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1.5 HPHT Testing

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1.5 HIGH PRESSURE / HIGH TEMPERATURE WELL TESTING

DEFINITION

The generally accepted definition of an HPHT well is:

“Any well where the undisturbed bottomhole temperature at total depth or the prospective reservoir section is
greater than 300°F and either the maximum anticipated pore pressure exceeds a hydrostatic gradient of 0.8 psi/ft
or pressure control equipment with a working pressure greater than 10,000 psi is required”.

On the UK Continental Shelf all wells must be drilled in accordance with the Design & Construction Regulations,
designed and published by the UK Health & Safety Executive.

Similar legislation exists in the rest of the oil producing world.

If the Clients well meets both of the criteria in the definition above, it should be treated as an HPHT well. The well
test should then be planned under the HPHT guidelines contained within this section.

The details of all proposed HPHT wells should be examined closely.

The following guideline contains some considerations for planning HPHT well operations. This guideline is not
exhaustive and each individual well may present unique problems to be overcome.

INTRODUCTION

When Planning a HPHT test it is extremely important that a system is designed that will allow the Client to
achieve his objectives whilst considering all relevant process and safety considerations. These will include:

− Safe and Environmentally acceptable production of hydrocarbons to surface.

− Responsive initiation of multiple barriers downhole and at surface.
− Reliable isolation and maximum security of the well.
− System tolerance of variable pressure and temperature.
− Maximum reliability with minimum intervention.

Recent trends in offshore activity have highlighted a significant increase in the drilling of deep, hot and high
pressure wells.

Expro’s experience and knowledge of HPHT environments enables us to know that consideration of High
pressure alone is not enough to determine the suitability of any proposed equipment.

It is therefore important to note that the limitations imposed by high temperature are greater than those of
pressure. Careful consideration must be given to the problem of restricting high surface temperatures.

The elastomers used in most drilling rig BOP’s are limited to a maximum working temperature of 250°F. Above
this temperature BOP ram seals cannot be guaranteed.

During the planning phase of HPHT wells, it is a good idea to run a process simulation to predict surface flowing
conditions and hence choke downstream temperatures. It can also help in predicting how long and under what
conditions the well can be flowed before the surface flowing temperature limitations are reached.

It is recommended that a process simulation be performed for all HPHT wells. A process simulation may assist in
the selection and design of surface flowlines that will withstand the potentially severe dynamic and thermal loads
that we may expect to encounter during testing operations.

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SURFACE EQUIPMENT DESIGN PROPOSAL

A typical sequence of events for the planning operation of an HPHT well would be as follows:
1. Establish operational objectives
2. Conduct detailed rig survey
3. Review equipment position & layout
4. Design system
5. Hazop System
6. Close out of all outstanding Hazop actions.
7. Independent review of system (Rig Owners – Certifying authority)
8. Procurement and manufacturing of equipment in line with timeframe agreed with client.
9. Installation and commissioning of equipment.

The Rig owners and client must be invited to input any suggestions as to equipment design and specification.
Only by consulting with the client and drilling company will we ensure accurate selection of equipment.
Equipment selection and procurement assistance can be sought from the Group Technical Resource function in
Aberdeen. Contact: [email protected]

RIG VISITS

During rig visits it is essential that all rig owned equipment that may be used during HPHT testing is thoroughly
checked out for suitability. Copies of certification for all rig owned relief lines, standpipes etc must be sought from
the rig owners. If any doubt exists about the suitability of any piece of Rig owned kit DO NOT USE IT.

HAZOP

It is highly recommended that a HAZOP be carried out on the proposed HPHT test system well in advance of
mobilisation of equipment. Sufficient time should be given to allow adequate closure of all outstanding Hazop
issues.

PROVISION OF DETAILED WELL TEST PLANNING REPORT

A detailed well test planning report or (design submittal) must be prepared in advance of the job. One copy of this
report should go to the rig owners, one copy must go to the client and Expro must hold another copy on file. This
is mandatory. The rig owners and Client must be invited to review and comment upon this document. Planning
reports must be sent to the Rig owners and clients with an accompanying letter explaining what the purpose of
the document is and also requesting that they review and comment upon it’s contents.
The rig owners should request that their certifying authority reviews the document and comments upon it.
If no response is forthcoming from the Rig owners, they must be contacted and made aware of their responsibility
to review the document. On no account should an HPHT operation proceed without both Rig Owners and client
reviewing the planning report. This is mandatory.

The planning report or (design submittal) must contain the following information as a minimum:
− Detailed P&ID and Equipment Layout drawings
− Detailed system pressure test procedures
− Temperature & Pressure monitoring procedures/safeguards/controls
− Detailed process tables from API RP 14C – SAFE, SAT & SAC must be included as a minimum.
− Detailed process line pressure drop sheets.
− Relief and vent system sizing calculations
− Detailed safety system design philosophy
− Any special safety or contingency procedures unique to the job

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EQUIPMENT SELECTION & DESIGN

Appropriate equipment should be selected, procured and used for all HPHT work. Equipment specific to this type
of work may include:

− Hubbed pipework with metal to metal seals

− Coflon lined Coflexip style production hoses
− High flowrate separation vessels such as Expro’s “Megaflow” Separator
− High temperature rated “double block” choke manifolds
− Supergreen burners
− “Power Chokes”, “Master Flo” or CCI type chokes

Minimise the use of elastomer seals upstream of the choke manifold as much as is practicably possible.

Special thought should go into radiated heat issues. Use long booms if available, consider the use of customised
water protection spray systems, consider carrying out a Flaresim (details from Group Technical Resource in
Aberdeen).

Expro has a wide range of 15,000 psi rated surface equipment, which includes the following items: -

a) Surface Test Tree’s (2 9/16” & 3 1/16”)

b) Coflon lined coflexip hoses (see note below)
c) Choke manifolds (double block & single block)
d) Graylok & Techlok Hubbed pipework
e) Heat Exchanger (1 off)

Equipment placed downstream of the heat exchanger is typically “standard” equipment. It is essential that all kit
is properly sized and selected to deal with expected flowrates, temperatures etc.

CHOKE SELECTION

On HPHT applications where very high choke velocities and or solids production are expected, normal “needle &
seat” design adjustable chokes will not stand these harsh conditions for any significant length of time. There are
numerous alternatives available throughout Expro and even more alternative designs on the open market.
Operational disasters have occurred in the past due to incorrect selection of a suitable design of choke. It is
imperative that a suitable choke design is selected to fulfil the given design parameters.

COFLEXIP HOSES

Recent tests undertaken by “Coflexip Stena Ltd” have proven that “Coflon” lined hoses have operated
successfully for extended periods at 150°C (302°F) with no detrimental effect on the hose. Coflexip will now rate
these hoses at 150°C for up to 500 Hours service. If 500-hrs service is reached a full external & internal
inspection of the hose must be carried out before the hose can be certified for use again.
If we plan to use a Coflexip hose at temperatures above 130°C, Coflexip should be contacted for clarifications on
terms & conditions of use.

EQUIPMENT SAFETY ASPECTS

A full evaluation of relief and vent systems must be performed. Relief valves and lines must be sized correctly to
cater for each individual well test and must be provided to relieve over-pressure and prevent catastrophic rupture
of lines or vessels.

On HPHT wells with high flowrates, relief line sizes may be much larger than on “conventional” tests. I.e. 6 inch
or 8 inch lines may be required to safely relieve a system. Line sizing calculations must be included in the
planning report.

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Emergency shutdown system’s must also be provided, extra automatic shutdown pilots may be needed to
secure the well in the event of equipment failure.

All pressure retaining equipment used on HPHT tests must have full traceability and a comprehensive
certification package should be prepared to cover all equipment to be used on the test. All equipment must be
fully rated for the intended pressures and temperatures it may encounter whilst on location.

The use of tapered threads on HPHT equipment upstream of the Heat Exchanger is not recommended. All
instrumentation used in an upstream environment should be of “parallel thread” design, i.e. Autoclave or similar.

PERSONNEL

All personnel should be briefed by their ops supervisor or line manager onshore prior to mobilisation to any
location where HPHT work is being undertaken.
All crewmembers should make themselves aware of the system design at the earliest opportunity. P&ID’s and
equipment layout drawings should be studied by all crewmembers prior to starting job operations.

OPERATIONAL PROBLEMS

On some HPHT applications the only way to restrict the surface temperature may be by choking back the well
and restricting the flowrates.
One way of choking back the well is to fit a hydraulically controlled choke onto the flow-wing outlet of the test
tree, this would have a cooling effect on the fluids immediately downstream. Alternatively the well can be choked
back at the choke manifold.
Where HPHT gas wells with high temperatures are tested Gas “flash off” may be a problem. This is where the
condensate “flashes off” to a gas phase. This phenomenon creates difficulties when collecting PVT samples from
the separator for the purpose of recombination.

EXPLOSIVE DECOMPRESSION

One of the major problems encountered in testing high pressure wells, is the problem of explosive
decompression. This phenomenon causes problems in that when seals are compressed under high pressure
some gaseous elements diffuse into the seal. If a rapid pressure drop occurs or after frequent pressure cycling,
materials not resistant may suffer extensive damage, usually in the form of splits and/or blisters. This is because
the entrained gas expands against the elasticity of the rubber causing severe internal damage that may split or
rupture the elastomer seal.
This problem is especially prevalent where there is a high CO2 content in the well gas stream and if this is the
case then explosive decompression may occur at relatively low pressures. This is due to the ability of the CO2
to permeate the elastomer.
It is recommended that elastomer seals with hardness rating above 85 RHD be used if explosive decompression
is expected to be a problem or if high concentrations of CO2 are expected.

The critical parameters most likely to affect Explosive Decompression performance are:-

a) Gas type
b) Pressure and decompression rate
c) Temperature
d) Soak time at pressure
e) Seal volume and exposed seal surface area
f) Initial squeeze (strain exerted on seal while rigging up hammer union).

One type of rubber seal designed to overcome this problem is the Anson Superseal which is based on Viton B (a
high fluorine content fluoroelastomer) which is given the compound name FR 58/90 (the 90 refers to the
hardness of the rubber).

The level of fluorine in the elastomer is thought to have a major effect on the solubility of gas in the seal and thus
resistance to explosive decompression as does the hardness of the elastomer.
Generally, the harder the elastomer seal the greater the resistance to gases permeating into it.

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The disadvantage of this is that the harder the seal, the worse the sealing properties.

If possible, bleeding down systems slowly will help prevent explosive decompression occurring.
Explosive decompression is one of the prime reasons why Expro recommend the use of metal to metal type
seals for all upstream pipework and components. If possible metal to metal seals should be used on all
equipment installed upstream of the heat exchanger on the High-Pressure side of the system.

UNLOADING HEAVYWEIGHT CUSHIONS

When unloading a heavyweight brine cushion or similar there exists a possibility that with a needle and stem
type adjustable choke, that the seat may "back-out", even though a copper gasket has been fitted.
This is due to the nature of the "heavy" fluids passing through the choke at high pressure, where turbulence is
set up as the flow passes the adjustable stem and cone. As this fluid passes through the choke seat, the drag it
exerts may be large enough to cause the seat to "back- out", even though it may have been torqued tight.

The recommended torque for this type of adjustable choke is in the nature of 1500 ft/lbs and to achieve this by
using an ordinary choke spanner may prove difficult. Use a Torque wrench to tighten the seat to the desired
torque.

It is also possible for the adjustable choke cone to shear off the stem. This is also due to the forces created by
the turbulence created by the "heavy" fluid passing through the choke.

DATA ACQUISITION

To complement our high pressure well test equipment and increase overall safety, an upgraded Data Acquisition
system is provided to acquire Bottom Hole Data, via memory gauges, and Surface Data, via the Surface data
Logger. This Data Logger will play an important part in the central monitoring and control of testing operations
and temperatures can be monitored easily at any point in the process train.

15,000 PSI EQUIPMENT

1. A 3" 15,000 psig Sub Sea Test Tree allows the landing string to be unlatched in the event of anchor failure or
as a precaution in the case of bad weather. The well is sealed by a proven twin ball fail safe valve assembly
that also provides an injection point for chemicals should there be a risk of hydrates.

2. A 3" 15,000 psig Retainer Valve is available and will act in conjunction with the SSTT and when closed
prevents the escape of hydrocarbons into the annulus when the landing string is unlatched at the SSTT.
Entry of wireline tools is simplified by a 3" 15,000 psig Lubricator Valve that is placed below the rotary table
thereby reducing the need for long lengths of surface lubricator above the flowhead.

3. A 3" 15,000 psi Temperature Sub is placed below the temporary flow head and allows the temperature of the
well fluid to be monitored prior to entering the flowhead and coflexip hose. Alternatively a tapped spool-
piece can be inserted on the flow-wing outlet of the flowhead prior to the coflexip hose.

4. It is critical to maintain the flowing temperature to 250°F or less when a coflexip hose is used because the
0
coflexip hose is rated to 266 F only. A temperature transducer placed in the temperature sub can either
give a digital display at the rig floor or be combined with the Surface Data Acquisition system to give either a
digital or analogue read-out with alarm functions.

5. A 2-9/16" 15,000 psig Lower Master Valve is placed below the temperature sub and swivel and can be either
manually or hydraulically actuated.

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6. A 2-9/16" or 3 1/16” 15,000 psig Surface Flowhead is placed on top of the landing string above the rotary
table and is equipped with a swivel that is immediately below the chemical injection sub to allow rotation of
the flowhead or tubing prior to, and during testing operations. The surface flowhead is equipped with a
failsafe actuated shutdown valve on the flow side which is operated by hi-lo pilots or remotely placed
shutdown buttons.

7. From the flow wing of the flowhead, the well effluent is conveyed by a 3” 15,000 psig Coflexip Flowline. The
15K production hose is suitable for H2S service and can handle Zinc Bromide and is also suitable for
continuous use over a temperature range of –4 0F to 266 0F. A 2” 15,000 psig Coflexip Kill Line is placed
between the rig manifold and a non-return valve on the kill side of the flowhead.

8. 3", 15,000 psig High Pressure Pipe with either Techlok or Graylok hubbed metal-to-metal seals is used to
connect the coflexip hose to the Data Header.

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