Documente Academic
Documente Profesional
Documente Cultură
Services
Schlumberger 2000
Schlumberger
225 Schlumberger Drive
Sugar Land, Texas 77478
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copying and recording, without prior written permission
of the publisher.
SMP-7086-3B
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Surface testing equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Standard set of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Equipment layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Classified zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Zone 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Zone 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Zone 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clean zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety standards for equipment layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
H2S service requirements and safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operation guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Equipment safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Heat radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Advanced Well Test Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Well test design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Equipment safety barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Surface safety systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Emergency shutdown system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Surface safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Flowhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
218-in. lightweight flowhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
214-in. flowhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
318- and 3116-in. flowheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
618-in. flowhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Data Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Sand-Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Dual-pot sand filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Sand separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cyclonic desander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Choke Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Heater types and applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Hydrate prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Viscosity reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Emulsion breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Steam-heat exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Indirect-fired heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Plate-steam exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Test Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Separator vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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
safety requirements.
A reservoir test can be performed only under dynamic conditions, which means that the reser-
voir 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 distur-
bance; this is called buildup. A pressure disturbance can also be created in a flowing well by
either increasing or decreasing the flow rate.
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).
2
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 iden-
tifies 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 fur-
ther 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.
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 shut-
down 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.
4
Recommended distances among equipment pieces also affect onshore and offshore surface
testing layouts (Figs. 3 and 4, respectively).
Zone 1 Zone 2
Surge tank: 45-ft [15-m] around Heat exchanger: 30-ft [10-m] around
Zone 1 Zone 2
6
a
b
d
c
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]
d c
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]
8
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).
Water solubility Four volumes of gas in one volume of water at 32F [0C]
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.
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 appropri-
ate 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.
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
1000 bbl water per Injected into the flame absorbs 6 MMBtu/hr
day (BWPD)
95 4 hr/D
100 2 hr/D
105 1 hr/D
110 2 hr/D
1
115 10 min/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 Electrotech-
nical 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.
All Schlumberger testing operations, together with all Schlumberger-manufactured surface test-
ing 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.
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 temper-
ature 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.
FLOWLINE UPSTREAM PT-201 (4-20mA SIGNAL TO CPU IN CONTROL ROOM) THIS INSTRUMENT PERFORMS THE PSHH, PSL & PSLL PRESSURE FUNCTIONS.
CHOKE PSHH-201 1 SEC X X X X 100% WP
PRESSURE PSL-201 1 SEC X X 500 PSIG
PSLL-201 1 SEC X X X X 200 PSIG
LOOP X
FLOWLINE DOWNSTREAM PT-202 (4-20mA SIGNAL TO CPU IN CONTROL ROOM) THIS INSTRUMENT PERFORMS THE PSHH, PSL & PSLL PRESSURE FUNCTIONS.
TO HEAT CHOKE PSHH-202 1 SEC X X X X 100% WP
EXCHANGER PRESSURE PSH-202 1 SEC X X 60% WP
PSLL-202 1 SEC X X X X 100 PSIG
LOOP X
H-002 PRESSURE PT-301 (4-20mA SIGNAL TO CPU IN CONTROL ROOM) THIS INSTRUMENT PERFORMS THE PSHH, PSL & PSLL PRESSURE FUNCTIONS.
HEAT OIL LINE PSHH-301 1 SEC X X X X 100% WP
EXCHANGER FROM PSH-301 1 SEC X X 80 % WP
HEATER TO PSLL301 1 SEC X X X X 100 PSIG
SEPARATOR PSV-003 1260 PSIG X
LOOP X
H-002 PRESSURE PT-322 (4-20mA SIGNAL TO CPU IN CONTROL ROOM) THIS INSTRUMENT PERFORMS THE PSHH, PSL & PSLL PRESSURE FUNCTIONS.
HEAT VESSEL PSHH-322 1 SEC X X X X 145 PSIG
EXCHANGER PSH-322 1 SEC X X 120 PSIG
PSLL322 1 SEC X X 30 PSIG
PSV-002 220 PSIG X SET POINT AT AMBIENT TEMP
LOOP X
D-001 PRESSURE PT-101 (4-20mA SIGNAL TO CPU IN CONTROL ROOM) THIS INSTRUMENT PERFORMS THE PSHH, PSL & PSLL PRESSURE FUNCTIONS.
SEPARATOR PSHH-101 1 SEC X X X X 83% WP
PSH-101 1 SEC X X 65% WP
PSL-101 1 SEC X X 15% WP
PSLL-101 1 SEC X X X X 100 PSIG
PSV-004 1197 PSIG X
PSV-005 1260 PSIG X
LOOP N/A X
OIL LEVEL LT-111 (4-20mA SIGNAL TO CPU IN CONTROL ROOM) THIS INSTRUMENT PERFORMS THE PSHH, PSL & PSLL PRESSURE FUNCTIONS.
LSHH-111 2 SEC X X X X 55 CM Top of sightglass
LSH-111 2 SEC X X 50 CM 5cm < top of sightglass
LSL-111 2 SEC X X 5 CM 5cm > bottom of sightglass
LSLL-111 2 SEC X X X X 0 CM Bottom of sightglass
LOOP X
D-002 PRESSURE PT-401 (4-20mA SIGNAL TO CPU IN CONTROL ROOM) THIS INSTRUMENT PERFORMS THE PSHH, PSL & PSLL PRESSURE FUNCTIONS.
SURGE TANK PSHH-401 1 SEC X X X X 50 PSIG
PSH-401 1 SEC X X 35 PSIG
PSLL-401 1 SEC X X 0 PSIG
PSV-006 50 PSIG X
LOOP X
OIL LEVEL LT-411 (4-20mA SIGNAL TO CPU IN CONTROL ROOM) THIS INSTRUMENT PERFORMS THE PSHH, PSL & PSLL PRESSURE FUNCTIONS.
LSHH-411 2 SEC X X X X Top of sightglass
LSH-411 2 SEC X X 20cm < top of sightglass
LSLL-411 2 SEC X X Bottom of sightglass
LOOP X
18
Customer :
Rig :
Well : Job No.:
SAFETY SYSTEM PHILOSOPHY Updated:
FIRST STAGE
Well parameters ( pressure, temperature and flow rates ) are continuously
monitored by the following :-
SECOND STAGE
Emergency shut down system
THIRD STAGE
Pressure safety valves (PSV) venting to safe areas from the following points:
This system is designed to protect from any blockage/rupture in the well test train between
the rig floor and burners
COMPONENT : Customer :
SAFETY Rig :
ANALYSIS Well : Job N:
SEPARATOR
TABLE Updated:
UNDESIRABLE EVENT CAUSE DETECTABLE CONDITION PROTECTION
AT COMPONENT PRIMARY SECONDARY
GAS BLOW-BY LEVEL CONTROL FAILURE LOW LIQUID LEVEL LSL-111 ESD
NOTE 2
NOTE 1 : EQUIPMENT DOWNSTREAM CAN SAFELY HANDLE MAXIMUM LIQUID CARRY-OVER. SEPARATOR CONTINUOUSLY MANNED
DURING OPERATIONS
NOTE 2 : EQUIPMENT DOWNSTREAM CAN SAFELY HANDLE MAXIMUM GAS RATES THAT CAN BE DISCHARGED THROUGH LIQUID OUTLET
SEPARATOR CONTINUOUSLY MANNED DURING OPERATIONS
20
Equipment safety barriers
Safety barriers and ESD systems must comply at a minimum with the Schlumberger internal
pressure policy, as summarized in Table 6.
4
3 2
6
8 5
9
11
12
10
1-Flowhead 8-Separator
2-Safety valve 9-Surge tank
13 3-Emergency shutdown 10-Transfer pump
4-Sand filter unit 11-Oil manifold
5-Choke manifold 12-Gas manifold
6-Steam exchanger 13-Burner boom
14 7-Steam generator 14-EverGreen burner
22
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.
ESD
Air control
supply console
Surge tank
Actuator
control ESD
line station
Separator
Flowhead
Steam exchanger
Surface safety valve
ESD
Pilot
station
02500 psi
Floor choke
manifold Erosion probe
Pilot 010,000 psi
In well testing operations, the ESD system controls the hydraulically operated flowline valve
on the flowhead. If required by the surface testing setup, it can also control an additional safety
valve, which can be located upstream of the choke. Pressure is applied to open valves and
released to close valves.
An ESD is push-button activated from stations located at the separator, heater or steam
exchanger, and tank. Another station is usually positioned at an escape route. Backing up the
ESD stations are high- and low-pressure pilots on the flowline upstream of the choke manifold,
upstream of the heater or steam exchanger and upstream of the separator (Fig. 12). The high-
pressure 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
PI 0150 psi
Erosion
High pilot Low pilot probe
Air vessel
ESD stations
Flowline
Actuator
Outlet
Inlet
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]
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
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.
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
Swivel
Flowline
Bottom 312-in. IF
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
Swivel
Master valve
Bottom 312-in. IF
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
Flowline
Kill line
Swivel
Master valve
Working pressure (psi [bar]) 5000 [345] 10,000 [690] 15,000 [1,035]
Temperature (F [C]) 4 to 250, 320 for 12 hr [20 to 121, 160 for 12 hr]
(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]
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]
Skid dimensions (ft [m]) 12.1 4.6 1.0 15.0 3.9 6.6 15.0 6.6 3.6
[3.7 1.4 0.3] [4.6 1.2 2.0] [4.6 2.0 1.1]
Skid weight (lbm [kg]) 1000 [455] 7040 [3200] 7040 [3200]
36
618-in. flowhead
The 618-in. flowhead (Fig. 18 and Table 11) is designed for high flow rates. It consists of
flowhead assembly
swab manual gate valve
two wing valves, one with a hydraulic actuator (flowline)
independent master valve
flowhead swivel
transportation basket.
Bottom On request
Skid dimensions (ft [m]) 15.0 6.6 3.9 [4.6 2.0 1.2]
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 Snap-
tite, Inc.
The specialized FHH-E data header flowline (Fig. 20) incorporates connections for sand
detection:
5 NPT ports (12-in. [12.7-mm] diameter)
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]
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]
Whenever solids are produced during a well test or cleanup operations, sand-handling equip-
ment 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.
Filter pot
Fluid inlet
Drain valve
Drain
Fluid inlet
Fluid outlet
Bypass valve
Top View
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
Flow rate
Footprint (ft [m]) 9.2 7.2 [2.8 2.2] 9.2 7.2 [2.8 2.2]
manifold
Operation
Sand removal through the sand line enables continuous operation.
46
Side View
Fluid inlet
Front View
Top View
Fluid outlet
Fluid inlet
Solid outlet
Gas outlet
Working pressure
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 accu-
mulator (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 sepa-
rated 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 accu-
mulator 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.
50
Table 15. Cyclonic Desander Specifications
SFCU-A
Service H2S
Flow rate
In 600
Out 10 to 20
Desander
Accumulator
Fluid outlet
Fluid inlet
Solid outlet
Solid outlet
Fluid inlet
Fluid outlet
Flush line
Top View
52
Choke Manifold
The choke manifold (Fig. 27 and Table 16) controls the fluid from the well by reducing the flow-
ing 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 down-
hole pressure and flow rate.
Working pressure 5000 [345] 5000 [345] 10,000 [690] 10,000 [690] 15,000 [1035]
(psi [bar])
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 7.2 6.2 8.2 6.9 8.5 7.2 8.2 6.9
[1.9 1.8] [2.2 1.9] [2.5 2.1] [2.6 2.2] [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]
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 read-
ing 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
54
Heat Exchanger
Heat exchangers, commonly called heaters, raise the temperature of well effluents, which pre-
vents hydrate formation, reduces viscosity and breaks down emulsions to facilitate the
separation of oil and water.
Hydrate prevention
Natural gas contains water vapor. Under certain choked flow conditions, sufficient expansion
occurs to lower the temperature of the flow and cause hydrate formation, which is when parti-
cles 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 hydro-
carbons are dissolved in water under low-temperature and high-pressure conditions. High
velocity, pressure pulsation and agitation accelerate the phenomenon, as do certain gases, par-
ticularly 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 high-
viscosity 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.
56
Side View
Front View
Adjustable
choke
Inlet
Bypass
Outlet
Steam inlet
Top View
Inlet
Bypass
Outlet
Working pressure (psi [bar]) 4900 [338] 10,000 [690] 10,000 [690] 15,000 [1035]
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 21.3 7.7 21.3 7.7 21.3 7.7
[6.1 2] [6.5 2.3] [6.5 2.3] [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 inlet
Air Controller
Automatic
control valve
Steam
Effluent
Effluent
Choke box
Steam
Steam exchanger
Steam generator
60
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.
Working pressure (coil) (psi [bar]) 5000 [345] upstream and downstream choke
Vessel
Fire tube
Liner
Stack
Flange
62
Exhaust
Air
intake
Side View
Adjustable
choke
Front View
Inlet
Bypass
Outlet
Top View
Propane
Automatic control valve
Vent
Diesel
Thermostatic valve
Air
Spark arrestor
Temperature bulb Coils Choke box
Effluent
Chimney
Bypass
Flame arrestor
Diesel burner
Pressure regulator
Mercury bulb Gas pilot light
Manual valve
Compressed air
Propane
Diesel
Mercury
Well fluid
Water
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 con-
ditioning 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 temper-
ature of the crude through the steam flow.
Operation
The plate-steam exchanger requires clean liquid.
Outlet
Safety valve
Safety valve
Inlet
Side View
Top View
Inlet
Outlet
66
Table 19. Plate-Steam Exchanger Specifications
STX-P STX-P
Steam Crude
Service H2S (fluid class DD)
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 inter-
nal 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.
Mist extractor
Access door
The vessel capacity for each phase depends on the in-situ conditions of pressure and temper-
ature and in-situ effluent properties such as
viscosities and densities of the liquids, which are a function of the amount of dissolved gas
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
dm l g
Vs = 0.0019 (1)
Cd g
24 3
Cd = + 1/ 2 + 0.34 (2)
Re Re
Re = 0.0049dm Vs ( ) g , (3)
g
70
and the critical velocity Vc is
12Vs L
Vc = , (4)
hg
where
dm = liquid droplet diameter (m)
= in-situ density (air = 1)
= viscosity (cp)
L = effective vessel length (ft)
h = 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) , (6)
14.73TZ
where
Ag = gas cross-sectional area (ft )
P = operating pressure (psi)
T = operating temperature (R)
Z = gas compressibility factor.
V
Qo = 128 , (7)
t
where
Qo = oil capacity (BOPD)
V = oil volume (bbl)
t = retention time (s).
P2
Gas metering
Air PGV2
supply
Relief
valve
PCV7 Gas outlet valves
PCV2 1 2 T3 4 3 (GOV)
4
3 2
1
T2 6
5
PGV3 P3 Nonreturn
swing valve
GOV7
GOV6 Safety valves
PGV1
PCV1 P1
T1 PCV3 PCV4
5
5
1 V3
3
T5 1
6 V1
4
2
6 7
2
8 Water outlet V2
3 4
7 5 WOV1
Liquid 1 WOV2
Shrinkage levels 3
tester V4
valves
valves (SLV) (LLV) 2 2 3
1 4
5 PCV6
Oil metering T4
Oil outlet valves (OOV)
Inlet line
Gas line
Oil line
Water line
72
Type of Level Liquid Capacity (BOPD) Gas Capacity (MMscf/D)
Separator Position for 1-min Retention Time
0 5 10 15 20 0 10 20 30 40 50 60 70 80 90
+6 in.
SEP-T
test separator Center line
42 in. 10 ft, 1440 psi
6 in.
600
800
1000
1200
1440
200
400
SEP-G +6 in.
test separator Center line
42 in. 15 ft, 720 psi
6 in.
200
400
600
720
SEP-N +6 in.
test separator Center line
48 in. 12.5 ft, 1440 psi
6 in.
200
400
600
800
1000
1200
1440
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.
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.
Vessel size 48 in. 12.5 ft [122 cm 3.8 m] 48 in. 12.5 ft [122 cm 3.8 m]
Footprint (ft [m]) 18.6 7.4 [5.68 2.24] 18.6 7.4 [5.68 2.24]
flow measuring system for gas with 6-in. orifice meter, orifice set and three-pen recorder
76
Side View
Front View
Top View
Oil outlet
Inlet
Water outlet
Gas outlet
Working pressure at max 1440 at 100F [100 at 38C] 1440 at 100F[100 at 38C] 1440 at 100F [100 at 38C]
temperature (psi [bar]) 1345 at 212F [93 at 100C] 1345 at 212F [93 at 100C] 1345 at 212F [93 at 100C]
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]
78
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.
LLL 41 [1160]
HLL 18 [510]
80
Front View Side View
Gas outlet
Fluid inlet
Oil outlet
Top View
Safety outlet Water outlet
Working pressure at max temperature (psi [bar]) 1970 at 300F [136 at 150C]
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 flow-
line. 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 stop-
ping 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.
Working pressure
To burners
To gauge tank
From separator
84
Gas manifold
The gas manifold (Fig. 49 and Table 25) directs the gas produced from the separator to the port
or starboard flareport a function of wind direction (Fig. 50). It consists of a skid-mounted assembly
with two ball valves.
To burner To burner
From separator
Working pressure
Footprint (ft [m]) 5.0 1.0 [1.5 0.38] 5.9 1.5 [1.80 0.45]
86
Tanks
Gauge and surge tanks are one of the methods used to measure the liquid flow rate from the sep-
arator. 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 compart-
ment 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.
88
Front View Top View
Oil inlet
Safety outlet
Side View
Temperature (F [C]) 4 to 212 [20 to 100] 32 to 212 [0 to 100] 4 to 212 [20 to 100]
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]
Temperature (F [C]) 4 to 212 [20 to 100] 32 to 212 [0 to 100] 4 to 212 [20 to 100]
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]
90
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
Oil outlet
Oil inlet
Footprint (ft [m]) 19.3 7.2 [5.90 2.20] 25.5 7.9 [7.75 2.40]
92
Transfer Pump
A transfer pump connected to the gauge tank outlet is used to empty one of the tank compart-
ments 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 high-
capacity, 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.
Flow rate at outlet pressure (B/D [m3/d]) 10,000 [1590] 5000 [795]
Footprint (ft [m]) 9.4 4.3 [2.9 1.3] 6.7 4.0 [2.2 1.2]
Outlet
Cut water
Impeller
Volute
Inlet
94
Front View
Control box
Outlet
Inlet
Side View
Centrifugal pump
Flow rate at outlet pressure (B/D [m3/d]) 4000 [636] 4000 [636]
Footprint (ft [m]) 11.0 2.8 [3.35 0.85] 12.1 2.8 [3.70 0.85]
Inlet
Rubber stator
Outlet
96
Side View
Inlet
Outlet
Rotor pump
Front View
Motor
Flow rate at outlet pressure (B/D [m3/d]) 2000 [318] 2000 [318]
Footprint (ft [m]) 4.3 2.2 [1.30 0.68] 4.9 2.4 [1.50 0.72]
Discharge
Idler
Suction
Rotor
98
Side View
Outlet
Inlet
Gear pump
Inlet Motor
Gear pump Control box
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.
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 usu-
ally requires varying the air, water and oil pressures and flow rates so that the flame does not
produce excessive black smoke (too rich in oil) or excessive white smoke (too rich in water). The
size of the air and oil nozzles also plays a major role in the burning process. Generally, a small
nozzle aids in the atomization process, but it also creates a larger backpressure, which limits the
flow rate through the burner. Charts are used based on flow rate to select the optimum nozzle sizes.
EverGreen burner
Development of the EverGreen burner was supported by European Economic Union THERMIE
funding with participation of the Institut Franais du Ptrole. The single-head, 12-nozzle system
effectively leverages pneumatic atomization and enhanced air induction (Fig. 61 and Table 32).
No water injection into the flame is required (Fig. 62).
Nozzle
Ignitor
Pilot
Propane line
Oil inlet
102
Table 32. EverGreen Burner Specifications
BRHE-AC
Service H2S
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]
Air
Oil
Air
Nozzle
Pilot
Water curtain
Propane line
Oil inlet
Gas line
104
Green Dragon high-efficiency burner
The three-head Green Dragon high-efficiency burner (Fig. 64 and Table 33) provides clean dis-
posal 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.
Heads 3 4
Footprint (ft [m]) 5.4 4.4 [1.65 1.33] 5.4 4.4 [1.65 1.33]
106
Water ring
Cylindrical hearth
Water nozzle
Atomizer
Pilot light
Ball valve
Supporting frame
Rotation system
Oil
Water
Heads 3
Diesel inlet
108
Drip pan
Air
Water
Diesel oil
110
Foot section
Head section
A Oil line
B Water line
D2 C Air line
D1 Gas line
E1 F D2 Additional gas line
E2
E1 Pilot line
A C E2 Cable
F Water-wall screen line
B D1
Sections 2 3
112
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.
A Oil line
B Water line
C Air line
D1 Gas line
D2 Gas line (optional)
E1 Pilot line
E2 Pilot cable
F Water screen
F E1 C
E2
A B
D2 D1
Sections 3 2