT PERFORMS THE PSHH, PSL & PSLL PRESSURE FUNCTIONS.
1 SEC
X
X
X
X
83% WP
1 SEC
X
X
65% WP
1 SEC
X
X
15% WP
1 SEC
X
X
X
X
100 PSIG
1197 PSIG
X
1260 PSIG
X
N/A
X
(4-20mA SIGNAL TO CPU IN CONTROL ROOM) THIS INSTRUMENT PERFORMS THE PSHH, PSL & PSLL PRESSURE FUNCTIONS.
2 SEC
X
X
X
X
55 CM
Top of sightglass
2 SEC
X
X
50 CM
5cm < top of sightglass
2 SEC
X
X
5 CM
5cm > bottom of sightglass
2 SEC
X
X
X
X
0 CM
Bottom of sightglass
X
PT-401
PSHH-401
PSH-401
PSLL-401
PSV-006
LOOP
LT-411
LSHH-411
LSH-411
LSLL-411
LOOP
(4-20mA SIGNAL TO CPU IN CONTROL ROOM) THIS INSTRUMENT PERFORMS THE PSHH, PSL & PSLL PRESSURE FUNCTIONS.
1 SEC
X
X
X
X
50 PSIG
1 SEC
X
X
35 PSIG
1 SEC
X
X
0 PSIG
50 PSIG
X
X
(4-20mA SIGNAL TO CPU IN CONTROL ROOM) THIS INSTRUMENT PERFORMS THE PSHH, PSL & PSLL PRESSURE FUNCTIONS.
2 SEC
X
X
X
X
Top of sightglass
2 SEC
X
X
20cm < top of sightglass
2 SEC
X
X
Bottom of sightglass
X
OIL LEVEL
D-002
SURGE TANK
PRESSURE
OIL LEVEL
200 PSIG
240 PSIG
ESD
PANEL-C001
MANUAL ESD
ESD 1
N/A
ESD
PANEL-C002
MANUAL ESD
ESD 2
N/A
18
DELAY
Customer :
Rig :
Well :
Updated:
Job No.:
FIRST STAGE
Well parameters ( pressure, temperature and flow rates ) are continuously
monitored by the following :A) COMPUTER ACQUISITION SYSTEM
1) Real time digital / analog output of well parameters
2) Hi/lo settings for any well parameter giving audible/visual alarm (manual reset)
B) MECHANICAL PRESSURE/TEMPERATURE RECORDERS
1) Foxboro pressure/temperature recorder for wellhead
2) Barton pressure/temperature recorder for separator
C) MANUAL PRESSURE/TEMPERATURE MONITORING
1) Dead Weight Tester, manual or electronic for pressure at wellhead.
2) Dial pressure gauges/pencil thermometers throughout the well test equipment.
DURING WELL TEST OPERATIONS, THE WELL PARAMETERS ARE CONTINUOUSLY MONITORED
WITH CROSS CHECKS BETWEEN A, B AND C TO ENSURE ACCURACY.
SECOND STAGE
Emergency shut down system
A) OVERALL SYSTEM CONTROLLING FLOWHEAD ISOLATION VALVE (SDV1)
AND FLOWLINE ISOLATION VALVE (SDV2)
THIS SYSTEM IS ACTIVATED BY : 1) Electrical ESD system.
2) Manual pull buttons.
3) Pneumatic hi pilots.
4) Pneumatic ESD erosion probe.
THIRD STAGE
Pressure safety valves (PSV) venting to safe areas from the following points:
1) PSV3 located on flowline to burners to allow for pressure relief.
2) PSV4& PSV5 located on the separator vessel to allow for pressure relief.
3) PSV1,PSE1 and PSV 2 located on heat exchanger vessels to allow for pressure relief
in case of over pressure of steam vessels.
4) PSV6 located on surge tank to allow for pressure relief.
This system is designed to protect from any blockage/rupture in the well test train between
the rig floor and burners
19
SAFETY
ANALYSIS
TABLE
UNDESIRABLE EVENT
LEAK
COMPONENT :
Customer :
Rig :
Job N:
Updated:
CAUSE
DETECTABLE CONDITION
AT COMPONENT
PROTECTION
PRIMARY
SECONDARY
CHOKE FAILURE
ON HEAT EXCHANGER
BLOCKED LINE
HIGH PRESSURE
NONE
NOTE 1
NONE
NOTE 1
DETERIORATION
RUPTURE
ACCIDENT
LOW PRESSURE
AND BACKFLOW
PSL-001
PSL-201
SDV-002
ESD
BLOCKED LINE
HIGH PRESSURE
PSH-301
PSV-003, ESD
DETERIORATION
RUPTURE
ACCIDENT
LOW PRESSURE
AND BACKFLOW
PSL-301
ESD
SAFETY
ANALYSIS
TABLE
COMPONENT :
Customer :
Rig :
SEPARATOR
Well :
Job N:
Updated:
UNDESIRABLE EVENT
CAUSE
DETECTABLE CONDITION
AT COMPONENT
PROTECTION
PRIMARY
SECONDARY
OVERPRESSURE
BLOCKED OUTLET
HIGH PRESSURE
PSH-101,PSH-301
UNDERPRESSURE
LOW PRESSURE
PSL-101
OVERFLOW
LSH-111
NOTE 1
ESD
GAS BLOW-BY
LSL-111
NOTE 2
ESD
LEAK
DETERIORATION
LOW PRESSURE
AND BACK FLOW
PSL-101
ESD
PSV-004, PSV-005
PSV-003
ESD
NOTE 1 : EQUIPMENT DOWNSTREAM CAN SAFELY HANDLE MAXIMUM LIQUID CARRY-OVER. SEPARATOR CONTINUOUSLY MANNED
DURING OPERATIONS
NOTE 2 : EQUIPMENT DOWNSTREAM CAN SAFELY HANDLE MAXIMUM GAS RATES THAT CAN BE DISCHARGED THROUGH LIQUID OUTLET
SEPARATOR CONTINUOUSLY MANNED DURING OPERATIONS
20
Oil
S2 + ESD
SS1
D1
<3000
Gas
H2S
Oil
Gas
S3 + ESD
SS1
D2
S3 + ESD
SS1
D2
S3 + ESD
SS1
D2
S2
SS0
D1
S2
SS0
D1
S2 + ESD
SS0
D2
S2 + ESD
SS0
D2
30005000
S2 + ESD
SS0
D1
S2 + ESD
SS0
D1
S3 + ESD
SS1
D2
S3 + ESD
SS1
D2
5,00010,000
S2 + ESD
SS1
D1
S3 + ESD
SS1
D2
S3 + ESD
SS1
D2
S3 + ESD
SS1
D2
10,00015,000
S3 + ESD
SS1
D2
S3 + ESD
SS1
D2
S3 + ESD
SS1
D2
S3 + ESD
SS1
D2
>15,000
S3 + ESD
SCSSV
D0
S3 + ESD
SCSSV
D0
S2 = master valve + flowline valve; S3 = master valve + flowline valve + SSV (surface safety valve); SS0 = subsurface valve, not mandatory; SS1 = E-Z Valve or
E-Z Tree* or SCSSV (surface controlled subsurface safety valve; D1 = drillstem test (DST) valve; D2 = DST valve + DST safety valve; D0 = downhole valve, not
mandatory with production string.
21
1
4
2
3
6
8
11
12
10
13
14
Figure 9. Surface safety equipment overview.
22
1-Flowhead
2-Safety valve
3-Emergency shutdown
4-Sand filter unit
5-Choke manifold
6-Steam exchanger
7-Steam generator
8-Separator
9-Surge tank
10-Transfer pump
11-Oil manifold
12-Gas manifold
13-Burner boom
14-EverGreen burner
at the separator
in an area away from all pressurized equipment, on an escape route.
ESD system components cannot be shared with process control functions.
23
ESD
station
Air
supply
ESD
control
console
Surge tank
Actuator
control
line
ESD
station
Separator
Flowhead
Steam exchanger
Surface safety valve
ESD
station
Pilot
02500 psi
Floor choke
manifold
Erosion probe
Pilot 010,000 psi
In well testing operations, the ESD system controls the hydraulically operated flowline valve
on the flowhead. If required by the surface testing setup, it can also control an additional safety
valve, which can be located upstream of the choke. Pressure is applied to open valves and
released to close valves.
An ESD is push-button activated from stations located at the separator, heater or steam
exchanger, and tank. Another station is usually positioned at an escape route. Backing up the
ESD stations are high- and low-pressure pilots on the flowline upstream of the choke manifold,
upstream of the heater or steam exchanger and upstream of the separator (Fig. 12). The highpressure pilot initiates well closure when the pressure in the flowline rises above a high-level
threshold (line plugged), and the low-pressure pilot initiates well closure when the pressure falls
below a low-level threshold (flowline rupture or leak).
24
The ESD system for well tests remotely closes a flowhead hydraulic actuator and surface
safety valve (SSV) equipped with hydraulic actuator simultaneously. Alternatively, it closes a
single-action fail-safe hydraulic actuator, provided that the hydraulic operating pressure is less
than 6000 psi [416 bar].
The ESD-C system consists of
ESD control console with air-driven hydraulic pump, hydraulic tank, storage reels with air
hoses, and hydraulic hoses for actuators
ESD stations
High- and low-pressure pilots (010,000 and 02,500 psi [0690 and 0172 bar], respectively).
Hydraulic pump
Manual pump
V4 interface
valve
Hydraulic tank
0150 psi
PI
Air
supply
06000 psi
PI
V5 reset
valve
0150 psi
PI
To hydraulic
safety valves
V7 bypass
valve
PI 030 psi
030 psi
PI
Quick
exhaust valve
V9 velocity
check valve
PI 0150 psi
High pilot
Air vessel
Low pilot
Erosion
probe
ESD stations
Flowline
Hydraulic circuit
Air circuit
PI
Air regulator
Valve
Pressure gauge
Check valve
25
Outlet
Inlet
26
SSV-G
SSV-HD
Service
5000 [345]
10,000 [690]
15,000 [1035]
Temperature (F [C])
ID (in. [mm])
3.0 [76]
3.0 [76]
3.0 [76]
Inlet
Outlet
3.7 [1.15]
4.3 [1.30]
4.3 [1.30]
3.9 [1.18]
3.9 [1.18]
4.1 [1.24]
2.0 [0.60]
2.0 [0.60]
2.0 [0.60]
1100 [500]
1188 [540]
1450 [660]
27
Flowhead
The flowhead is located directly on top of the well and is the first piece of equipment that fluid
from the well flows through (Fig. 14). Its five principal functions in controlling fluid flow in and
out of the well are to
Flowhead
29
30
Lifting sub
Swivel
Kill line valve
Flowline valve
Flowline
Flowhead
31
H2S
5000 [345]
Temperature (F [C])
ID (in. [mm])
218 [54]
400,000 [1780]
250,000 [1110]
Connection
412-in. 4 S.A.
Bottom
312-in. IF
Flowline
Kill line
218 [54]
218 [54]
9.8 [3.00]
2.6 [0.80]
0.5 [0.14]
1320 [600]
32
214-in. flowhead
The well test 214-in. flowhead (Fig. 16 and Table 9) consists of
Lifting sub
Swab valve
Fail-safe
sleeve-type valve
Kill line
Flowline
Swivel
Master valve
Flowhead
33
10,000 [690]
Temperature (F [C])
ID (in. [mm])
214 [57]
420,000 [1870]
200,000 [890]
Connection
412-in. 4 S.A.
Bottom
312-in. IF
Flowline
Kill line
2 916 [65]
2 916 [65]
14.4 [4.40]
2.5 [0.76]
2.0 [0.60]
2300 [1045]
34
flowhead assembly
swab manual gate valve
two wing valves, one with a hydraulic actuator (flowline)
independent master valve
flowhead swivel
transportation skid.
Lifting sub
Swab valve
Flowline
Kill line
Swivel
Master valve
Flowhead
35
FHT-G
FHT-HD
Service
5000 [345]
10,000 [690]
15,000 [1,035]
Temperature (F [C])
ID (in. [mm])
3116 [78]
3116 [78]
300,000 [1330]
490,000 [2180]
660,000 [2940]
200,000 [890]
300,000 [1330]
320,000 [1420]
Connection
612-in. 4 S.A.
612-in. 4 S.A.
7-in. 5 S.A.
Bottom
On request
On request
On request
Flowline
Kill line
318 [79]
3116 [78]
3116 [78]
318 [79]
3116 [78]
3116 [78]
12.0 [3.65]
12.5 [3.80]
13.3 [4.06]
3.6 [1.10]
3.6 [1.10]
4.1 [1.25]
3.8 [1.15]
3.6 [1.10]
4.1 [1.25]
4400 [2000]
4994 [2270]
8530 [3870]
1000 [455]
7040 [3200]
7040 [3200]
36
618-in. flowhead
The 618-in. flowhead (Fig. 18 and Table 11) is designed for high flow rates. It consists of
flowhead assembly
swab manual gate valve
two wing valves, one with a hydraulic actuator (flowline)
independent master valve
flowhead swivel
transportation basket.
Flowhead
37
6000 [415]
Temperature (F [C])
ID (in. [mm])
618 [156]
500,000 [2220]
258,000 [1150]
Connection
912-in. 4 S.A.
Bottom
On request
Flowline
Kill line
618 [156]
618 [156]
13.5 [4.10]
5.2 [1.60]
3.9 [1.20]
10,270 [4660]
7040 [3190]
38
Data Header
The data header is used to connect instruments and sensors for the acquisition of data upstream
of the choke manifold (Fig. 19 and Table 12). The standard data header includes four to six ports
for pressure and temperature manometers and transducers. Depending on the pressure, the
connections are either National Pipe Thread (NPT) or Autoclave Engineers, Division of Snaptite, Inc.
The specialized FHH-E data header flowline (Fig. 20) incorporates connections for sand
detection:
5 NPT ports (12-in. [12.7-mm] diameter)
thermo well (12-in. diameter)
BX151 flange for mounting Sandec* sand-detection flow equipment.
Data Header
39
Thermo well
Sandec probe
Flow
Figure 20. Data header with Sandec probe mounted in side view (top) and schematic (bottom).
40
FHH-CD
FHH-E
FHH-D
Service
H2S
H2S
H2S
H2S
5000 [345]
10,000 [690]
10,000 [690]
15,000 [1035]
Temperature (F [C])
ID (in. [mm])
2 516 [58]
2 3364 [64]
2 516 [58]
2 3364 [64]
Inlet
Outlet
6.56 [2.00]
6.56 [2.00]
7.11 [2.80]
7.00 [2.10]
1.54 [0.50]
1.54 [0.50]
2.00 [0.60]
1.54 [0.50]
3.0 [76]
3.0 [76]
3.0 [76]
3.0 [76]
200 [90]
220 [100]
352 [160]
390 [175]
Data Header
41
Sand-Handling
Equipment
Whenever solids are produced during a well test or cleanup operations, sand-handling equipment is required. The main objective is to avoid erosion caused by high-flow velocity and the
presence of solids to downstream equipment. For gas wells, particular attention should be paid
to the set-up. The type of Schlumberger purpose-built equipment used for sand handling
depends on the type of solids produced, such as formation sand or fracturing flowback.
The frame-mounted pots have a telescopic lifting support for convenient filter replacement.
Typical applications are barefoot completion cleanups and maximum sand-free rate tests.
Sand-Handling Equipment
43
Front View
Side View
Filter pot
Fluid inlet
Drain valve
Drain
Fluid inlet
Fluid outlet
Bypass valve
Top View
Figure 22. Three views of the dual-pot sand filter.
Operation
The maximum sand concentration for continuous operation is about 10-lbm/min solids. This
value is based on a 50% solids slurry with a solids specific gravity of 2.7.
44
SFDP-B
Service
H2S
H2S
10,000 [690]
5000 [345]
Temperature (F [C])
5000 [795]
5000 [795]
35 [991]
35 [991]
200
200
11.5 [300]
11.5 [300]
1500 [103]
1500 [103]
Fluid inlet
Fluid outlet
Drain outlet
Transport
13.1 [4]
13.1 [4]
In use
24.2 [7.4]
24.2 [7.4]
16,535 [7500]
16,535 [7500]
Flow rate
sizes available
Sand-Handling Equipment
45
Sand separator
The sand separator (Figs. 23 and 24 and Table 14) removes solids in the production stream.
Oil/gas/water separation is completed in an associated three-phase separator. The sand separator is ideally suited for well cleanup after a sand fracturing treatment, when a large volume of
sand can be lifted up during the initial flowback phase.
The sand separator consists of
42-in. 10-ft [106-cm 3.05-m] vessel with 18-in. [53-cm] entry
sand compartment with weir
double cyclone cluster
sand drain line
two 3-in. pilot-operated, modulating action pressure relief safety valves
manifold
safety discharge line.
Operation
Sand removal through the sand line enables continuous operation.
46
Side View
Fluid inlet
Gas outlet
Solid outlet
Fluid outlet
Front View
Fluid outlet
Fluid inlet
Gas outlet
Solid outlet
Top View
Fluid outlet
Fluid inlet
Solid outlet
Gas outlet
Sand-Handling Equipment
47
H2S
Working pressure
(psi to 100F [bar to 38C])
1440 [100]
1345 [93]
Temperature (F [C])
32 to 212 [0 to 100]
Fluid inlet
Fluid outlet
Drain outlet
8.1 [2.50]
30,860 [14,000]
48
Cyclonic desander
The frame-mounted cyclonic desander unit (Fig. 25 and Table 15) is a solids removal unit that
consists of
The entire well stream is fed into the desander vessel, where it is directed into the insert.
Cyclonic separation of the sand takes place in the insert, with sand falling down into the accumulator (Fig. 26). The insert size is selected to meet the specified design conditions for a range
of flow rates, fluid properties and sand loads. The desander and accumulator vessels are separated by a double block-and-bleed ball valve system, and the accumulator is also drained through
a similar arrangement.
The desander is left on-line during the purging process. The solids separated during purging
collect in the holding space beneath the insert in the desander vessel and are passed to the accumulator once the accumulator is reopened to the process.
Projects for which the cyclonic desander is usually specified include underbalance drilling and
four-phase separation processes.
Operation
The maximum sand concentration for continuous operation is about 10-lbm/min solids. This
value is based on a 50% solids slurry with a solids specific gravity of 2.7.
Sand-Handling Equipment
49
50
H2S
5000 [345]
Temperature (F [C])
Flow rate
Liquid (B/D [m3/d])
4500 [715]
35 [991,200]
2 to 20
Peak
4000 [11.3]
600
Out
10 to 20
Fluid inlet
Fluid outlet
Vent outlet
22 [6.7]
26,400 [12,000]
Wet
29,700 [13,500]
Sand-Handling Equipment
51
Front View
Side View
Desander
Accumulator
Fluid outlet
Fluid inlet
Solid outlet
Solid outlet
Fluid inlet
Fluid outlet
Flush line
Top View
Figure 26. Three views of a cyclonic desander.
52
Choke Manifold
The choke manifold (Fig. 27 and Table 16) controls the fluid from the well by reducing the flowing pressure and achieving a constant flow rate before the fluid enters the processing equipment
on the surface. When a well is being tested, critical flow (at which the downstream pressure is
approximately one-half of the upstream pressure) must be achieved across the choke. At critical
flow, changes in pressure and flow rate made downstream from the choke do not affect the downhole pressure and flow rate.
FMF-BF
(bypass)
FMF-G
FMF-BG
(bypass)
FMF-HD
Service
H2S
H2S
H2S
H2S
H2S
Working pressure
(psi [bar])
5000 [345]
5000 [345]
10,000 [690]
10,000 [690]
15,000 [1035]
Temperature [F [C])
ID (in. [mm])
3.0 [51]
3.0 [51]
3.0 [51]
3.0 [51]
3.0 [51]
Inlet
3-in. 1002 F
3-in. 1002 F
3-in. 1502 F
3-in. 1502 F
API 6BX
Outlet
3-in. 1002 M
3-in. 1002 M
3-in. 1502 M
3-in. 1502 M
API 6BX
6.2 5.9
[1.9 1.8]
7.2 6.2
[2.2 1.9]
8.2 6.9
[2.5 2.1]
8.5 7.2
[2.6 2.2]
8.2 6.9
[2.5 2.1]
3.2 [0.97]
3.2 [0.97]
3.3 [1.02]
3.3 [1.02]
3.3 [1.02]
3785 [1720]
5070 [2300]
4180 [1900]
5510 [2500]
6060 [2750]
Choke Manifold
53
The choke manifold consists of valves and fittings arranged to direct the flow through one of
two choke boxes. One box is configured as a variable choke, and the other as a fixed choke
(Fig. 28). The fixed choke box is set by screwing in a calibrated choke bean. The bean sizes are
usually in graduations of 164 in. [0.4 mm] to produce a flow rate that can be specified at the end
of a test. The fixed choke can be changed during operation when the flow is directed through the
variable choke box. The variable choke is a variable geometry orifice that is easily changed without isolating the choke box. If the choke size and upstream pressure under critical flow
conditions are known, the flow rates during cleanup can be estimated.
Operation
The well is opened to flow on a variable choke. The choke size is increased until the specified
flowing wellhead pressure is attained. The choke bean size that corresponds to the barrel reading on the variable choke at the flowing wellhead pressure is then installed in the fixed choke
box, and flow is diverted through the fixed choke at the specified rate.
Front View
Fluid inlet
Side View
Fluid outlet
Fluid outlet
Top View
Variable choke
Figure 28. Three views of the choke manifold.
54
Fluid inlet
Fixed choke
Heat Exchanger
Heat exchangers, commonly called heaters, raise the temperature of well effluents, which prevents hydrate formation, reduces viscosity and breaks down emulsions to facilitate the
separation of oil and water.
Hydrate prevention
Natural gas contains water vapor. Under certain choked flow conditions, sufficient expansion
occurs to lower the temperature of the flow and cause hydrate formation, which is when particles of water and some light hydrocarbons in the natural gas become solid. Hydrate formation is
a serious problem; if particles freeze in the surface equipment, the valves and flowmeters
become inoperative and chokes are blocked.
Natural gas hydrates resemble granular snow. These chemical compounds of hydrocarbons
and water form at temperatures above the normal freezing point of water when certain hydrocarbons are dissolved in water under low-temperature and high-pressure conditions. High
velocity, pressure pulsation and agitation accelerate the phenomenon, as do certain gases, particularly H2S and CO2. A heater is used to help maintain the temperature above the point at
which hydrates can form.
Viscosity reduction
High viscosity impairs the flow of an effluent through a pipe. It is usually not a problem in well
testing. However, the combined effects of changes in composition as the reservoir fluid is brought
to the surface ambient temperature may raise the viscosity and affect testing efficiency. Because
viscosity is temperature dependent, a heater can be used to lower the viscosity and prevent highviscosity problems.
Emulsion breakdown
With the inevitable production of water from a reservoir, it is necessary to separate oil from
water. Under certain conditions, the oil and water emulsify and do not separate unless chemicals
are injected or the effluent temperature is raised with a heater.
Heat Exchanger
55
Steam-heat exchangers
Steam-heat exchangers have almost completely replaced indirect-fired heaters for offshore work
and are also used where regulations do not permit the use of indirect-fired heaters. Figures 29
and 30 show typical steam-heat exchangers. A steam-heat exchanger is virtually free of fire risk.
It requires an adequate supply of steam to operate. Some rigs have a sufficient steam supply,
but usually a steam generator must also be used. Third-party companies provide steam
generator service.
56
Side View
Steam inlet
Condensate outlet
Front View
Adjustable
choke
Inlet
Bypass
Outlet
Steam inlet
Top View
Inlet
Bypass
Outlet
Heat Exchanger
57
The steam-heat exchanger design most commonly used for testing has a capacity of
4.3 MMBtu/hr (Table 17). As shown in Fig. 31, it has a shell and also a tube, which is a highpressure vessel. Steam provided to the shell is passed around the tube bundle. Heat is transferred from the steam to the tube bundle and, in turn, to the effluent. A choke between the inlet
and outlet of the steam-heat exchanger allows preheating the effluent before the pressure is
dropped at the choke. The temperature control of a steam-heat exchanger is shown in Fig. 32.
Table 17. Steam-Heat Exchanger Specifications
Service
STX-BBS
STX-CCN
STX-D
STX-CCQ
H2S
H2S
H2S
H2S
Vessel size
Working pressure (psi [bar])
4900 [338]
10,000 [690]
10,000 [690]
15,000 [1035]
Temperature (F [C])
32 to 250
[0 to 121]
4 to 250
[20 to 121]
32 to 250
[0 to 121]
4 to 320
[20 to 160]
Capacity (MMBtu/hr)
4.3
4.3
4.3
4.3
Fluid inlet
Fluid inlet
Steam inlet
Steam outlet
20 6.4
[6.1 2]
21.3 7.7
[6.5 2.3]
21.3 7.7
[6.5 2.3]
21.3 7.7
[6.5 2.3]
8.1 [2.5]
8.5 [2.6]
8.5 [2.6]
8.5 [2.6]
19,800 [8980]
26,400 [11,980]
26,400 [ 11,980]
26,840 [12,170]
58
Choke
Steam trap
Manual valves
Steam inlet
Automatic control valve
Effluent
inlet
Effluent
outlet
Temperature controller
Thermometric well
Heat Exchanger
59
Pressure regulator
Air
Controller
Automatic
control valve
Steam
Effluent
Effluent
Choke box
Steam
Temperature bulb
Steam exchanger
Steam generator
Figure 32. Steam-heat exchanger temperature control.
60
Steam trap
Indirect-fired heater
The Schlumberger indirect-fired diesel heater (Figs. 3335 and Table 18) consists of
vessel for water bath at atmospheric pressure, including 4-in. split coil with intermediate
choke, adjustable choke with 112-in. [3.81-cm] seat and solid stem tip
manifold equipped with three 318-in. gate valves rated 5000-psi [345-bar] working pressure
diesel shutdown valve actuated by pilot light stoppage and temperature controller (Fig. 36)
flame arrestor on burner air inlet
spark arrestor on chimney exhaust.
32 to 200 [0 to 93]
Inlet
Outlet
Diesel inlet
14-in.
13.1 [4.0]
27,450 [12,450]
Heat Exchanger
NPT
61
Vessel
Fire tube
Liner
Stack
Flange
62
Exhaust
Air
intake
Side View
Adjustable
choke
Front View
Inlet
Bypass
Outlet
Top View
Heat Exchanger
63
Spark arrestor
Temperature bulb
Coils
Choke box
Effluent
Chimney
Bypass
Effluent
Air ring
Flame arrestor
Diesel burner
Pressure regulator
Mercury bulb
64
Plate-steam exchanger
The plate-steam exchanger is especially designed for high-efficiency heating downstream of the
manifold (Figs. 37 and 38 and Table 19). It is ideally suited for use in heavy-oil operations to raise
the temperature of the effluent for better disposal to oil burners. It can also be used for oil conditioning prior to export. The unit is skid mounted with a protective frame and consists of
plate exchanger
crude manifold equipped with bypass and pressure relief valve
steam manifold equipped with a Fisher 2-in. control relief valve for regulating the temperature of the crude through the steam flow.
Operation
The plate-steam exchanger requires clean liquid.
Heat Exchanger
65
Front View
Outlet
Safety valve
Safety valve
Inlet
Steam outlet
Steam inlet
Side View
Condensate outlet
Steam inlet
Top View
Inlet
Outlet
66
STX-P
Crude
H2S (fluid class DD)
174 [12]
464 [32]
376 [191]
Flow rate
1854 kg/hr
8000 BOPD
Inlet
4-in. 150 RF
6-in. 300 RF
Outlet
2-in. 150 RF
6-in. 300 RF
7.8 [2.40]
8820 [4000]
Heat Exchanger
67
Test Separator
Test separators are versatile pieces of equipment used to separate, meter and sample all phases
of the effluent. Because test separators are used on exploration wells where effluent phases are
not known, they must be able to treat a wide variety of effluents, such as gas, gas condensate,
light oil, heavy oil and foaming oil as well as oil containing water and impurities such as mud
or solid particles. Schlumberger also provides a wide range of separators for high-content H2S
service.
Figure 39 shows the main elements of a test separator, which are the vessel (including internal components, pressure and level regulators, and safety devices), the piping necessary for
different phases and metering (fitted with corresponding metering devices), and the skid and
its protective frame. Separators are also equipped with a built-in shrinkage tester, Barton
recorder and sampling points.
Test Separator
69
Separator vessel
The principal internal components of a separator are shown in Fig. 40. The coalescing plates prevent droplets larger than 15 mm from being carried into the outlet gas stream, and the mist
extractor, which is the last obstacle the gas must pass before leaving the separator vessel, blocks
fine liquid droplets still in the gas stream. The blocked droplets coalesce and fall back into the
oil phase.
Safety valve
Foam breaker
Coalescing
plates
Gas outlet
Mist extractor
Access door
Oil-level controller
Effluent inlet
Water outlet
Deflector plate
Vortex breaker
Oil outlet
Water-level controller
Weir
The vessel capacity for each phase depends on the in-situ conditions of pressure and temperature and in-situ effluent properties such as
viscosities and densities of the liquids, which are a function of the amount of dissolved gas
vessel operating liquid level
vessel internals
required liquid gas separator efficiency in terms of size of liquid droplet to be separated from
the gas phase.
Calculations for the oil and gas capacities and internal pressure are made as follows:
The settling velocity Vs, drag coefficient Cd and Reynolds number Re are calculated as
Vs = 0.0019
Cd =
dm l g
Cd g
24
3
+ 1/ 2 + 0.34
Re Re
( ) g ,
Re = 0.0049dm Vs
70
(1)
(2)
(3)
12Vs L
,
hg
(4)
where
dm
L
h
=
=
=
=
=
(5)
and in MMscf/D is
qg =
(AgVc )P (520)(0.0864) ,
14.73TZ
(6)
where
Ag
P
T
Z
=
=
=
=
(7)
where
Qo = oil capacity (BOPD)
V = oil volume (bbl)
t = retention time (s).
Test Separator
71
Separators are highly versatile in their operation because the level of the oil can be adjusted
across a range of 6 in. [15.24 cm] from the center line of the vessel (Fig. 41). The pneumatic
liquid-level controller has a long vertical float to accommodate the range of oil levels. The controller actuates either the small- or large-diameter regulation valve fitted in parallel on the oil
outlet to regulate the oil rate from very low flow to the maximum capacity of the separator
(Fig. 42). The valves close when air supply is not available, and the oil/gas interface is observed
with a sight-glass level.
P2
Gas metering
PGV2
Air
supply
Relief
valve
PCV7
PCV2
1
3
T2
PGV3 P3
T3 4 3
Nonreturn
swing valve
GOV7
GOV6
PGV1
PCV1
T1 PCV3
Safety valves
P1
PCV4
T5
4
V3
1
2
3
7
Shrinkage
tester
valves (SLV)
V1
2
4
5
Liquid
levels
valves
(LLV)
V2
Water outlet
WOV1
WOV2
1
V4
2 3
2
1
Oil metering
PCV6
T4
Oil outlet valves (OOV)
Inlet line
Gas line
Oil line
Water line
72
Type of
Separator
Level
Position
0
+6 in.
Center line
6 in.
200
400
600
800
1000
1200
1440
SEP-T
test separator
42 in. 10 ft, 1440 psi
SEP-G
test separator
42 in. 15 ft, 720 psi
+6 in.
Center line
200
400
600
720
6 in.
1200
1440
600
800
1000
200
400
+6 in.
SEP-N
test separator
Center line
48 in. 12.5 ft, 1440 psi
6 in.
The water level is also regulated pneumatically. By using an interface controller to regulate
the oil-water interface, the separator can continuously eliminate the separated water; however,
water levels exceeding 10% of the capacity of the vessel cannot be controlled efficiently. The level
controller actuates a regulation valve on the water outlet. Like the oil regulation valve, the water
valve is also closed by a lack of air supply.
Test Separator
73
74
Operation
Operational benefits include
SEP-ND
Service
H2S
H2S
Vessel size
1440 [100]
1440 [100]
Temperature (F [C])
32 to 212 [0 to 100]
32 to 212 [0 to 100]
1345 [93]
1315 [90]
LLL
8200 [1300]
8200 [1300]
HLL
16,500 [2600]
16,500 [2600]
LLL
90 [2,500,000]
90 [2,500,000]
HLL
75 [2,100,000]
75 [2,100,000]
Fluid inlet
Gas outlet
Oil outlet
Water outlet
Relief outlet
Drain outlet
7.9 [2.42]
7.9 [2.42]
43,210 [19,600]
43,210 [19,600]
Low
liquid level (LLL) and high liquid level (HLL) at 720 psi [50 bar]
Test Separator
75
76
Side View
Front View
Gas outlet
Oil outlet
Fluid inlet
Water outlet
Top View
Oil outlet
Inlet
Water outlet
Gas outlet
Test Separator
77
SEP-U
SEP-W
Service
H2S
H2S
H2S
Vessel size
42 in. 10 ft
[106 cm 3.28 m]
42 in. 10 ft
[106 cm 3.28 m]
42 in. 10 ft
[106 cm 3.28 m]
Temperature (F [C])
32 to 212 [0 to 100]
32 to 300 [0 to 150]
LLL
6650 [41]
6650 [41]
6650 [41]
HLL
14,400 [90]
14,400 [90]
14,400 [90]
LLL
60 [1690]
60 [1690]
60 [1690]
HLL
25 [707]
25 [707]
25 [707]
Fluid inlet
Gas outlet
Oil outlet
Water outlet
Relief outlet
Drain outlet
7.9 [2.50]
7.9 [2.50]
7.9 [2.50]
30,800 [14,000]
30,800 [14,000]
30,800 [14,000]
LLL
78
H2S
Vessel size
720 [50]
10,500 [1670]
HLL
23,800 [3800]
41 [1160]
HLL
18 [510]
Fluid inlet
Gas outlet
Oil outlet
Water outlet
Relief outlet
2 relief valves
Drain outlet
23.25 [7.09]
7.4 [2.24]
8.0 [2.42]
35,200 [16,000]
LLL
Test Separator
79
80
Front View
Side View
Gas outlet
Fluid inlet
Oil outlet
Safety outlet
Top View
Water outlet
Drain
Fluid inlet
Safety outlet
Drain
Water outlet
Oil outlet
Gas outlet
Test Separator
81
H2S
2220 [153]
Temperature (F [C])
32 to 300 [0 to 149]
1500 [240]
100 [2800]
Inlet
Gas outlet
Oil outlet
Water outlet
Drain outlet
Safety outlet
27.3 [8.32]
30,800 [14,000]
82
The oil produced by the separator can be directed through an oil manifold to the gauge tank,
surge tank, production flowline or burner depending on the test circumstances. The manifold
usually has five 2-in. ball valves.
From the gauge tank, the flow is piped to the oil manifold by way of a transfer pump. The
pump boosts the pressure so that the flow can be supplied to a burner or reinjected into a flowline. If a surge tank is used, the manifold serves the same purpose. In effect, the manifold directs
the flow from the separator without interruption to the burner or flowline. For offshore tests, two
burners are typically used to support continuous testing without respect to the prevailing wind
direction. The oil manifold can direct flow to either the port or starboard burner without stopping the well test because of undesirable wind directions.
The gas manifold performs the same functions. The gas from the separator is directed through
the gas manifold to one of the burners depending on the prevailing wind during the test.
Oil manifold
The skid-mounted oil manifold (Fig. 47 and Table 24) is fitted with five valves. Oil is directed
through the manifold valves to one of three test components as shown in Fig. 48:
starboard burner
port burner
storage tank.
H2S
Working pressure
(psi at 100F [bar at 38C])
1440 [100]
1345 [93]
Temperature (F [C])
32 to 212 [0 to 100]
Inlet
Outlet
1.4 [0.44]
880 [400]
83
From separator
Figure 48. Flow directions through the oil manifold.
84
Gas manifold
The gas manifold (Fig. 49 and Table 25) directs the gas produced from the separator to the port
or starboard flareport a function of wind direction (Fig. 50). It consists of a skid-mounted assembly
with two ball valves.
To burner
To burner
From separator
Figure 50. Flow directions through the gas manifold.
85
MFD-BDA
H2S
H2S
1440 [100]
1440 [100]
1345 [93]
1345 [93]
Temperature (F [C])
32 to 212 [0 to 100]
32 to 212 [0 to 100]
Inlet
Outlet
1.3 [0.40]
1.5 [0.46]
550 [218]
710 [322]
Service
Working pressure
86
Tanks
Gauge and surge tanks are one of the methods used to measure the liquid flow rate from the separator. A surge tank can also be used as a second-stage separator. The use of surge tanks is
compulsory for offshore operations and whenever H2S is present. An atmospheric gauge tank
accurately determines the shrinkage factor by measuring the oil volume change at atmospheric
pressure on a large volume; the same is applicable for a surge tank operating at atmospheric
pressure.
Surge tank
The surge tank is a pressurized vessel used to measure liquid flow rates and obtain an accurate
measurement of shrinkage and the meter factor (Figs. 51 and 52). The two types of surge tanks are
Both types of surge tanks have an automatic pressure control valve on the gas outlet line to
maintain backpressure up to the maximum working pressure of 50 psi for the single compartment and 150 psi for the dual compartments. The change in volume is inferred from the level
indicator on the basis of the physical dimensions of the surge tank. High- and low-level alarms
warn when gauging will stop.
Safety features include a safety relief valve in case the vessel is accidentally overpressured
beyond the maximum working pressure. A grounding strap is attached to the surge tank for
static discharge. A separate gas vent line with flame arrestor to the burner must be used with a
surge tank. The tank cannot be connected directly to the separator gas outlet because the
pressure could exert backpressure on the surge tank.
Tanks
87
88
Top View
Front View
Oil inlet
Gas outlet
Oil outlet
Safety outlet
Side View
Oil inlet
Oil outlet
Gas outlet
Safety outlet
Tanks
89
VST-BB
VST-BC
Service
H2S
H2S
H2S
50 [3.5]
50 [3.5]
50 [3.5]
Temperature (F [C])
32 to 212 [0 to 100]
80 [12.2]
80 [12.2]
80 [12.2]
Oil inlet
Oil outlet
Gas outlet
Safety outlet
Drain
19.7 [6.0]
19.7 [6.0]
19.7 [6.0]
13,420 [6000]
13,420 [6000]
13,420 [6000]
VST-BC
VST-FB
VST-N
Service
H2S
H2S
H2S
50 [3.5]
50 [3.5]
50 [3.5]
Temperature (F [C])
32 to 212 [0 to 100]
2 50 [2 8]
2 50 [2 8]
2 50 [2 8]
Oil inlet
Oil outlet
Gas outlet
Safety outlet
Drain
25.0 [7.60]
25.0 [7.60]
25.0 [7.60]
26,500 [12,000]
26,500 [12,000]
26,500 [12,000]
VST-N
90
has an ANSI class 600 oil manifold and DNV 2.1.1 frame.
Front View
Oil outlet
Oil inlet
Flame arrestor
Top View
Oil outlet
Oil inlet
Tanks
91
FGTS-C
Service
General
General
Atmospheric
Atmospheric
Temperature (F [C])
32 to 212 [0 to 100]
32 to 212 [0 to 100]
2 50 [2 8]
2 100 [2 16]
Oil inlet
Oil outlet
8.5 [2.60]
9.7 [2.95]
10,000 [4536]
17,530 [7950]
92
Transfer Pump
A transfer pump connected to the gauge tank outlet is used to empty one of the tank compartments while the other is being filled. Most pumps are electric powered, but diesel-driven pumps
are also available. To reinject the oil from the separator into an existing flowline, a highcapacity, high-pressure transfer pump is used.
Another use of transfer pumps is for pressure boosting when there is insufficient pressure to
achieve atomization at the burner.
Figure 54 shows a gear-type transfer pump.
Transfer Pump
93
PMP-GD
Service
H2S
H2S
410 [28]
300 [20]
Temperature (F [C])
32 to 212 [0 to 100]
10,000 [1590]
5000 [795]
Motor
Electric 125 kW
Electric 49 kW
Inlet
Outlet
17.4 [2.30]
5.2 [1.60]
6920 [3140]
4180 [1900]
Outlet
Cut water
Impeller
Volute
Inlet
Figure 55. Centrifugal transfer pump cross section.
94
Front View
Control box
Outlet
Inlet
Side View
Electrical motor
Top View
Centrifugal pump
Transfer Pump
95
PMP-TDC
Service
Not NACE
Not NACE
300 [20]
300 [20]
Temperature (F [C])
32 to 200 [0 to 93]
32 to 200 [0 to 93]
4000 [636]
4000 [636]
Motor
Electric 30 kW
Diesel 52 hp
Inlet
Outlet
4.7 [1.42]
5.0 [1.53]
3300 [1500]
4400 [2000]
Inlet
Rubber stator
Outlet
Helical rotor
Figure 57. Screw-type transfer pump cross section.
96
Oil
Side View
Inlet
Outlet
Rotor pump
Front View
Motor
Outlet
Rotor pump
Inlet
Control box
Transfer Pump
97
PMP-TCB
Service
Not NACE
Not NACE
200 [13.8]
200 [13.8]
Temperature (F [C])
32 to 200 [0 to 93]
32 to 200 [0 to 93]
2000 [318]
2000 [318]
Motor
Electric 11 kW
Diesel 15 hp
Inlet
Outlet
2.8 [0.86]
6.3 [1.91]
946 [430]
1078 [490]
Discharge
Idler
Suction
Rotor
98
Side View
Outlet
Inlet
Gear pump
Front View
Outlet
Motor
Inlet
Gear pump
Control box
Transfer Pump
99
Oil Burners
and Booms
Burners are designed to efficiently dispose of the oil produced at the surface during an offshore
well test, which avoids oil storage and pollution problems. To limit the heat radiation on rigs,
burners are installed on 60- to 85-ft [18- to 26-m] long booms to keep them a safe distance from
the rig.
Applications
Burners and booms are used for the following applications:
Unusual applications for burners include burning high-viscosity oil from a sunken tanker or
burning the oil emulsion collected on beaches after a release.
Different types of burners are used for burning oil, oil-base mud or foam.
Oil burners have one or more combustion heads to accommodate the expected flow rate.
Atomizers break the effluent into very fine droplets for efficient burning.
Pilot lights are remotely controlled.
Heads are manually or pneumatically oriented, depending on the prevailing wind.
Green Dragon* series burners have a water ring on each combustion head that sprays water
into the flame to improve combustion and reduce heat radiation.
Booms have the following principal features:
of modular design and available in two lengths
provide access to the burners
oriented horizontally or vertically
contain all necessary piping for the burners.
101
The use of burners has been instrumental in the development of extensive offshore well testing. Before burners were introduced, most offshore tests required costly storage facilities to hold
the oil. Therefore, for technical and safety reasons, only small quantities of oil could be produced,
which limited the area of investigation and the information about the well that could be obtained
from a test. Burners dispose of oil in a manner that is both safe and environmentally responsible, which is why burners are used more frequently for onshore tests also.
Operation
To efficiently combust well effluent without producing unburned particles and smoke, the well
effluent must be reduced to very fine droplets. This process, called atomization, is achieved by
using the energy resulting from the pressure of the well effluent
supplying additional energy (air pressure) to enhance the process.
This mechanical and pneumatic process is conducted in the atomizer. Efficient burning usually requires varying the air, water and oil pressures and flow rates so that the flame does not
produce excessive black smoke (too rich in oil) or excessive white smoke (too rich in water). The
size of the air and oil nozzles also plays a major role in the burning process. Generally, a small
nozzle aids in the atomization process, but it also creates a larger backpressure, which limits the
flow rate through the burner. Charts are used based on flow rate to select the optimum nozzle sizes.
EverGreen burner
Development of the EverGreen burner was supported by European Economic Union THERMIE
funding with participation of the Institut Franais du Ptrole. The single-head, 12-nozzle system
effectively leverages pneumatic atomization and enhanced air induction (Fig. 61 and Table 32).
No water injection into the flame is required (Fig. 62).
Nozzle
Ignitor
Pilot
Propane line
Oil inlet
102
H2S
Heads
1 with 12 nozzles
960 [66.2]
150 [10.3]
15,000 [2385]
5 1200 [5 185]
Oil inlet
Water inlet
Air inlet
90
8.2 [2.50]
1980 [900]
Air
Oil
Air
103
Key advantages of using the EverGreen burner are that it operates smoke free and fallout free
for minimal environmental impact and efficiently burns all types of oil, including heavy crude oils.
The EverGreen burner includes two gas pilots, frame-front igniting system and a water screen
(Fig. 63). The 180 rotating mounting makes the nozzles readily accessible for maintenance.
Nozzle
Pilot
Water curtain
Propane line
Pilot
Oil inlet
Gas line
Figure 63. EverGreen burner mounted on boom.
104
Boom
105
BRN-HCB
Service
H2S
H2S
Heads
300 [20]
300 [20]
7000 [1113]
9000 [1430]
Temperature (F [C])
32 to 200 [0 to 93]
32 to 200 [0 to 93]
Power supply
110/220 VAC
110/220 VAC
Oil inlet
Water inlet
Air inlet
11.6 [3.53]
8.3 [2.53]
2090 [950]
2530 [1150]
106
Water ring
Cylindrical hearth
Water nozzle
Atomizer
Pilot light
Ball valve
Supporting frame
Rotation system
Oil
Air
Swivel joint
Water
Figure 65. Green Dragon burner schematic.
107
Mud burner
The mud burner (Fig. 66 and Table 34) provides an economical solution for disposing of oil-base
mud during drilling operations in an environmentally acceptable manner. The mud burner can
also be used to burn high-viscosity oils.
Its design is based on that of oil burners and also uses atomizers. The mud burner consists of
the following:
pneumatic actuators on the oil and air valves
pneumatic control panel for high-efficiency burning and rotation control
rotation device and swivel joint distributor
gas pilot light and electric ignition.
H2S
Heads
300 [20]
5000 [795]
150 [10.3]
Temperature (F [C])
32 to 200 [0 to 93]
Power supply
110/220 VAC
Water inlet
Air inlet
Diesel inlet
Upper head
Lower heads
9.2 [2.81]
1870 [1050]
108
Drip pan
109
Burner boom
To reduce heat radiation and the risk of fire, the burner is mounted on a boom to keep it away
from the rig. The boom is usually made up of two lightweight sections, which give it a length of
60 ft. The length of the boom can be extended to 85 ft by adding an intermediate section.
The structural design of the boom provides access to the burner and contains piping to supply
the burner with air, water, oil and propane. The boom also includes the gas flare pipe. The water
line is fitted with a filter to prevent debris from plugging the water nozzles.
The boom is mounted on the rig with a rotating base plate and guy lines (Fig. 67). Horizontal
guy lines are used to orient the boom, and vertical guy lines fixed to the structure of the rig (king
post) support the boom. The rotating base plate enables horizontal and vertical movements to
facilitate orienting the boom. The boom axis should be placed slightly above the horizontal axis
so oil left in the boom piping after flaring operations does not leak out, especially when the boom
is installed on a floating rig. For safe burning in changing winds, two booms are usually installed
on opposite sides of a drilling rig.
110
Foot section
Head section
111
D2
E1
E2
D1
UBM-G
Service
H2S
H2S
Sections
Burner
4 head max
4 head max
100 [160]
100 [160]
Temperature (F [C])
32 to 212 [0 to 100]
32 to 212 [0 to 100]
Gas line
Oil line
Water line
Air line
60 [18]
85 [26]
2.9 [0.89]
2.9 [0.89]
10,800 [4900]
15,210 [6900]
Dynamic,
112
no ice
Oil line
Water line
Air line
D1
Gas line
D2
E1
Pilot line
E2
Cable
E1
E2
Oil line
Water line
Air line
D1
Gas line
D2
E1
Pilot line
E2
Pilot cable
Water screen
D2
D1
UBB-B
Service
H2S
H2S
Sections
Burner
6 head
6 head
100 [160]
100 [160]
Temperature (F [C])
Gas line
Oil line
Water line
Air line
85 [26]
60 [18]
3.6 [1.10]
3.6 [1.10]
16,980 [7700]
11,680 [5300]
Dynamic,
2 in. of ice
113