Well 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Well Testing Services

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

Type N test separator (48 in. 12.5 ft, 1440 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Horizontal test separator (42 in. 10 ft, 1440 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Type G test separator (42 in. 15 ft, 720 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Vertical gas separator (2200 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Oil and Gas Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Oil manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Gas manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Surge tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Atmospheric gauge tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Centrifugal transfer pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Screw-type transfer pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Gear-type transfer pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Oil Burners and Booms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Benefits and features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
EverGreen burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Green Dragon high-efficiency burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Mud burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Burner boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Standard burner boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Heavy-duty burner boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

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.

Surface testing equipment

The reservoir engineering term for the time period in which the well experiences changes in
pressure is called the pressure transient. At the surface, the fluids produced during pressure
transients must be handled using temporary installations of surface testing equipment because
permanent production facilities usually have not yet been installed. This equipment must safely
and reliably perform a wide range of functions:

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.

Well Testing Services

Introduction

Standard set of equipment

A standard set of surface testing equipment consists of

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:

Equipment layout and spacing must be in accordance with classified zones.

All pieces of surface testing equipment must be grounded.
The electrical connection required for certain pieces of surface testing equipment, such as
transfer pumps or laboratory cabins, must be safe and approved according to industry standards.
Piping used for high-pressure wells must be anchored.
Piping must be color coded to identify the working pressure of the pipe. It is also helpful to
label the piping to identify the fluids passing through it.
The dominant wind direction must be identified to properly orient equipment that vents or
burns gas.

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.

Well Testing Services

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.

Safety standards for equipment layout

The onshore and offshore safety standards illustrated in Figs. 1 and 2, respectively, can be summarized as follows:

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).

Flowhead: 45-ft [15-m] around

Indirect heater: 30-ft [10-m] around

Tank: 45-ft [15-m] around

Separator: 30-ft [10-m] around

Zone 1

Zone 2

Figure 1. Onshore testing layout.

Well Testing Services

Safety

Flowhead: 30-ft [10-m] around

Surge tank: 45-ft [15-m] around

Heat exchanger: 30-ft [10-m] around

Separator: 10-ft [3-m] around

Zone 1
Figure 2. Offshore testing layout.

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]

Figure 3. Onshore recommended distances (figure not to scale).

Well Testing Services

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]

Figure 4. Offshore recommended distances (figure not to scale).

H2S service requirements and safety

Hydrogen sulfide (H2S) is dangerous because it has a wide explosive range and is highly toxic
(Table 1). Although H2S has a distinctive offensive odor at low concentrations, the sense of smell
cannot be relied upon to detect its presence because the olfactory center of the brain deadens
over time and at higher concentrations and can no longer detect the odor. If inhaled in sufficient
quantities, H2S paralyzes the respiratory center in the brain, resulting in a loss of consciousness,
respiratory failure and death (Table 2).
Table 1. H2S Properties
Properties

Description

Color

None

Odor

Extremely offensive, often characterized as rotten eggs

Density

1.189, heavier than air (1.000)

Explosive limits

4.3% to 46%

Ignition temperature

500F [260C]

Water solubility

Four volumes of gas in one volume of water at 32F [0C]

Table 2. H2S Toxicity

Concentration

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%]

Maximum 8-hr work period allowed.

100 ppm [0.01%]

Odor disappears in 3 to 15 min as sense of smell is deadened; eyes and throat burn.

200 ppm [0.02%]

Odor disappears quickly; eyes and throat burn.

500 ppm [0.05%]

Sense of reasoning and balance lost; respiratory problems develop within 2 to 15 min; prompt
resuscitation required.

700 ppm [0.07%]

Loss of consciousness occurs quickly and breathing stops; death occurs unless the affected
person is removed and immediately resuscitated.

1000 ppm [0.1%]

Immediate loss of consciousnesspermanent brain damage or death results unless the

affected person is removed and immediately resuscitated.

Well Testing Services

Safety

Operation guidance
When you are working in conditions in which H2S can be encountered, always follow these
guidelines:

Conduct a mandatory prejob safety meeting for all personnel involved.

Maintain constant supervision of the job and use a minimum of two experienced, H2Scertified engineers or technicians.
Always carry a mask.
Do not allow H2S to escape into the atmosphere in any place where it can accumulate.
Monitor the wind direction constantly.
Wear breathing apparatus when
surface sampling
measuring gas gravity
changing Daniel orifices
changing chokes
bleeding off lubricators or sand traps
walking on burner booms.
Operate instruments with compressed air or nitrogen. Do not allow H2S to be sucked into
compressors.

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.

Oil and gas system

Below 265 psia [18.3 bar] and below 15-ppm concentration of H2S, no H2S requirements
Above 265 psia [18.3 bar], everywhere upstream of the tanks H2S-rated equipment is
required. H2S requirements must also be met for any equipment where P C > 50,000
(P = pressure in psia and C = concentration of H2S in ppm).

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

Greatest solar radiated heat at soil level

440 Btu/hr/ft2

Upper limit for harmless exposure of bare human skin

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

Heats wood to 800F [427C] and ignites it

1000 bbl oil per

day (BOPD)

Radiates 93 MMBtu/hr

1 MMscf/D

Radiates 13 MMBtu/hr

1000 bbl water per

day (BWPD)

Injected into the flame absorbs 6 MMBtu/hr

Easy solutions for managing excess heat are to

inject water into the flame
install additional water screens behind the burners
install water ramps alongside the hull where excess heat can be radiated
use longer booms (85 ft [26 m]).

Well Testing Services

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

Well Testing Services

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.

Well Testing Services

Advanced Well Test Design

15

Figure 5. Schlumberger-Riboud Product Center ISO certification.

16

Well test design

For high-pressure, high-temperature or high-rate well testing, a Hazard and Operability (HAZOP)
study and well test design review must be conducted for each test or project. The well
test design review is based on the safety analysis techniques defined in API RP 14C (Figs. 6
through 8). ESD systems must be designed accordingly for applications at pressures greater than
10,000 psi or high flow rates. (High-rate tests are defined as >30 MMscf/D for gas wells and
>8000 BOPD for oil wells.) The following guidelines are recommended.

Basic three-stage safety system architecture

Well parameters (pressure, temperature, flow rate, H2S content, etc.) should be monitored
continuously with redundant electronic and manual systems, and the measurements are to
be compared with the operating envelope parameters defined for the well test design.
ESD systems that control the wellhead valve, subsea safety valve and flowline valve should
be activated by manual control, low- and high-pressure pilots, or fusible loops and temperature sensors.
Pressure safety valves should vent each section of the flowline that has a working pressure
rating less than the maximum shut-in wellhead pressure.

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.

Well Testing Services

Advanced Well Test Design

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

PSH NOT REQ AS MWHP<MAWP

H-001
HEAT
EXCHANGER

EROSION
OF COIL

ERP-001

5 SEC

LINKED TO PNEUMATIC ESD

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

LINKED TO PNEUMATIC ESD

SET POINT AT AMBIENT TEMP

ESD
PANEL-C001

MANUAL ESD

ESD 1

N/A

LOCATED ON DRILL FLOOR

PNEUMATIC SYSTEM

ESD
PANEL-C002

MANUAL ESD

ESD 2

N/A

LOCATED AT CHOKE MANIFOLD

PNEUMATIC SYSTEM

Figure 6. Sample HAZOP analysis chart.

18

DELAY

SAFETY SYSTEM PHILOSOPHY

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

Figure 7. Safety system design philosophy.

Well Testing Services

Advanced Well Test Design

19

SAFETY
ANALYSIS
TABLE
UNDESIRABLE EVENT

15K FLOW SEGMENT

OVERPRESSURE

LEAK

1.1K FLOW SEGMENT

OVERPRESSURE
LEAK

COMPONENT :

Customer :
Rig :

FLOWLINE SEGMENTS Well :

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

NOTE 1 : PSV NOT REQUIRED ON FLOWLINE SEGMENT PROVIDING MAWP>SITP

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

OUTFLOW EXCEEDS INFLOW

LOW PRESSURE

PSL-101

OVERFLOW

INFLOW EXCEEDS OUTFLOW

LEVEL CONTROL FAILURE

HIGH LIQUID LEVEL

LSH-111
NOTE 1

ESD

GAS BLOW-BY

LEVEL CONTROL FAILURE

LOW LIQUID LEVEL

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

Figure 8. Safety analysis table.

20

Equipment safety barriers

Safety barriers and ESD systems must comply at a minimum with the Schlumberger internal
pressure policy, as summarized in Table 6.
Table 6. Minimum Safety Valve Configuration
Flow Rate or Shut-In Wellhead
Pressure (psi)

Oil

High flow rate (gas: 30 MMscf/D,

liquid: 8000 B/D)

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

Production string mandatory

S3 + ESD
S3 + ESD
SCSSV
SCSSV
D0
D0

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.

Well Testing Services

Advanced Well Test Design

21

Surface safety systems

A typical layout, shown in Fig. 9, for offshore surface well test equipment includes items such as
a safety valve and emergency shutdown, which form the safety system.
7

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

Emergency shutdown system

An ESD system is recommended for all well testing operations to provide quick shutdown in
response to a pipe leak or break, equipment malfunction, fire or similar emergency (Fig. 10).
A remote station or ESD console (Fig. 11) is used to safely close flowline valves. A minimum of
two remote control stations is recommended at these locations:

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.

Figure 10. ESD console.

Well Testing Services

Advanced Well Test Design

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

Figure 11. ESD system layout.

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

Figure 12. ESD schematic.

Well Testing Services

Advanced Well Test Design

25

Surface safety valve

The SSV is used to shut in the flow upstream of the choke manifold in case of an emergency
(Fig. 13 and Table 7). It is operated by the ESD system. SSVs are supplied with a supporting base
frame, inlet connection (female union) and outlet connection (male union).
Actuator

Outlet

Inlet

Figure 13. Surface safety valve.

26

Table 7. SSV Specifications

SSV-F

SSV-G

SSV-HD

Service

H2S (fluid class DD)

H2S (fluid class DD)

H2S (fluid class DD)

Working pressure (psi [bar])

5000 [345]

10,000 [690]

15,000 [1035]

Temperature (F [C])

4 to 250, 350 for 12 hr [20 to 120, 175 for 12 hr]

ID (in. [mm])

3.0 [76]

3.0 [76]

3.0 [76]

Inlet

3-in. Fig. 1002 F

3-in. Fig. 1502 F

3-in. API 6BX flange

Outlet

3-in. Fig. 1002 M

3-in. Fig. 1502 M

3-in. API 6BX flange

Length (ft [m])

3.7 [1.15]

4.3 [1.30]

4.3 [1.30]

Height (ft [m])

3.9 [1.18]

3.9 [1.18]

4.1 [1.24]

Width (ft [m])

2.0 [0.60]

2.0 [0.60]

2.0 [0.60]

Weight (lbm [kg])

1100 [500]

1188 [540]

1450 [660]

Well Testing Services

Advanced Well Test Design

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

support the weight of the test string

enable up and down (reciprocal) movement of the test string. If a swivel is attached, the test
string can also be rotated. Whether a swivel is required depends on the type of downhole test
equipment used. Some tools can be fully operated using up and down movement, some require
rotation, and others require both types of movement.
control flow out of the well through a flow valve
provide a kill line connection so that the well can be killed off after a testing operation is done
or during an emergency. The kill line is essential for controlling pressure in the well. Pressure
control is used to pull the downhole test string out of the well after testing is complete and is
critical for safety. For example, if the downhole pressure is too high, the tool string could be
pushed up through the rig floor.
introduce tools into the well through the swab valve.

Well Testing Services

Flowhead

29

Figure 14. Flowhead.

30

2 18-in. lightweight flowhead

The lightweight flowhead (Fig. 15 and Table 8) supports the drillstring and enables the following
operations:

flowing the well

killing the well
rotating the string without disconnecting.
The 218-in. ID well test flowhead consists of
swab valve kelly cock
integrated swivel flowhead
kill line 2-in. [51-mm] valve
flowline 2-in. valve
master valve kelly cock.

Lifting sub

Swab valve kelly cock

Swivel
Kill line valve

Flowline valve
Flowline

Master valve kelly cock

Figure 15. Lightweight flowhead.

Well Testing Services

Flowhead

31

Table 8. Lightweight Flowhead Specifications

FHL-F
Service

H2S

Working pressure (psi [bar])

5000 [345]

Temperature (F [C])

4 to 300 [20 to 150]

ID (in. [mm])

218 [54]

Max tensile load

(lbf at 0 psi [kN at 0 bar])

400,000 [1780]

(lbf at 5000 psi [kN at 345 bar])

250,000 [1110]

Connection

412-in. 4 S.A.

Bottom

312-in. IF

Flowline

2-in. Fig. 1502 M

Kill line

2-in. Fig. 1502 F

Swab valve ID (kelly cock) (in. [mm])

218 [54]

Master valve ID (kelly cock) (in. [mm])

218 [54]

Height (ft [m])

9.8 [3.00]

Width (ft [m])

2.6 [0.80]

Length (ft [m])

0.5 [0.14]

Weight (lbm [kg])

1320 [600]

32

214-in. flowhead
The well test 214-in. flowhead (Fig. 16 and Table 9) consists of

2916-in. swab manual gate valve

214-in. flow sub assembly with built-in remotely operated fail-safe valve
214-in. flowhead swivel
independent 2 916-in. master valve.

Lifting sub

Swab valve

Fail-safe
sleeve-type valve

Kill line

Flowline

Swivel

Master valve

Figure 16. 214-in. flowhead.

Well Testing Services

Flowhead

33

Table 9. 214-in. Flowhead Specifications

FHT-M
Service

H2S (fluid class DD)

Working pressure (psi [bar])

10,000 [690]

Temperature (F [C])

20 to 250 [28 to 121]

ID (in. [mm])

214 [57]

Max tensile load

(lbf at 0 psi [kN at 0 bar])

420,000 [1870]

(lbf at 5000 psi [kN at 345 bar])

200,000 [890]

Connection

412-in. 4 S.A.

Bottom

312-in. IF

Flowline

2-in. Fig. 1502 M

Kill line

2-in. Fig. 1502 F

Swab (gate) valve ID (in. [mm])

2 916 [65]

Master (gate) valve ID (in. [mm])

2 916 [65]

Height (ft [m])

14.4 [4.40]

Width (ft [m])

2.5 [0.76]

Length (ft [m])

2.0 [0.60]

Weight (lbm [kg])

2300 [1045]

34

318- and 3116-in. flowheads

The well test 318- and 3116-in. flowheads (Fig. 17 and Table 10) consist of

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

Kill line valve

Actuator for flowline valve

Flowline

Kill line

Swivel

Master valve

Figure 17. 318- and 3116-in. flowheads.

Well Testing Services

Flowhead

35

Table 10. 318- and 3116-in. Flowhead Specifications

FHT-F

FHT-G

FHT-HD

Service

H2S (fluid class DD)

H2S (fluid class DD)

H2S (fluid class DD)

Working pressure (psi [bar])

5000 [345]

10,000 [690]

15,000 [1,035]

Temperature (F [C])
ID (in. [mm])

4 to 250, 320 for 12 hr [20 to 121, 160 for 12 hr]

318 [79]

3116 [78]

3116 [78]

(lbf at 0 psi [kN at 0 bar])

300,000 [1330]

490,000 [2180]

660,000 [2940]

(lbf at 5000 psi [kN at 345 bar])

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

3-in. Fig. 1002 M

3-in. Fig. 1502 M

API 6BX flange

Kill line

3-in. Fig. 1002 F

3-in. Fig. 1502 F

API 6BX flange

Swab (gate) valve ID (in. [mm])

318 [79]

3116 [78]

3116 [78]

Master (gate) valve ID (in. [mm])

318 [79]

3116 [78]

3116 [78]

Height (ft [m])

12.0 [3.65]

12.5 [3.80]

13.3 [4.06]

Width (ft [m])

3.6 [1.10]

3.6 [1.10]

4.1 [1.25]

Length (ft [m])

3.8 [1.15]

3.6 [1.10]

4.1 [1.25]

Weight (lbm [kg])

4400 [2000]

4994 [2270]

8530 [3870]

Skid dimensions (ft [m])

12.1 4.6 1.0

[3.7 1.4 0.3]

15.0 3.9 6.6

[4.6 1.2 2.0]

15.0 6.6 3.6

[4.6 2.0 1.1]

Skid weight (lbm [kg])

1000 [455]

7040 [3200]

7040 [3200]

Max tensile load

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.

Figure 18. 618-in. flowhead.

Well Testing Services

Flowhead

37

Table 11. 618-in. Flowhead Specifications

FHT-L
Service

H2S (fluid class DD)

Working pressure (psi [bar])

6000 [415]

Temperature (F [C])

20 to 250 [28 to 121]

ID (in. [mm])

618 [156]

Max tensile load

(lbf at 0 psi [kN at 0 bar])

500,000 [2220]

(lbf at 5000 psi [kN at 345 bar])

258,000 [1150]

Connection

912-in. 4 S.A.

Bottom

On request

Flowline

3-in. Fig. 1502

Kill line

3-in. Fig. 1502

Swab (gate) valve ID (in. [mm])

618 [156]

Master (gate) valve ID (in. [mm])

618 [156]

Height (ft [m])

13.5 [4.10]

Width (ft [m])

5.2 [1.60]

Length (ft [m])

3.9 [1.20]

Weight (lbm [kg])

10,270 [4660]

Skid dimensions (ft [m])

15.0 6.6 3.9 [4.6 2.0 1.2]

Skid weight (lbm [kg])

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.

Figure 19. Data header.

Well Testing Services

Data Header

39

Thermo well
Sandec probe

Flow
Figure 20. Data header with Sandec probe mounted in side view (top) and schematic (bottom).

40

Table 12. Data Header Specifications

FHH-CC

FHH-CD

FHH-E

FHH-D

Service

H2S

H2S

H2S

H2S

Working pressure (psi [bar])

5000 [345]

10,000 [690]

10,000 [690]

15,000 [1035]

Temperature (F [C])

20 to 250 [28 to 121]

ID (in. [mm])

2 516 [58]

2 3364 [64]

2 516 [58]

2 3364 [64]

Inlet

3-in. Fig. 1002 F

3-in. Fig. 1502 F

3-in. Fig. 1502 F

3-in. Fig. 2202 F

Outlet

3-in. Fig. 1002 M

3-in. Fig. 1502 M

3-in. Fig. 1502 M

3-in. Fig. 2202 M

Length (ft [m])

6.56 [2.00]

6.56 [2.00]

7.11 [2.80]

7.00 [2.10]

Height (ft [m])

1.54 [0.50]

1.54 [0.50]

2.00 [0.60]

1.54 [0.50]

Diameter (in. [mm])

3.0 [76]

3.0 [76]

3.0 [76]

3.0 [76]

Weight (lbm [kg])

200 [90]

220 [100]

352 [160]

390 [175]

Well Testing Services

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.

Dual-pot sand filter

The dual-pot sand filter (Figs. 21 and 22 and Table 13) removes sand and other solid particles
from well effluent. It is usually located upstream of the choke manifold. The dual-pot sand filter
consists of

two 46-L filter pots

interconnecting piping with bypass and drain.

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.

Figure 21. Dual-pot sand filter.

Well Testing Services

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

Table 13. Dual-Pot Sand Filter Specifications

SFDP-A

SFDP-B

Service

H2S

H2S

Working pressure (psi [bar])

10,000 [690]

5000 [345]

Temperature (F [C])

4 to 250 [20 to 121]

4 to 250 [20 to 121]

Liquid (B/D [m3/d])

5000 [795]

5000 [795]

Gas (MMscf/D [Mm3/d])

35 [991]

35 [991]

Standard screen size (m)

200

200

Equivalent flow area (in. [mm])

11.5 [300]

11.5 [300]

Max P (psi [bar])

1500 [103]

1500 [103]

Fluid inlet

3-in. Fig. 1502

3-in. Fig. 1502

Fluid outlet

3-in. Fig. 1502

3-in. Fig. 1502

Drain outlet

2-in. Fig. 1502

2-in. Fig. 1502

Footprint (ft [m])

9.2 7.2 [2.8 2.2]

9.2 7.2 [2.8 2.2]

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

Height (ft [m])

Weight (lbm [kg])

Other

sizes available

Well Testing Services

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.

Figure 23. Sand separator.

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

Figure 24. Three views of a sand separator.

Well Testing Services

Sand-Handling Equipment

47

Table 14. Sand Separator Specifications

SFU-A
Service

H2S

Working pressure
(psi to 100F [bar to 38C])

1440 [100]

(psi to 212F [bar to 100C])

1345 [93]

Temperature (F [C])

32 to 212 [0 to 100]

Fluid inlet

3-in. Fig. 602

Fluid outlet

3-in. Fig. 602

Drain outlet

3-in. Fig. 602

Pressure safety valve (PSV) outlet

3-in. Fig. 602

Footprint (ft [m])

18.6 7.3 [5.68 2.24]

Height (ft [m])

8.1 [2.50]

Weight (lbm [kg])

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

desander vessel that contains a single cyclone insert

sand accumulator vessel.

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.

Well Testing Services

Sand-Handling Equipment

49

Figure 25. Cyclonic desander.

50

Table 15. Cyclonic Desander Specifications

SFCU-A
Service

H2S

Working pressure (psi [bar])

5000 [345]

Temperature (F [C])

4 to 250 [20 to 120]

Flow rate
Liquid (B/D [m3/d])

4500 [715]

Gas [MMscf/D [m3/d])

35 [991,200]

Fluid viscosity (cp)

2 to 20

Solid contents (lbm/1000 bbl) [kg/m3])

Inlet

10 to 100 [0.03 to 0.3]

Peak

4000 [11.3]

Max particle size (m)

In

600

Out

10 to 20

Fluid inlet

4-in. Fig. 1002

Fluid outlet

4-in. Fig. 1002

Flushing water inlet

2-in. Fig. 1502

Vent outlet

2-in. Fig. 1502

Solids and water discharge

3-in. Fig. 1502

Footprint (ft [m])

9.5 7.3 [2.9 2.2]

Height (ft [m])

22 [6.7]

Weight (lbm [kg])

Dry

26,400 [12,000]

Wet

29,700 [13,500]

Well Testing Services

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.

Figure 27. Choke manifold.

Table 16. Choke Manifold Specifications

FMF-F

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])

4 to 250 [20 to 121]

4 to 320 [20 to 160]

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

Footprint (ft [m])

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]

Height (ft [m])

3.2 [0.97]

3.2 [0.97]

3.3 [1.02]

3.3 [1.02]

3.3 [1.02]

Weight (lbm [kg])

3785 [1720]

5070 [2300]

4180 [1900]

5510 [2500]

6060 [2750]

Well Testing Services

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.

Heater types and applications

Heaters are used in almost all aspects of petroleum production and processing. They vary in size
and complexity from a simple hot-water bath to a sophisticated cracking furnace in a refinery.
Heaters are generally classified as direct or indirect fired.
In a direct-fired heater, the fluid being heated flows through tubes that are surrounded by a
firebox and are in direct contact with the heat source. A domestic boiler is an example of a
direct-fired heater. There are limitations to the use of direct-fired heaters in the oil industry.
In an indirect fired heater, the well fluid being heated flows through tubes that are surrounded by water in a vessel. The heat source heats the water via a firebox.

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.

Well Testing Services

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.

Figure 29. Steam-heat exchanger.

56

Side View

Steam inlet

Condensate outlet

Front View

Adjustable
choke
Inlet

Bypass
Outlet
Steam inlet

Top View
Inlet
Bypass
Outlet

Figure 30. Three views of a steam-heat exchanger.

Well Testing Services

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

42 in. 15 ft [106 cm 4.57 m]

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

3-in. Fig. 1002

3-in. Fig. 1502

3-in. Fig. 1502

3-in. Fig. 2202

Fluid inlet

3-in. Fig. 1002

3-in. Fig. 1502

3-in. Fig. 1502

3-in. Fig. 2202

Steam inlet

3-in. Fig. 206

3-in. Fig. 206

3-in. Fig. 206

3-in. Fig. 206

Steam outlet

3-in. Fig. 206

3-in. Fig. 206

3-in. Fig. 206

3-in. Fig. 206

Footprint (ft [m])

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]

Height (ft [m])

8.1 [2.5]

8.5 [2.6]

8.5 [2.6]

8.5 [2.6]

Weight (lbm [kg])

19,800 [8980]

26,400 [11,980]

26,400 [ 11,980]

26,840 [12,170]

58

Safety relief valve

Choke

Steam trap

Steam condensate outlet

Manual valves

Steam inlet
Automatic control valve
Effluent
inlet

Effluent
outlet

Temperature controller
Thermometric well

Figure 31. Steam-heat exchanger schematic.

Well Testing Services

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.

Table 18. Indirect-fired Heater Specifications

IHT-BAF
Service

H2S (fluid class DD)

Working temperature (F [C])

32 to 200 [0 to 93]

Working pressure (coil) (psi [bar])

5000 [345] upstream and downstream choke

Heating capacity (MMBtu/hr)

Inlet

3-in. Fig. 1002 F

Outlet

3-in. Fig. 1002 M

Diesel inlet

14-in.

Footprint (ft [m])

19.2 7.4 [5.85 2.25]

Height (ft [m])

13.1 [4.0]

Weight (lbm [kg])

27,450 [12,450]

Well Testing Services

Heat Exchanger

NPT

61

Figure 33. Indirect-fired heater.

Vessel

Fire tube

Liner
Stack

Flange

Figure 34. Indirect-fired heater schematic.

62

Exhaust

Air
intake

Side View

Adjustable
choke
Front View

Inlet
Bypass
Outlet

Top View

Figure 35. Three views of an indirect-fired heater.

Well Testing Services

Heat Exchanger

63

CMA control box

Propane
Automatic control valve
Vent
Diesel
Thermostatic valve
Air

Spark arrestor

Temperature bulb

Coils

Choke box
Effluent

Chimney
Bypass

Effluent

Air ring
Flame arrestor

Diesel burner
Pressure regulator
Mercury bulb

Gas pilot light

Manual valve
Compressed air
Propane
Diesel
Mercury
Well fluid
Water

Figure 36. Indirect-fired heater temperature controls.

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.

Figure 37. Plate-steam exchanger.

Well Testing Services

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

Figure 38. Three views of a plate-steam exchanger.

66

Table 19. Plate-Steam Exchanger Specifications

STX-P
Steam
Service

STX-P
Crude
H2S (fluid class DD)

Working pressure (psi [bar])

174 [12]

464 [32]

Working temperature (F [C])

376 [191]

131 to 194 [55 to 90]

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

Footprint (ft [m])

11.8 5.6 [3.60 1.72]

Height (ft [m])

7.8 [2.40]

Weight (lbm [kg])

8820 [4000]

Well Testing Services

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.

Figure 39. Test separator.

Well Testing Services

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

Second 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

Figure 40. Cross-section schematic of test separator vessel.

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)

and the critical velocity Vc is

Vc =

12Vs L
,
hg

(4)

where
dm

L
h

=
=
=
=
=

liquid droplet diameter (m)

in-situ density (air = 1)
viscosity (cp)
effective vessel length (ft)
pad height (ft)

and the subscripts g and l denote gas and liquid, respectively.

The gas rate in ft3/s is
q g = Ag Vc

(5)

and in MMscf/D is
qg =

(AgVc )P (520)(0.0864) ,
14.73TZ

(6)

where
Ag
P
T
Z

=
=
=
=

gas cross-sectional area (ft )

operating pressure (psi)
operating temperature (R)
gas compressibility factor.

Oil capacity is calculated as

V
Qo = 128 ,
t

(7)

where
Qo = oil capacity (BOPD)
V = oil volume (bbl)
t = retention time (s).

Well Testing Services

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

Gas outlet valves

(GOV)
2
1

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

Figure 41. Separator flow sheet.

72

Type of
Separator

Level
Position
0

Gas Capacity (MMscf/D)

0 10 20 30 40 50 60 70 80 90

+6 in.
Center line
6 in.
200
400
600
800
1000
1200
1440

SEP-T
test separator
42 in. 10 ft, 1440 psi

Liquid Capacity (BOPD)

for 1-min Retention Time
5
10
15
20

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.

Figure 42. Separator capacity.

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.

Well Testing Services

Test Separator

73

Type N test separator (48 in. 12.5 ft, 1440 psi)

Type N separators are designed for high flow rates and high pressure (Fig. 43 and Table 20). They
consist of the following:

48-in. 12.5-ft vessel with access door

removable cyclone inlet cluster
inlet 4-in. fullbore check valve
internal coating of vessel
isolation valves on flow meters (upstream and downstream)
pneumatic control valves on oil and water outlets
two lateral standpipes with oil- and water-level controllers
two pilot-operated safety valves on the vessel and one on the oil inlet manifold together in an
independent discharge line
skid mount with full drip pan, protective frame and protective roof panel.

Figure 43. Type N test separator.

74

Operation
Operational benefits include

foam-free separation (no carryover)

increased achievable flow rates
no emulsion formation
better coalescence from better liquid separation
weight and volume reduction
simple scaling up by adding cyclones
water knockout down to few percent oil
water polishing down to 20-ppm oil.

Table 20. Test Separator Specifications

SEP-NC

SEP-ND

Service

H2S

H2S

Vessel size

48 in. 12.5 ft [122 cm 3.8 m]

48 in. 12.5 ft [122 cm 3.8 m]

Maximum working pressure

(psi at 100F [bar at 38C])

1440 [100]

1440 [100]

Temperature (F [C])

32 to 212 [0 to 100]

32 to 212 [0 to 100]

Working pressure at max temperature

(psi [bar])

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

3-in. Fig. 602

3-in. Fig. 602

Gas outlet

4-in. Fig. 602

4-in. Fig. 602

Oil outlet

3-in. Fig. 602

3-in. Fig. 602

Water outlet

2-in. Fig. 602

2-in. Fig. 602

Relief outlet

4-in. Fig. 602

4-in. Fig. 602

Drain outlet

2-in. Fig. 602

2-in. Fig. 602

Footprint (ft [m])

18.6 7.4 [5.68 2.24]

18.6 7.4 [5.68 2.24]

Height (ft [m])

7.9 [2.42]

7.9 [2.42]

Weight (lbm [kg])

43,210 [19,600]

43,210 [19,600]

Liquid capacity (B/D [m3/d])

Gas capacity (MMscf/D [m3/d])

Low

liquid level (LLL) and high liquid level (HLL) at 720 psi [50 bar]

Well Testing Services

Test Separator

75

Horizontal test separator (42 in. 10 ft, 1440 psi)

The standard three-phase horizontal test separator separates and measures the gas, oil and
water produced by a well. This separator is compatible with all Schlumberger well testing equipment and is used primarily in well testing operations and in cleaning up new completions or
stimulated wells.
The horizontal test separator is a self-contained unit with all valves and pneumatic controls
required to regulate the pressure and fluid levels (Fig. 44 and Table 21). The redundant safety
design incorporates two preset relief valves. The unit consists of the following:
42-in. 10-ft vessel with 18-in. access door
oil compartment with weir
isolation valves on flow meters (upstream and downstream)
flow measuring system for oil with dual flowmeter
flow measuring system for gas with 6-in. orifice meter, orifice set and three-pen recorder
flow measuring system for water
pneumatic control valves on oil and gas outlets
manual control valve on water outlet
two pilot-operated safety valves
safety discharge line connected to gas outlet or an independent gas flare
lateral standpipe with oil-level controller.

76

Side View

Front View

Gas outlet

Oil outlet
Fluid inlet

Water outlet

Top View
Oil outlet

Inlet
Water outlet
Gas outlet

Figure 44. Three views of a standard horizontal separator.

Well Testing Services

Test Separator

77

Table 21. Horizontal Test Separator Specifications

SEP-T

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]

Working pressure at max

temperature (psi [bar])

1440 at 100F [100 at 38C]

1345 at 212F [93 at 100C]

1440 at 100F[100 at 38C]

1345 at 212F [93 at 100C]

1440 at 100F [100 at 38C]

1345 at 212F [93 at 100C]

Temperature (F [C])

32 to 212 [0 to 100]

4 to 212 [20 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

3-in. Fig. 602

3-in. Fig. 602

3-in. Fig. 602

Gas outlet

3-in. Fig. 602

3-in. Fig. 602

3-in. Fig. 602

Oil outlet

2-in. Fig. 602

2-in. Fig. 602

2-in. Fig. 602

Water outlet

2-in. Fig. 602

2-in. Fig. 602

2-in. Fig. 602

Relief outlet

3-in. Fig. 602

3-in. Fig. 602

3-in. Fig. 602

Drain outlet

2-in. Fig. 602

2-in. Fig. 602

2-in. Fig. 602

Footprint (ft [m])

18.6 7.4 [5.68 2.24]

18.6 7.4 [5.68 2.24]

18.6 7.4 [5.68 2.24]

Height (ft [m])

7.9 [2.50]

7.9 [2.50]

7.9 [2.50]

Weight (lbm [kg])

30,800 [14,000]

30,800 [14,000]

30,800 [14,000]

Liquid capacity (B/D [m3/d])

Gas capacity (MMscf/D [Mm3/d])

LLL

78

and HLL at 720 psi [50 bar]

Type G test separator (42 in. 15 ft, 720 psi)

With its extended length vessel, the type G separator (Table 22) has a high liquid capacity at
medium pressure.
Table 22. Type G Test Separator Specifications
SEP-G
Service

H2S

Vessel size

42 in. 15 ft [107 cm 4.57 m]

Maximum working pressure

(psi at 100F [bar at 38C])

720 [50]

Liquid capacity (B/D [m3/d])

LLL

10,500 [1670]

HLL

23,800 [3800]

Gas capacity (MMscf/D [Mm3/d])

LLL

41 [1160]

HLL

18 [510]

Fluid inlet

3-in. Fig. 602

Gas outlet

3-in. Fig. 602

Oil outlet

3-in. Fig. 602

Water outlet

2-in. Fig. 602

Relief outlet

2 relief valves

Drain outlet

2-in. Fig. 602

Length (ft [m])

23.25 [7.09]

Width (ft [m])

7.4 [2.24]

Height (ft [m])

8.0 [2.42]

Weight (lbm [kg])

35,200 [16,000]

LLL

and HLL at 720 psi [50 bar]

Well Testing Services

Test Separator

79

Vertical gas separator (2200 psi)

The vertical gas separator (Figs. 45 and 46 and Table 23) is designed for high gas flow rates.
It consists of the following:

cyclone cluster separating unit

8-in. orifice meter, orifice set and three-pen recorder
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.

Figure 45. Vertical gas separator.

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

Figure 46. Three views of a vertical gas separator.

Well Testing Services

Test Separator

81

Table 23. Vertical Gas Separator Specifications

SEPV-A
Service

H2S

Working pressure (psi at 100F [bar at 38C])

2220 [153]

Working pressure at max temperature (psi [bar])

1970 at 300F [136 at 150C]

Temperature (F [C])

32 to 300 [0 to 149]

Liquid capacity (B/D [m3/d])

1500 [240]

Gas capacity (MMscf/D [Mm3/d])

100 [2800]

Inlet

6-in. 900 RF 4-in. Fig. 1002

Gas outlet

6-in. 900 RF 4-in. Fig. 1002

Oil outlet

2-in. 900 RF 2-in. Fig. 1002

Water outlet

2-in. 900 RF 2-in. Fig. 1002

Drain outlet

2-in. 900 RF 2-in. Fig. 1002

Safety outlet

6-in. 300 RF 6-in. Fig. 206

Footprint (ft [m])

10.6 8.0 [3.23 2.44]

Height (ft [m])

27.3 [8.32]

Weight (lbm [kg])

30,800 [14,000]

82

Oil and Gas Manifolds

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.

Table 24. Oil Manifold Specifications

MFD-BCA
Service

H2S

Working pressure
(psi at 100F [bar at 38C])

1440 [100]

(psi at 212F [bar at 100C])

1345 [93]

Temperature (F [C])

32 to 212 [0 to 100]

Inlet

3-in. Fig. 602

Outlet

3-in. Fig. 602

Footprint (ft [m])

7.1 2.3 [2.16 0.71]

Height (ft [m])

1.4 [0.44]

Weight (lbm [kg])

880 [400]

Well Testing Services

Oil and Gas Manifolds

83

Figure 47. Oil manifold.

From gauge tank

To burners
To gauge tank

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.

Figure 49. Gas manifold.

To burner

To burner

From separator
Figure 50. Flow directions through the gas manifold.

Well Testing Services

Oil and Gas Manifolds

85

Table 25. Gas Manifold Specifications

MFD-ADB

MFD-BDA

H2S

H2S

(psi at 100F [bar at 38C])

1440 [100]

1440 [100]

(psi at 212F [bar at 100C])

1345 [93]

1345 [93]

Temperature (F [C])

32 to 212 [0 to 100]

32 to 212 [0 to 100]

Inlet

3-in. Fig. 602

4-in. Fig. 602

Outlet

3-in. Fig. 602

4-in. Fig. 602

Footprint (ft [m])

5.0 1.0 [1.5 0.38]

5.9 1.5 [1.80 0.45]

Height (ft [m])

1.3 [0.40]

1.5 [0.46]

Weight (lbm [kg])

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

single-compartment vessel (Table 26)

dual-compartment vessel, which enables one compartment to be emptied with a transfer
pump while the other is being filled (Table 27).

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.

Well Testing Services

Tanks

87

Figure 51. Vertical surge tank.

88

Top View

Front View

Oil inlet

Gas outlet

Oil outlet

Safety outlet

Side View

Oil inlet
Oil outlet

Gas outlet
Safety outlet

Figure 52. Three views of a vertical surge tank.

Well Testing Services

Tanks

89

Table 26. Single-Compartment Surge Tank Specifications

VST-BA

VST-BB

VST-BC

Service

H2S

H2S

H2S

Working pressure (psi [bar])

50 [3.5]

50 [3.5]

50 [3.5]

Temperature (F [C])

4 to 212 [20 to 100]

32 to 212 [0 to 100]

4 to 212 [20 to 100]

Capacity (bbl [m3])

80 [12.2]

80 [12.2]

80 [12.2]

Oil inlet

3-in. Fig. 602

3-in. Fig. 602

3-in. Fig. 602

Oil outlet

3-in. Fig. 602

3-in. Fig. 602

3-in. Fig. 602

Gas outlet

4-in. Fig. 602

4-in. Fig. 602

4-in. Fig. 602

Safety outlet

4-in. Fig. 602

4-in. Fig. 602

4-in. Fig. 602

Drain

3-in. Fig. 602

3-in. Fig. 602

3-in. Fig. 602

Footprint (ft [m])

8.0 7.9 [2.45 2.40]

8.0 7.9 [2.45 2.40]

8.0 7.9 [2.45 2.40]

Height (ft [m])

19.7 [6.0]

19.7 [6.0]

19.7 [6.0]

Weight (lbm [kg])

13,420 [6000]

13,420 [6000]

13,420 [6000]

VST-BC

has an ANSI class 600 oil manifold.

Table 27. Dual-Compartment Surge Tank Specifications

VST-FA

VST-FB

VST-N

Service

H2S

H2S

H2S

Working pressure (psi [bar])

50 [3.5]

50 [3.5]

50 [3.5]

Temperature (F [C])

4 to 212 [20 to 100]

32 to 212 [0 to 100]

4 to 212 [20 to 100]

Capacity (bbl [m3])

2 50 [2 8]

2 50 [2 8]

2 50 [2 8]

Oil inlet

3-in. Fig. 602

3-in. Fig. 602

3-in. Fig. 602

Oil outlet

3-in. Fig. 602

3-in. Fig. 602

3-in. Fig. 602

Gas outlet

4-in. Fig. 602

4-in. Fig. 602

4-in. Fig. 602

Safety outlet

4-in. Fig. 602

4-in. Fig. 602

4-in. Fig. 602

Drain

3-in. Fig. 602

3-in. Fig. 602

3-in. Fig. 602

Footprint (ft [m])

8.0 6.2 [2.45 1.89]

8.0 6.2 [2.45 1.89]

8.0 6.2 [2.45 1.89]

Height (ft [m])

25.0 [7.60]

25.0 [7.60]

25.0 [7.60]

Weight (lbm [kg])

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.

Atmospheric gauge tank

The gauge tank (Fig. 53 and Table 28) is a nonpressurized vessel used to measure low flow rates
or to calibrate inferential or positive-displacement meters. It has two compartments, one of
which can be emptied by the transfer pump while the other is being filled. The sight-glass level
is used to calculate the change in volume based on the physical dimensions of the tank.
Safety features include flame arrestors on each vent of the gauge tank and a thief hatch in case
the vessel is accidentally overpressured. The grounding strap attached to the tank prevents the
buildup of static charge.
The gauge tank cannot be used when H2S is present in the effluent because the gas released
from the tank is vented to the atmosphere, where it could endanger personnel.
Side View

Front View

Oil outlet
Oil inlet

Flame arrestor

Top View

Oil outlet
Oil inlet

Figure 53. Three views of an atmospheric gauge tank.

Well Testing Services

Tanks

91

Table 28. Atmospheric Gauge Tank Specifications

FGTS-B

FGTS-C

Service

General

General

Working pressure (psi [bar])

Atmospheric

Atmospheric

Temperature (F [C])

32 to 212 [0 to 100]

32 to 212 [0 to 100]

Capacity (bbl [m3])

2 50 [2 8]

2 100 [2 16]

Oil inlet

2-in. Fig. 602

2-in. Fig. 602

Oil outlet

3-in. Fig. 602

3-in. Fig. 602

Footprint (ft [m])

19.3 7.2 [5.90 2.20]

25.5 7.9 [7.75 2.40]

Height (ft [m])

8.5 [2.60]

9.7 [2.95]

Weight (lbm [kg])

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.

Figure 54. Gear-type pump.

Well Testing Services

Transfer Pump

93

Centrifugal transfer pump

The transfer pump unit consists of a centrifugal pump (Figs. 55 and 56 and Table 29) driven by
an electric motor with a Star/Delta starter.
Table 29. Centrifugal Transfer Pump Specifications
PMP-GA

PMP-GD

Service

H2S

H2S

Outlet pressure (psi [bar])

410 [28]

300 [20]

Temperature (F [C])

4 to 212 [20 to 100]

32 to 212 [0 to 100]

Flow rate at outlet pressure (B/D [m3/d])

10,000 [1590]

5000 [795]

Motor

Electric 125 kW

Electric 49 kW

Inlet

3-in. Fig. 602

2-in. Fig. 602

Outlet

3-in. Fig. 602

2-in. Fig. 602

Footprint (ft [m])

9.4 4.3 [2.9 1.3]

6.7 4.0 [2.2 1.2]

Height (ft [m])

17.4 [2.30]

5.2 [1.60]

Weight (lbm [kg])

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

Figure 56. Three views of a centrifugal transfer pump.

Well Testing Services

Transfer Pump

95

Screw-type transfer pump

The transfer pump unit (Figs. 57 and 58 and Table 30) consists of a screw-type pump driven by
an electric motor with a Star/Delta starter or by a diesel motor.
Table 30. Screw-Type Transfer Pump Specifications
PMP-EDC

PMP-TDC

Service

Not NACE

Not NACE

Outlet pressure (psi [bar])

300 [20]

300 [20]

Temperature (F [C])

32 to 200 [0 to 93]

32 to 200 [0 to 93]

Flow rate at outlet pressure (B/D [m3/d])

4000 [636]

4000 [636]

Motor

Electric 30 kW

Diesel 52 hp

Inlet

3-in. Fig. 602

3-in. Fig. 602

Outlet

3-in. Fig. 602

3-in. Fig. 602

Footprint (ft [m])

11.0 2.8 [3.35 0.85]

12.1 2.8 [3.70 0.85]

Height (ft [m])

4.7 [1.42]

5.0 [1.53]

Weight (lbm [kg])

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

Figure 58. Two views of the screw-type transfer pump.

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Transfer Pump

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Gear-type transfer pump

The transfer pump unit (Figs. 59 and 60 and Table 31) consists of a gear-type pump driven by an
electric motor with a Star/Delta starter or by a diesel motor.
Table 31. Gear-type Transfer Pump Specifications
PMP-ECB

PMP-TCB

Service

Not NACE

Not NACE

Outlet pressure (psi [bar])

200 [13.8]

200 [13.8]

Temperature (F [C])

32 to 200 [0 to 93]

32 to 200 [0 to 93]

Flow rate at outlet pressure (B/D [m3/d])

2000 [318]

2000 [318]

Motor

Electric 11 kW

Diesel 15 hp

Inlet

3-in. Fig. 602

3-in. Fig. 602

Outlet

2-in. Fig. 602

2-in. Fig. 602

Footprint (ft [m])

4.3 2.2 [1.30 0.68]

4.9 2.4 [1.50 0.72]

Height (ft [m])

2.8 [0.86]

6.3 [1.91]

Weight (lbm [kg])

946 [430]

1078 [490]

Discharge

Idler
Suction
Rotor

Figure 59. Gear-type transfer pump cross section.

98

Side View

Outlet
Inlet

Gear pump

Front View

Outlet

Motor

Inlet
Gear pump

Control box

Figure 60. Two views of a gear-type transfer pump.

Well Testing Services

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:

on- and offshore well testing

well cleanup
waste disposal
disposal of oil-base mud
disposal of foam during stimulation jobs
safety on drilling rigs in case of kick.

Unusual applications for burners include burning high-viscosity oil from a sunken tanker or
burning the oil emulsion collected on beaches after a release.

Benefits and features

Burners have the following features and benefits:

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.

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Oil Burners and Booms

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

Figure 61. EverGreen burner.

102

Table 32. EverGreen Burner Specifications

BRHE-AC
Service

H2S

Heads

1 with 12 nozzles

Maximum oil pressure (psi [bar])

960 [66.2]

Oil capacity at oil pressure (BOPD [m3/d])

Max 12,000 at 480 psi [1908 at 33 bar]

Min 2,500 at 100 psi [397 at 7 bar]

Water shield pressure (psi [bar])

150 [10.3]

Water shield capacity (BWPD [m3/d])

15,000 [2385]

Air capacity at max flow rate (ft3/min [m3/min])

5 1200 [5 185]

Oil inlet

3-in. Fig. 206

Water inlet

4-in. Fig. 206

Air inlet

4-in. Fig. 206

Heat radiation (Btu/hr/ft2 at 100 ft)

650 (with water screen)

Noise (dBA at 100 ft)

90

Footprint (ft [m])

14.8 5.2 [4.50 1.6]

Height (ft [m])

8.2 [2.50]

Weight (lbm [kg])

1980 [900]

Air

Oil

Air

Figure 62. EverGreen burner nozzle schematic.

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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 and air lines

Oil inlet

Gas line
Figure 63. EverGreen burner mounted on boom.

104

Boom

Green Dragon high-efficiency burner

The three-head Green Dragon high-efficiency burner (Fig. 64 and Table 33) provides clean disposal of the oil produced during well testing. It consists of the following:

pneumatic actuators on the oil and air valves

pneumatic control panel for high-efficiency burning and rotation control
rotation system and swivel joint distributor (Fig. 65)
gas pilot light and electric ignition.

Figure 64. Green Dragon three-head burner.

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Oil Burners and Booms

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Table 33. Green Dragon High-Efficiency Burner

BRN-HBD

BRN-HCB

Service

H2S

H2S

Heads

Working pressure (psi [bar])

300 [20]

300 [20]

Capacity at working pressure

(BOPD [m3/d])

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

3-in. Fig. 206

3-in. Fig. 206

Water inlet

3-in. Fig. 206

3-in. Fig. 206

Air inlet

2-in. Fig. 206

2-in. Fig. 206

Footprint (ft [m])

5.4 4.4 [1.65 1.33]

5.4 4.4 [1.65 1.33]

Height (ft [m])

11.6 [3.53]

8.3 [2.53]

Weight (lbm [kg])

2090 [950]

2530 [1150]

106

Water ring
Cylindrical hearth
Water nozzle
Atomizer
Pilot light
Ball valve
Supporting frame

Oil check valve

Rotation system

Oil

Air

Swivel joint

Water
Figure 65. Green Dragon burner schematic.

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Oil Burners and Booms

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.

Table 34. Mud Burner Specifications

BRN-HEA
Service

H2S

Heads

Working pressure (psi [bar])

300 [20]

Capacity at working pressure

(BOPD [m3/d])

5000 [795]

Water pressure (psi [bar])

150 [10.3]

Temperature (F [C])

32 to 200 [0 to 93]

Power supply

110/220 VAC

Mud or oil inlet

3-in. Fig. 206

Water inlet

3-in. Fig. 206

Air inlet

2-in. Fig. 206

Diesel inlet
Upper head

1-in. Fig. 206

Lower heads

2-in. Fig. 206

Footprint (ft [m])

5.3 4.5 [1.63 1.36]

Height (ft [m])

9.2 [2.81]

Weight (lbm [kg])

1870 [1050]

108

Drip pan

Mud or crude oil

Diesel oil
Air
Water
Diesel oil

Figure 66. Mud burner inlet flows.

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Oil Burners and Booms

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

Rotating base plate

Figure 67. Burner boom piping and double-rotating base plate.

Well Testing Services

Oil Burners and Booms

111

Standard burner boom

The standard boom has the piping situated laterally on the side of the boom (Fig. 68 and
Table 35).

D2
E1
E2

D1

Figure 68. Standard burner boom.

Table 35. Standard Burner Boom Specifications

UBM-F

UBM-G

Service

H2S

H2S

Sections

Burner

4 head max

4 head max

Wind capacity (mph [km/h])

100 [160]

100 [160]

Temperature (F [C])

32 to 212 [0 to 100]

32 to 212 [0 to 100]

Gas line

3-in. Fig. 206

3-in. Fig. 206

Oil line

3-in. Fig. 206

3-in. Fig. 206

Water line

3-in. Fig. 206

3-in. Fig. 206

Air line

2-in. Fig. 206

2-in. Fig. 206

Total length (ft [m])

60 [18]

85 [26]

Width (ft [m])

2.9 [0.89]

2.9 [0.89]

Weight (lbm [kg])

10,800 [4900]

15,210 [6900]

Dynamic,

112

no ice

Oil line

Water line

Air line

D1

Gas line

D2

Additional gas line

E1

Pilot line

E2

Cable

Water-wall screen line

Heavy-duty burner boom

Designed for the North Sea, the heavy-duty burner boom (Fig. 69 and Table 36) can withstand
winds up to 100 mph as well as ice conditions. The piping is below the gangway.

E1
E2

Oil line

Water line

Air line

D1

Gas line

D2

Gas line (optional)

E1

Pilot line

E2

Pilot cable

Water screen

D2

D1

Figure 69. Heavy-duty burner boom piping.

Table 36. Heavy-Duty Burner Boom Specifications

UBB-A

UBB-B

Service

H2S

H2S

Sections

Burner

6 head

6 head

Wind capacity (mph [km/h])

100 [160]

100 [160]

Temperature (F [C])

4 to 212 [20 to 100]

4 to 212 [20 to 100]

Gas line

3-in. Fig. 206

3-in. Fig. 206

Oil line

3-in. Fig. 206

3-in. Fig. 206

Water line

3-in. Fig. 206

3-in. Fig. 206

Air line

4-in. Fig. 206

4-in. Fig. 206

Total length (ft [m])

85 [26]

60 [18]

Width (ft [m])

3.6 [1.10]

3.6 [1.10]

Weight (lbm [kg])

16,980 [7700]

11,680 [5300]

Dynamic,

2 in. of ice

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Oil Burners and Booms

113