Surface well testing, Equipment & Function

Well testing is potentially hazardous and requires good planning and co-
operation/co- ordination between all the parties involved. The final aim is to
improve performance and efficiency in terms of safety, quality and costs, while
providing all personnel involved in Testing activities with common guidelines in
all areas .

1.OBJECTIVE:-.
1.1 The objectives of an exploration well test are to:
• Conduct the testing in a safe and efficient manner.
• Determine the nature of the formation fluids.
• Measure reservoir pressure and/or injectivity.
• investigate formation characteristics.
• Evaluate boundary effects.
• Obtain representative formation fluid samples for laboratory analysis.
• Define well productivity.

2. SURFACE EQUIPMENT & FUNCTION

1. 1. Flow head/Control Head
2. 2. Coeflex
3. 3. Choke manifold (10k by 5K or 5k by 3K)
4. 4. 1440psi Oil and Gas manifold
5. 5. Emergency shut down (ESD) system
6. 6. 1440psi Separator
7. 7. Indirect heater or heat exchanger
8. 8. Burners(60ft or 80ft)
9. 9. Storage Tanks( Gauge tank or Surge Tank)
10.10. Compressors
11.11. Piping:
12.a. 3"piping
13.b. 2" piping
14.c 3" elbow
15.d. 2" elbow
16.e. 2 and 3" hoses
17.12. Lab (contains,centrifuge, gravitometer, fittings and others)
18.13 Sand trap and Particle Monitors.
19. H2S Monitors
3.1 This sub-section contains the list of surface equipment and the
criteria for use.
3.1. Flow head Or Surface Test Tree Modern
flow heads are of solid block construction, i.e. as a single steel
block, as opposed to the earlier modular unit which was
assembled from various separate components. Irrespective of
the type, both should contain:
• Upper Master Valve for emergency use only.
• Lower Master Valve situated below the swivel for
emergency use only.
• Kill Wing Valve on the kill wing outlet connected to the
cement pump or the rig manifold.
• Flow Wing Valve on the flow wing outlet, connected to
the choke manifold, which is the ESD actuated valve.
• Swab Valve for isolation of the vertical wireline or coil
tubing access.
• Handling Sub which is the lubricator connection for
wireline or coiled tubing and is also for lifting the tree.
• Pressure Swivel which allows string rotation with the flow
and kill lines connected.
3.2 .Coflexi Hoses And Pipework
 Coflexi hoses must be installed on the flow head correctly so as
to avoid damage. They must be connected so that they hang
vertically from the flow head wings. The hoses should never be
hung across a wind wall or from a horizontal connection unless
there is a pre-formed support to ensure they are not bent any
tighter than their minimum radius of 5ft. Hoses are preferred
to chiksan connections because of their flexibility, ease of hook
up and time saving. They are also less likely to leak due to
having fewer connections. On floaters, they connect the
stationary flowhead to the moving rig and its permanent
pipework. Permanently installed surface lines should be used
with the minimum of temporary connections supplied from the
surface testing contractor. Ideally these temporary
connections should be made-to-measure pipe sections with
welded connections, however chiksans can be used but must
be tied down to the deck.
3.3 Relief Valve
Additional protection can be given by installing relief valves in
the lines. Is now common practice to have a relief valve on the
line between the heater and the separator to cater for any
blockage downstream which may cause over-pressure in the
line. If there is further risk from plugging of the burner nozzles
by sand carry-over, then consideration should be given to
installing further relief valves downstream of the separator to
protect this lower pressure rated pipework. Note: Ensure that
the Coflexip hoses are suitable for use with corrosive brines.

3.5 DATA Injection Header

This item is usually situated immediately upstream of the choke.
The data/injection header is merely a section of pipe with several
ports or pockets to mount the following items:
• Chemical injection
• Wellhead pressure recording
• Temperature recording
• Wellhead pressure recording with a dead weight tester
 • Wellhead sampling

• Sand erosion monitoring

• Bubble hose.
Most of the pressure and temperatures take off will be duplicated
for the Data Acquisition System sensors.

3.6Choke Manifold
The choke manifold is a system of valves and chokes for
controlling well flow and usually has one adjustable and one
fixed choke. Some choke manifolds may also incorporate a
bypass line. The valves are used to direct the flow through
either of the chokes or the bypass. They also provide isolation
from pressure so that the choke changes can be made. A well
shall be brought in using the adjustable or variable choke. This
choke should never be fully closed against well flow. The flow
should then be redirected to the appropriately sized fixed
choke for stable flow conditions. The testing contractor should
ensure that a full range of fixed chokes are available in good
condition. Due to the torturous path of the fluids through the
choke, flow targets are positioned where the flow velocities
are high and impinge on the bends. Ensure these have been
checked during the previous refurbishment to confirm they
were still within specification.

3.7 Steam Heater And Generator Heat

Heat is required from the steam heater, or heat exchanger,
to:
• Prevent hydrate formation on gas wells
• Prevent wax deposition when testing high waxy, paraffin
type crudes
• Break foams or emulsions
 • Reduce viscosity of heavy oils. For use on high flow rate
wells, a 4ins bore steam heater should be used to reduce
high back pressures. The heat required to raise a gas by 1o F
can be estimated from the formula: 2,550 x Gas Flow
(mmscf/day) x Gas Specific Gravity (air = 1.000), BTU/hr/o F
The heat needed to raise an oil by 1o F can be estimated
from: 8.7 x Oil Flow (bbls/day) x Oil Density (gms/cm3),
BTU/hr/o F Always use the largest steam heater and
associated generator that space or deck loading will allow as
the extra output is contingency for any serious problem which
may arise.

3.8 Separator
The test separator is required to:
• Separate the well flow into three phases; oil, gas and water
• Meter the flow rate of each phase, at known conditions
• Measure the shrinkage factor to correct to standard conditions
• Sample each phase at known temperature and pressure.
WEAFRI standard separator is a horizontal three phase, 1,440psi
working pressure unit. This can handle up to 60mmscf/day of dry gas or up to
10,000bopd and associated gas at its working pressure.Gas is metered using a
Daniel’s orifice plate gas meter. The static pressure, pressure drop across the
orifice plate and the temperature are all recorded. From this data the flow rate
is calculated. The liquid flowrates are measured by positive displacement or
vortex meters. The oil shrinkage factor is physically measured by allowing a
known volume of oil, under controlled conditions, to de-pressurise and cool to
ambient conditions. The shrinkage factor is the ambient volume, divided by the
original volume. The small volume, however, of the shrinkage meter means
that this is not an accurate measurement.The oil flow rate is corrected for any
volume taken up by gas, water, sand or sediment. This volume is calculated by
multiplying the combined volume by the BS&W measurement and the
tank/meter factor. Oil meters are calibrated onshore but it is also necessary to
divert the oil flow to a gauge tank for a short period to obtain a combined
shrinkage/meter factor as the meter calibration is subject to discrepancy with
varying oil gravity and viscosity.
 3.9 Relief Valves System
The separator relief system is calibrated onshore. The separator should
only be tested to 90% of the relief valve setting. It is important that the
separator bypass valves, diverter valves for the vent lines leading from the
separator relief valve, rupture disc or back-up relief valve, are checked for ease
of operation.

3.10 Data Acquisition System

It is now common custom to use computerised Data Acquisition
Systems (DAS) on well tests. However, it is essential that manual readings are
still separately recorded for correlation of results and contingency in the event
of problems occurring to the system. These systems can collect, store and
provide plots of:
• Surface data
• Downhole data from gauges
• Memory gauge data.
The main advantage of DAS is that real time plots can be displayed at
the well site for troubleshooting. Another advantage is that all of the surface
(and possibly downhole) data is collected into one system and can be supplied
on a floppy disk for the operator to analyse and subsequently prepare well
reports.

3.11 Gauge/Surge Tanks And Transfer Pumps

A gauge tank is an atmospheric vessel whereas a surge tank is usually
rated to 50psi WP and is vented to the flare. A surge tank is essential for
safe working if H2S production is anticipated. Therefore, surge tanks
should always be used on wildcat wells and gauge tanks used only in low
risk situations. Tanks are used for checking the oil meter/shrinkage
factors and for measuring volumes at rates which are too low for
accurate flow meter measurement. They usually have a capacity of one
hundred barrels and some with twin compartments so that one
compartment can be filled while the other is pumped to the burner via
the transfer pump. Tanks can also be used for collecting large
atmospheric samples of crude for analysis or used as a secondary
separator for crudes which require longer separation times.
3.12 Diverter Manifolds, Burners and Booms Burner
heads
are mounted on the end of the booms which are usually installed on
opposing sides of seprator. Two portable air compressors, one as back-
up, are required, suitably fitted with check valves. It is recommended
that the air compressors are manifolded together to provide a
continuous supply of. The burners have propane pilot lights which are
ignited using a remote spark ignition system

3.13 Emergency Shut Down (ESD)

system is the primary safety system in the event of an uncontrolled
escape of hydrocarbons at surface. The system consists of a hydraulically
or pneumatically operated flowhead flow wing valve, control panel and a
number of remotely air operated pilot valves. When a pilot or the main
valve in the panel is actuated, it causes a loss of air pressure in turn
dropping out the main hydraulic valve which releases the pressure from
the flowhead ESD valve actuator. The push button operated pilot valves
are strategically placed at designated accessible areas where the test
crew can actuate them by pushing the button when they observe an
emergency situation.

3.14 ACCESSORY EQUIPMENT

 Chemical Injection Pump
The main chemicals that are injected into the production flow are
hydrate inhibitors, de- foamers, de-emulsifiers and wax inhibitors. The
chemicals are injected by an air driven chemical injection pump at,
either the data/injection header, flowhead or at the SSTT/sub- surface
safety valve. Chemicals must be supplied with toxicological and safety
data sheets as per regulations.
 Sand Detectors
sand detectors can be installed at the data/injection header
upstream of the choke if sand production is expected to
cause erosion. These devices operate by detecting the
impingement of sand on a probe inserted into the
flowstream. The accuracy is reasonable in single phase gas
 flow but less consistent in multi-phase flow. The simplest
approach to sand detection is to take frequent BS&W
samples at the data/injection manifold to monitor for sand
production. If the flow rates are low, samples taken from
the high side of flowline might incorrectly show little or no
sand, therefore a suitable sample point must also be
available on the low side of the manifold. Samples should
then be collected from both points. The problem with this
method is determining if the sand is causing erosion or not.
An erosion coupon or probe can also be installed on the
manifold which will indicate if erosion is occurring. When
sand production is anticipated on a test, sand traps should
be employed. These large, high pressure vessels would be
situated upstream of the choke manifold and remove the
sand before it reaches the higher velocity flow rates at the
choke. Control of the flowrate also can prevent erosion by
keeping it below the point where sand is lifted up the
wellbore to surface; however, this inflicts severe limitations
on the test design. Erosion can eventually cause:
• Reduced pipe wall thickness and cutting of holes in
pipework, including valves and chokes.
• Damaging (sandblasting) the separator and filling it
with sand.
• Cutting out of burner nozzles
• Sanding up the well and possibly plugging of
downhole test tools.

3.15Crossovers
Crossovers warrant special attention They are of the utmost
importance as they connect every piece of equipment in the test string
which have differing threads. In addition, they must be checked with
each mating item of equipment before use. 3.16
3.16 RIG UP EQUIPMENT
The main items of rig equipment used for testing, such as the
permanent pipework, it is essential that all the necessary rig equipment
which is to be used, has been checked.
 3.17 DATA GATHERING INSTRUMENTATION
This section describes the instrumentation required for measuring flow
rates, pressures, temperatures, gas and fluid properties which is listed
below:
3.17.1. Offshore Laboratory and Instrument Manifold Equipment
• Hydrometer for measuring gravity of produced liquids.
• Manometer for calibrating DP meters.
• Shrinkage tester to allow the calculation of production in stock tank
barrels.
• Dead-weight tester for pressure gauge checking and calibration.
• Gas gravitometer to measure gas gravity.
• Centrifuge for determining BS&W content. • Selection of pressure
gauges.
• Draeger tubes for measuring H2S and CO2 concentrations.
• Chemical injection pump.
• Surface pressure recorder.
• Water composition analysis test kit.
• Vacuum pump for evacuating sample containers.
• Downhole sampling kit.
Some instrumentation is mounted on the test seprator such as:
• Oil flow meters on both separator oil lines.
• Gas flow meter.
• Thermometers.
• Pressure gauges.

Surge Or Metering Tank

• Sight glasses and graduated scales.
• Thermometer.
 • Pressure Gauge.

Steam Heater
• Temperature controller. Other special instrumentation must be listed in the
specific test programme.
The two of the most important parameters measured during well testing
are downhole pressures and temperatures. This data is obtained from
BHP gauges installed as close to the perforations as is practicable. BHP
gauges are either mechanical or electronic type gauges .
Bourdon Tube Gauge This is a mechanical gauge and was the first type of
pressure gauge and is very robust. The well pressure elastically deforms
a Bourdon tube, the deflection of which is scribed directly on a time
chart. After recovery of the chart it is read and translated into pressure.
Charts can be read with hand operated chart reader or electronically by a
computerised chart reader. The gauge accuracy is much lower than any
of the electronic gauges.
 Fl owhead HIGH PRESSURE SET UP. 5Kpsi

ESD panel
Phase Tester

Choke Manifold

Stea m exchanger

By Pass Manifold

LOW PRESSURE Sepa rator

La b Ca bin SET UP. 1440 psi
Chemical
Injection

Pump

Surge Ta nk
Air compressors

85 ft Boom 85 ft Boom