Surface WELL TESTING

SERVICES

Prepared by: Mohamed Korany

WELL TESTING
Well Testing Equipment
 STANDARD SURFACE TEST EQUIPMENT LAYOUT
Off-Shore
Surface Test Tree
Choke Manifold Separator Test Tank

Indirect Heater

Transfer Pump

Burner Burner

Burner Boom Burner Boom

Surface Test Tree

Provides Temporary
Wellhead during
Testing Operations
 Surface Test Tree
Equipment Purpose and Requirements
• Surface Test Tree
• To direct and control the flow of the equipment from the
tubing to the process equipment.
• Comprises of Four Valves, Swivel and Handling
Subs..
• Kill Valve , Swab Valve , Master Valve, Flowline valve with
remote controlled actuator.
• Must have a swivel to allow rotation of the tubing string.
 Surface Test Tree

Stiff joint

Check valve
 Surface Test Tree
Swivel Joint
Allow pipe rotating for
manipulating down-hole tools
without turning the test head
Surface
Test
Tree

Followed are
typical STT
specifications
for a set of
flowhead types
Surface Test Tree

and

Co-flexible
Hose
 Co-flexible Hose

• Purpose
• To Allow fluids to flow from the Surface Tree to the Choke
Manifold.
• Allows for tidal movement on a floating vessel
• Reduces number of leak points when compared with chicksan
flexible pipe joints.
• Must be handled and stored with care.
 Co-flexible Hose
 Used as kill and flow lines from STT
 Data Header
Provides access to the process fluid upstream of the choke
manifold to allow:
- Measuring of Pressures
- Measuring of Temperatures
- Gathering of Samples
- Injecting of Chemicals

Flange Ends Weco Ends

 Pipe Unions
• Pipe Rating Supercedes Union Rating
• HES Common Unions
• 206 2,000 psi Standard N/A Sour
• 602 6,000 psi Standard and Sour
• 1502 15,000 psi Standard 10,000 Sour
• 2202 15,000 psi Sour
 Color Codes & union seal

• Pressure Ratings (psi) Union Seals and O-rings

• 20,000 White
• 15,000 Orange Nitrile - Standard Service /
• 10,000 Yellow CO2
• 5,000 Gray Viton - Sour Service
• 2,000 Blue Teflon - All Purpose
• 1,440 Purple Aflas - All Purpose
• 600 Brown
• 250 Black
• 50 Gold
 Choke Manifold
• Provides a means of
controlling and
adjusting the flow
from the reservoir

• Reduces downstream
pressure to a safe
level

• Permits flowing
through variable or
fixed chokes to
maintain controlled
constant flow during
beaning manipulation
Choke Manifold

Solid Block – 5 valves

 Choke Manifolds
Adjustable & Fixed Chokes
 Dual Parallel Chokes
Equivalent Choke size D3 = D12+ D22

Low Pressure Coils

High pressure Coil

Low Pressure Coils

May occur at Choke Manifold or Steam Exchanger

 Critical Flow

When Pressure Downstream is  1/2 or Less than the

Upstream Pressure

• Rates May Be Estimated w/ Choke Coefficients

• Downstream Pressure Is Not Affecting Rate and BHP
• Allows Proper Staging of Pressure / Temperature
Drops
Non-Critical Flow

When Pressure Downstream is More than 1/2 the Upstream

Pressure

Rates May Not Be Estimated w/ Choke Coefficients

Downstream Pressure Is Affecting Rate / BHP
 Gas Estimate

• Based on Certain Assumptions

• Dry gas
• 6 in. long positive choke
• Critical flow
• Gas is ideal

• Qmcf/d = Choke Coefficient x Pressure (psia)

(Gravity x Temperature oR).5
 Gas Estimate Example

• Flow Conditions
• Well flowing on a 18/64 choke with a wellhead pressure
of 3247 psia.
• Wellhead temperature is currently 86oF and a sample of
gas registered .583 on the Ranarex.

What is the estimated gas rate?

Qmcf/d = 33.93 x 3247 = 6,175 mcf/d

(.583 x 546).5
 Heater

• Prevent Hydration

• Reduces Surface Tension and Viscosity of Oil

• Breaking emulsion, foam and wax.

• Prevent the plugging of the production line by

increasing the down stream temperature.
 Heaters

• Types

• Direct Heater where the heating source is in direct contact

with the fluid being heated. (Not Recommended)

• Indirect Heaters where the heat is transferred to heating

medium which in turn heats the fluid. By gas fired, diesel fired
or electrical.

• Steam Heat Exchangers , where steam is used to heat coils

through which the fluid is passing.
Indirect Fired Heater

Consists of a large, low-pressure tank

that contains water or glycol heated by
a gas or diesel burner in a tube
 Heaters
• .5 MMBtu/hr to 6MMBtu/hr
* Btu = British thermal units
Energy required to raise 1 pound of water 1oF
• Indirect
• Gas Fired
• Diesel
• Electrical
• Steam Heat Exchangers
 Heaters

Gas Fired Heaters

• Firetube with a gas-fired burner

• Water medium surrounds coils and firetube
• Gas regulation source
• Separator supply - Fisher regulators and
Kimray thermostats
• External - Propane / sweet gas
• Ignition safety
• Stack and spark arrestor
 Heaters

Diesel Fired Heater

• Vessel, coils, firetube, water medium, stack

• Diesel burner
• Diesel pump
• Electrical blower
• Electronic ignition
• Diesel tank
• Improved heat transfer
• Do not use the heater during the clean up period.
Indirect Fired Heater

Internal View
Indirect Fired
Heater
Tell tale : is a hole has
thickness less than
the coil, when erosion
occur this hole will
allow release the flow
through the shell of
the vessel at a small
rate until change the
coil.
 Steam heat exchanger
• Steam heat exchanger are usually also considered to be an
indirect heater.
• The construction is similar to the indirect heater except the
burner and fired tube are removed.

• Operation:
• The steam from an external source such as steam generator
or steam boilers is passed into the vessel ,where it transfers
the heat to the well production in the coils.
• The steam condenses to water (due to heat exchange between
the oil and the steam) then either dump the water or return to
the generator.
• Easier and safer operation makes this type of heater the best.
 Steam heat exchanger

• Operation:
• The main disadvantage is the need to large volumes of steam.
• CAUTION: use extreme care when working with steam.
Steam Heat Exchanger
 Steam Heat Exchangers

• Pressurized Vessel - 150 to 350 psi

• Relief system
• Coils and choke(s)(5000-10000 psi)for
H.P coil and 2000psi for L.P. coil
• Steam generator
• Thermostatic DMV
• Steam trap (Bestobell)
 Steam Heat Exchangers
• Safety
• The Heater will be equipped with
• Safety Valve set at 100% of vessel rating
• Rupture Disc
• Steam Lines
• Non-Return Valves on steam lines.
• Degasser require in steam return line to monitor for
presence of hydrocarbons in the returned steam.
• Temperature Control Device
• Thermocouple device controlling a valve to regulate the
amount of steam to the vessel.
 Steam Heat Exchanger

Steam Heat Exchanger Temperature Control

 Heater Performance
Indirect Gas Fired

Performance for 5,000 psi - 2 mm BTU/hr Heater (Gas Flow)

 Heater Performance
Indirect Gas Fired

Performance for 5,000 psi - 2 mm BTU/hr Heater (Liquid Flow)

 Separator
Pressure vessel used to separate well fluids
into gaseous and liquid components.
 Separators

• The Separator will provide a means for

• metering of the various fluids

• permit sampling of the fluids
• allow for the removal of water from the oil
• containing the pressure safely within the pressure
envelope
 Separators

• Types
• Two phase - Gas and liquids
• Three phase - Gas, oil and water
• Designs
• Horizontal
• Capacity, separation efficiency, maintenance
• Vertical
• Less floor space, foreign material, liquid levels
• Spherical
 Separators
• Sizes
• Diameters - 24”, 36”, 42, 48”, 60”, 84”
• Lengths - 7’, 10’, 15’, 20’
• Pressure ratings
• 50 psi, 150 psi, 250 psi, 600 psi, 1440 psi
• Capacities
• Liquids - 2,000-60,000 bpd
• Gas - 18-150 MMscfd
• Retention time
 Separators

Classification

• Separators can be classified according to

• Working Pressure (250 - 1440 psi)
• Operating Temperature (above -20 Deg F or for low
temperatures down to -50 Deg F)
• Length and Diameter (which will affect the
retention time and the size of the vapor
disengaging area)
 Horizontal Test Separator
Main Parts and other Factors assist in separation:

 Mist Extractors
 Change of Flow Direction
 Change of Velocity
 Centrifugal Force
 Coalescing Packs
 Settling
 Agitation
 Inlet Diverter
 Baffling
 Heat
 Chemicals
 strainers
Horizontal Test Separator
Vertical Separator
 Flow Rate Measurements

MEASUREMENTS

Higher the velocity of the Gas the higher the differential pressure.

Turbulent
Laminar Flow

Straightening Vanes

Replaceable orifice
Pressure Tapping 1 inch on either side of the plate.
Separator Control Valves
Level Control
 Separators

Level Control

Caged Mounting
Gas Metering
Daniel’s Box

A Gas Rate
measurement
device
 Gas Metering
Daniel’s Box

Allows orifice plate changing under flow conditions

 Gas Metering
D.P. Cell (Barton)

Measures diff. press. & separator

press. to calculate gas rate
 Separators
Gas Gravity Meter

Portable gas gravitometer (Ranarex)

 Separators
Gas gravitymeter

Portable Gas Gravitymeter

The proportional torque differential

indicator operates on the principle
that the torque produced on the
shaft of an impulse wheel activated
by a jet of gas is proportional to the
specific weight of the gas. The
difference in torque produced by air
and the tested gas is shown on an
indicator scaled to read in terms of
specific gravity. Recommended
equipment is the Portable Ranarex
indicator.
 Separators

Gas gravitymeter
How do we define Gas Specific Gravity?

 gas
SG 
 dry air

SG = Specific Gravity
Pgas = Gas from the well
Pdry air = Air taken from atmosphere which has been
dried
 Separators
Gas gravitymeter
How does it do this?
 Separators

How do we determine a Gas Gravity

The specific gravity of separator gas is determined by the

Ranarex Gravitometric method. The instrument operates
on the principle that the kinetic energy of the gas is
compared to the kinetic energy of air impinging on
counter rotating impellers.
The unit has a specific gravity measuring scale for light
gas of 0.52 – 1.03 and for heavy gas 0.970 – 1.90.
For PWS using a gas “as is” to dry air comparison is
required. We wish to determine the specific gravity by
comparing the gas being metered in its natural state to an
air at standard conditions.
 Separators
Liquid Meters

Halliburton Type

Measures oil, condensate or water rate

 Liquid Meters

Signal Out

Pickup

Rotor

Rotor

Meter Operation
Liquid Meters

Installation
Drawing
Liquid Meters
Reading device

Flow Analyzer-Totalizer
 Liquid Meters
Meter Ranges
Meter Model Size Range ( gall/min ) Range ( bbl/day )

Type Number (inches) Minimum Maximum Minimum Maximum

Floco F2500 - 1 1 6 60 206 2057

Floco F2500 - 2 2 6 60 206 2057

Floco F2500 - 3 3 9 90 308 3086

Floco F382 2 30 250 1029 8571

Floco F383 3 30 250 1029 8571

Rotron xxxx - 20 2 25 250 857 8571

Rotron xxxx - 30 3 60 650 2057 22286

Rotron xxxx - 40 4 200 1200 6857 41113

Halliburton   1 5 50 170 1700

Halliburton   1.5 15 180 500 6100

Halliburton   2 40 400 1300 13000

Halliburton   3 60 600 2100 21000

Halliburton   4 100 1200 3400 41000

Safety Relief Valves

To relief unsafe high

vessel pressure
 Safety Rupture Disk
Provides backup safety for Relief Valve
Separator Capacities
Separator capacity curves
 Separators

What is inside the Controller?

A. Supply Air Pressure

B. Relay
C. Proportional Band
D. Set Point Scale
E. Outlet Air Pressure
F. Beam
G. Nozzle
H. Bourdon Tube
I. Nozzle Block Adjustment
 Separators

How does it work?

A level controller (Fisher Level-
trol) maintains the liquid level
in the separator by use of a
displacer, flapper, and nozzle
arrangement. The liquid level
controller senses changes in the
separator levels and sends a
output signal accordingly to
either open or close the
normally closed liquid valve.
The proportional band
adjustment allows one to set the
degree of level sensitivity that
will cause reaction.
 Separators

What does the displacer look like?

 Separators

How do we connect it to the controller?

Let’s see how it works?
 Relay

18

6 24

0 30

2 Psi
Output set at 6psi
Valve closed
but on point of
Opening
6 Psi

35 PSI Supply
 Relay

18

6
0 30

C As the level rises

the flapper moves
~4 Psi towards Nozzle causing
an increase in pressure
above the top diaphragm.
The Diaphragm moves
down closing the valve
at “A” and opening the
A valve at “B” This allows
the supply pressure
12Psi to increase the pressure
to the actuator opening
the valve at “C” which
B will then cause the
level to drop.
 Relay
18

6
0 30

C As the level falls

the flapper moves
away from the Nozzle
causing a Decrease
in pressure above the top
diaphragm.
The Diaphragm moves
up closing the valve
at “B” and opening the
A valve at “A ”. Pressure is
vented o atmosphere and the
6 Psi valve at “C” is closing.

35 PSI Supply B
 18

6
0 30

C As the level rises

the flapper moves
towards Nozzle causing
an increase in pressure
above the top diaphragm.
The Diaphragm moves
down closing the valve
at “A” and opening the
A valve at “B” This allows
the supply pressure
to increase the pressure
to the actuator opening
the valve at “C” which
B will then cause the
level to drop.
 Separators

Controllers – Gas

What kind of Controller is this?

Controller 4150/4160
What is it used for?
To Control the pressure within the Separator.
Why?
Without pressure in the separator then you would
not be able to remove fluids.
 Separators

How does it control the Pressure?

A pressure controller (Fisher Wizard) maintains the

pressure in the separator by use of a bourdon tube,
flapper, and nozzle arrangement. The pressure
controller senses changes in the separator pressure
and sends a output signal accordingly to either open
or close the normally open back pressure valve.
The proportional band adjustment allows one to set
the degree of pressure sensitivity that will cause
reaction.
 Separators

How does it affect the valve?

b b

Is this direct acting or reverse acting valve?

Direct Acting.
 Separators

What is inside the controller?

A. Supply Pressure
B. Relay
C. Output Pressure
D. Proportional Band
E. Pressure set point
F. Bourdon Tube
G. Nozzle block adj.
H. Beam
I. Nozzle
J. Nozzle Block
Is this a direct acting controller or Reverse
Acting?
Reverse Acting!
Separators
How does it work?
 Separators

Proportional Control, what do we mean?

It is defined as control action in which a

continuous linear relation exists between
the value of the controlled variable and
the position of the valve.
 Test Tanks
• Liquid flow measurement
• Storage of Liquids
• Meter Calibration
• Second or Third Stage Separation
• Provide NPSH for Pumps
 Test Tanks
1- Gauge (atmospheric) Tanks

• Single or dual compartments

• Atmospheric (few ounces of
pressure)
• Flame arrestor for vent
• Tank strap or sightglasses
• Metal tape w/ plumb bob
• Powder
• Water indicator
• Systematic strapping procedure
 Test Tanks

1- Gauge (atmospheric) Tanks

• Gauge Tank
• Non Pressurized
• Used for low flow rates to calibrate velocity or positive displacement
meters.
• Usually double compartment to allow continuous flow to and from the tank.
• Must never be used if H2S is suspected.
• Safety features include flame arrestors, a thief hatch to prevent over
pressure.
• The tank must be earthed to the deck/ground to prevent static buildup.
 Test Tanks

2- Surge (pressurized) Tanks

• Surge Tanks safety Features

• High and low level audible alarms
• Safety relief valve set at WP
• Earthing strap to avoid static build up.
• High Pressure pilot device which will close in the
surface tree should the vessel pressure be exceeded.
 Test Tanks

Surge Tanks

• Surge Tanks - Designed to serve as a second stage separator.

• Allows for the production of H2S
• Usually a single compartment with a working pressure of 50-250 psi
• Pressure maintained by a back pressure valve
• Measurements of shrinkage and meter factor can be made

Surge Tanks safety Features:

High and low level audible alarms

Safety relief valve set at WP
Earthing strap to avoid static build up.
High Pressure pilot device which will close in the
surface tree should the vessel pressure be exceeded.
 Test Tanks

• Pressurized
• 50-250 MAWP
• Sightglasses
• Relief System
• Possible Options
• Liquid level controllers
and valves
• Liquid and gas metering
• Hi/Lo pressure or liquid
level ESDs
 Test Tank

Atmospheric
OR
Pressurized
 Burner Boom

To burn the Crude Oil , gas or water far a way from

an Offshore Rig to Allow the Safe Burning of
Produced Hydrocarbons.

U-shaped Booms:
Lengths - 60, 90, and 120 feet

Flare Stacks
Heights - 60 and 90 feet
 Burner Booms
• Mounted on the side of the rig to provide a safe
platform for mounting the burner heads.
• The boom design should account for
• Heat radiation created by the burning hydrocarbons
• Load requirements from the product lines,
personnel; and in some cases snow and ice.
• Dynamic loading due to the movement of the
floating vessel.
 Burner Boom Safety
• Never allow work on the boom without the service
technician wearing a life vest and tag line.
• Always send two men down to the burner one to go
out along the burner the other to watch the first.
• Do not permit work on the burner in strong winds or
exceptionally rough seas.
• Burner booms should only be hung and mounted by
qualified “Riggers”
U-Shaped Burner Boom
Burner

On-shore
Burner

Or Off-shore
 Transfer Pumps

 Transfer Crude from Tank to Burner, Flare pit or Pipeline

 Provide Crude to Burner at Constant Pressure and Rate

 Transfer Pumps
• Types
• Electric driven Centrifugal
• High current draw when starting may require
sophisticated “Soft Start Units” to be used.
• Controls required to be explosion proof.
• 10,000 @ 400 psi
• Diesel driven Centrifugal
• Air start turbo charged diesel engine requires zone 2
classification (Spark arrestor, Overspeed protection)
• 10,000 bpd @ 255-425 psi (motor vary)
• Pumps - Dean or Sunflo centrifugal
• Maintenance
 Transfer Pumps

A transfer pump connected to the

gauge tank outlet is used to empty
one of the tank compartments
while the other is being filled.

Another use of transfer pumps is

for pressure boosting when there
is insufficient pressure to achieve
atomization at the burner.
 Transfer Pumps
Most pumps are electric powered, but diesel-driven
pumps are also available.

Diesel Pump Electric Pump

 Chemical Injection Pumps
Provided to inject Chemicals :
a) Hydration Inhibitor (methanol or glycol)
b) Corrosion Inhibitor
c) Demulsifying Agents
d) Foam Inhibitors
e) Dewaxing agents

A Positive Displacement type

 Equipment Layout & Rig up

Onshore
recommended
distances
 Equipment Layout & Rig up

Offshore
recommended
distances
 Equipment Layout & Rig up

A typical
offshore
rig up
 Safety System
 Provides Emergency Well Shut-in

 Well Safety Systems are designed to sense

conditions and shut in well(s) when such
conditions deviate from the preset limits.
ESD Control Units

ESD Console
 Surface Safety Valve - SSV
( ESD Actuator Valve )
 Surface safety valve (SSV) is
used to shut in the flow
upstream of the choke manifold
in case of emergency

 Operated by the ESD system

 SSV’s are supplied with a

supporting base frame, inlet
and outlet connections
ESD Station Button
 FLOW MEASUREMENT
Computerised Systems
SCHEMATICS
Can be customized to suit a particular application. All
System Software views Channel Values can be written to the bit map image to
display values related to the process layout.

SINGLE SEPARATOR HOME PAGE

 FLOW MEASUREMENT
Computerised Systems
Surface Computerized Acquisition
Network (SCAN)

Replaced manual
calculations/reports

 System configuration:
• Logger unit (24 channels)
• Cables and splitter-boxes
• Windows based software
• Sensors / instrumentation
• Computer(s) & peripherals
• UPS
• Remote monitors (optional)
• Network communication

Sapesco (SMS)
 FLOW MEASUREMENT
Computerixed Systems
SCAN Cabling System

Back view of Logger

Complete System
connections from safe
including drum
area distribution box
cables

Process Area
Distribution Safe Area
Box Distribution Box
 Reporting

Typical results of a well test job

Surface WELL TESTING
SERVICES

Sand Production
 Sand Management System

Main equipments:

1-De-sander

2-Sand filter
 1- De-sander

Benefits:
• A voids erosion of wellhead choke to
guarantee safe operations
• Reduce surface facility erosion
• Allows to measure proppant return.
• Avoids erosion or blockage of equ.
downstream.
• Allow high pressure rate.
 De-sander
DESANDER
10,000 psi WP
9

Desander Vessel 8

• Cyclone Chamber
10

• Accumulator Vessel 11

• Isolation System
12 13

14 15

• Integral Flushing System 16 17

 De-sander

 In some applications it
removes up to 99% of
the produced solid

Principle of operation:

Centrifugal separation attained due

to cyclonic motion
 De-sander
Filter
De-sander
Unit
Unit

Krebs Cyclone Unit

Solids Outlet

Flow inlet

Cyclone
(Plan view) Original Sand- cut
Unit Flow Outlet Unit
Solids

Cyclone De-sander
De-sander

Back
 2-Sand Filter

Dual-Pot Sand Filter

- Removes sand and other solid

particles from well effluent
- Usually located upstream of
choke manifold
- Typical applications are sand-
control completion cleanups and
maximum sand-free rate tests
 Sand Filter

SAND FILTERS
10,000 psi WP

26
Output to
Downstream
Overflow From the Desander 18
25

20
Equipment
24

19 21

23

22
27

28

31

29
32 33

Flushing System 30
34
 Sand Filter

Consists of two filter and

inter-connecting piping with
bypass and drain
 Sand Filter

The factors affecting the pressure a cross the

filters:

• Fluid viscosity at the inlet conditions.

• Fluid density at the inlet conditions,

• Volume the flow rate of the fluid phase.