Well Testing Equipment

Hatem Hussein
Senior CWI Engineer
 1. SWT EQUIPMENT

2. FLOWHEAD & SWIVEL

3. SURFACE SAFETY VALVE (SSV) & ESD

4. CHOKE MANIFOLD & DATA HEADER

Contents
5. SEPERATOR & TRANSFER PUMP

6. HEAT EXCHANGER

7. GAUGE & SURGE TANK

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 1) SWT Equipment
The surface test equipment required to conduct a well test will depend both on the planned operations and also on where
the test is being conducted, onshore or offshore (jack-up or a floating vessel). In this chapter we shall look at the major
components of a surface test package which are commonly used on a variety of testing operations.

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 1) SWT Equipment

Simplified Well Test Equipment Diagram

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 1) SWT Equipment
Recommended Practices:

1. All tests should incorporate an Emergency Shut-Down (ESD) system. The manual shutdown buttons should be located in the following

areas: close to the well testing spread, on the drill floor near to the drillers dog house and in safe locations away from the main testing area.

2. For high pressure, sour gas and sand frac clean ups, a dual isolation, double block and bleed valve arrangement is recommended for the

choke manifold. In all other cases a single valve isolation arrangement is deemed acceptable if there are further tested latent barriers

upstream of the choke that can be activated in the event of a leak.

3. The bubble hose and needle valve should be positioned downstream of the choke.

4. All flowlines should be tied down or pinned.

5. The number of flowline bends and elbows should be minimized.

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 2) FLOWHEAD & SWIVEL
• When testing a well, a surface shut off is usually provided by a flow control head or Flowhead
that functions as a temporary Christmas tree.
• The Flowhead is located on top of the well and is the first piece of equipment at the surface
that fluid flow through.
Functions:
1. Support the weight of the test string and provides a means of surface well control when
completing, testing, or performing live well intervention operations
2. A dynamic swivel is located between the main valve block and the lower master valve,
allowing rotation of the string without rotating the flowhead Valve actuators are controlled
from a console located on the rig floor and link to the emergency shutdown system for the
flow wing valve. This configuration allows for remote shut-in of the well at the flowhead
3. It flows out of the well through flow valve & pump fluid into the well through kill valve
4. It allows tools (surface wireline or coiled tubing equipment) to be introduced into the well
through the swab valve and handling sub.

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 2) FLOWHEAD & SWIVEL
• The Surface Test Tree used during a DST is usually a four way cross (often mono-block construction)

with four valves. The surface test tree should be able to support the full string weight and all four

valves should be able to seal with differential pressure from either side.

• It is quite common to find surface test trees with either the master valve, or the production wing valve,

or both, hydraulically operated with these valves set to close on loss of hydraulic pressure from the

control line.

• It is good practice to include a non-return valve in the kill wing line

• Most surface trees include a swivel to allow pipe rotation as this may be required to set packers or

operate rotation type drill stem testing tools. The swivel is a pressure balanced sub that allows

unrestricted rotation of the upper or lower half with respect to each other.

• Particularly on high pressure wells the inclusion of a lower master valve below the swivel is

recommended.

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 2) FLOWHEAD & SWIVEL
 Additional features;
• Provides at least two surface pressure barriers
• Ensures reliable shut-in for harsh environment operations
• Provides immediate flow shut-in if downstream equipment fails
• Prevents overpressure conditions on downstream equipment
• Allows test string to be hung from the elevator
• Enables rotation of the string without rotating the flowhead
• Includes double metal-to-metal seal for reliability in harsh environments
• Activates remotely
• Automatically closes flow valve if control pressure is lost
• Allows a kill-line connection for pressure testing, injection, or killing the well
• Allows tools to be introduced and run into the well through the swab valve

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 2) FLOWHEAD & SWIVEL
Swivel
• The flowhead swivel is inserted between the master valve and the main valve block. It allows the subsurface equipment to be rotated with respect to the main
flowhead block. Using a swivel, it is possible to rotate the subsurface equipment without disconnecting the flow line or the kill line. An example of this is using the
swivel to set the drill stem test (DST) packer downhole. Another example is to re-latch the subsurface connection used with floating rigs.

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 2) FLOWHEAD & SWIVEL
• The swivel is designed to allow rotation of the subsurface string while supporting the weight of the whole subsurface string. Roller

bearings are used to support the significant weight of the test string and the downhole tools. Ball bearings are used to support the lighter

weight of the flowhead and the equipment above the flowhead.

• The swivel should not be rotated under pressure which means that it is not designed to hold the pressure when submitted to a

continuous rotating movement like in drilling operations. The most common applications (as mentioned earlier) are done with the

pressure close or equal to zero at a very low rotating speed .

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 3) SURFACE SAFETY VALVE (SSV)
Hydraulic Surface Safety Valve - SSV is designed to quick closure due to a pipe leak or burst, equipment malfunction, fire, or similar
emergency.
The Surface safety valve (SSV) is normally closed, pressure needs to be applied to the actuator to compress the spring and open the
valve.
The pressure needed to keep the valve open can be provided with a simple hand pump which, in an emergency, is bled off on the rig
floor. However, a more sophisticated system called an emergency shut down system(ESD) is recommended because it allows the
actuator to be activated remotely.
The available safety valve sizes from 1-13/16" through to 7-1/16",of pressure rating from 2000psi to 15000psi.

Hydraulic Surface Safety Valve feature:

• Visual position indicator.
• Optional fire protection (fusible loop).
• Separate stems can make them easy disassembling and maintaining.

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 3) Emergency Shutdown System ESD
• The well, rig and surface test facilities must be protected by an integrated
emergency shut-down system ESD
• The key valve on the Emergency Shut Down ESD system is the hydraulically or
pneumatically operated flow wing valve on the flow head which can be
operated remotely from selected positions on the wellsite.
• If the air supply is lost, the flow wing valve will close shutting the well at the
flowhead
• Hi-Low pressure pilots may also be integrated into the system, these are pre-set
pilots which may be set to a specific pressure and are installed at various key
points in the system to affect an emergency shut down should pressure exceed
the allowable working pressure of the particular component.
• They should be set (pressure) to actuate before the relief valve can operate.
ESD P & ID
• The ESD system with all its sensors, shut in and relief valves should be draw on
the P & ID drawing (Process and instrumentation Drawing)

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 4) Choke manifold
• A production choke is a device incorporating an orifice that is used to control

fluid flow or downstream system pressure.

• It’s function is also to accomplish critical flow in order to have good

measurements at the separator (no pressure interference from the well).

• Chokes are available in many configurations but usually have an adjustable and a

fixed choke built into a manifold system.

• The manifold allows the well flow to be diverted by an arrangement of gate valves

through either the adjustable or fixed choke leg.

• Either leg can be isolated from the flow without the need to shut in the well.

• The isolated leg, can be then de-pressurized and opened up for repair, cleanout

or choke bean replacement.

• Standard is double block and bleed manifolds.

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 4.1) Choke manifold types
1. Adjustable choke
• Adjustable chokes enables the fluid flow and pressure parameters to be changed over a wide range to suit
process or production requirements.
• They consist of a conical stem attached to a threaded shaft which can move the cone of the stem in or out of a
cone shaped seat or bean.
• The position of the choke is indicated in 64ths of an inch
• They are susceptible to wear and erosion but both cone and seat can be replaced.
• They are mainly used for opening up wells (starting flow) and clean up periods.
• They are not used for test flow periods (hours or days) as they are not accurate enough when it comes to orifice
size due their susceptibility to erosion and vibration at high rates can cause the choke to close or open during
flow.
• They will not provide a positive shut off when closed some leakage will occur so the isolating gate valves must
be closed as well when shutting in the well.

3” NOM adjustable choke stem and seat

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 4.1) Choke manifold types
2. Fixed choke
• Fixed chokes use an insert seat or bean similar to the one used in adjustable choke
• They are accurately manufactured and the bore is of an very fine finish to reduce turbulence during flow.
• The bore is available in sizes from 4/64” to 72/64” in 4/64” steps and from 80/64” to 128/64” in 8/64” steps.
• Fixed beans are machined in tungsten carbide) resistant to erosion with more expensive types having a ceramic
insert.
• Usually are 6” long to provide a long life during extended flow periods.

3” NOM fixed bean

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 4.2) Choke size Conversion
Choke size in 64th of an inch Choke size in millimeter Choke size in 64th of an inch Choke size in millimeter

4/64 1.5875 52/64 20.6375

8/64 3.1750 56/64 22.2250
12/64 4.7625 60/64 23.8125
16/64 6.3500 64/64 25.4000
20/64 7.9375 68/64 26.9875
24/64 9.5250 72/64 28.5750
28/64 11.1125 80/64 31.7500
32/64 12.7000 88/64 34.9250
36/64 14.2875 96/64 38.1000
40/64 15.8750 104/64 41.2750
44/64 17.4265 112/64 44.4500
48/64 19.0600 120/64 47.6250
Surface Well Testing 1 inch = 25.4 mm 128/64 50.8000 16
 4.3) Data Header
• The upstream data header is a HP section of pipe that is inserted into the flow line between the hydraulic actuated surface shut
down valve (SSV) and the inlet side of the choke manifold.
• It is used to attached pressure gauges and thermometers for recording surface flowing and shut in pressures.
• Samples maybe taken at this point if the choke upstream pressure is above the fluid bubble point.
• It is important to use at least two needle valves (10k psi) on every sample or pressure measuring point (double barrier philosophy)
• Chemicals can also be injected if required upstream of the choke manifold, i.e. glycol, methanol, de-emulsifiers,…etc.
• Other data header can be used in downstream of choke manifold and upstream and downstream of sand filters if used.
• Sand detection is often done with clamp-on type acoustic devices that will detect sand production as a function of sound. The sand
detector probe manifold is also mounted downstream of the choke manifold.

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 5) Separator and Transfer Pump
 Separator

• The separator is the heart of the well test surface package, it separates the produced reservoir fluids into three phases

and controls and measure the flow rate of each phase.

• Samples of the phases may also be taken at the separator. The standard industry test separator is the 3-phase horizontal

type, 1,440 psig maximum working pressure unit which can handle up to 80 mmscf/day of dry gas or up to 10,000 BPD of

oil and associated gas at its working pressure.

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 5) Separator and Transfer Pump
 DESCRIPTION AND TYPES

• Whilst there are several variations of separator design, they are either vertical or horizontal and either cylindrical or spherical in shape.

• The separator selected for the proposed well test should be sized to provide optimum flow rate for the expected conditions.

• Separation is accomplished principally by gravity, the heavier liquids falling to the bottom and the gas rising to the top.

• Float valves or other liquid-level controllers regulate the level of the water and oil in the bottom of the separator.

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 5) Separator and Transfer Pump

Horizontal 3-phase Separator

Vertical 3-phase Separator

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 5) Separator and Transfer Pump
 Notes on Separator operation:

• Separators are designed so that produced fluids enter the vessel, where they are retained long enough for the oil to separate and float to the top of the water.

• This process is enhanced by deflector plates that slow flow velocity and by coalescing plates that gather oil into large droplets.

• Once the oil and water have separated, the oil then flows over a weir into a separate section of the vessel while water remains in the original compartment.

• Mechanical water- and oil-level controller arms, with attached floats lifted by the rising fluid, trigger valves (not shown) that release oil and water along their respective flowlines.

• Mist extractors remove oil droplets from the gas phase before gas exits through a valve at the top of the vessel.

• Safety valves allow gas to escape into the atmosphere rather than overpressure the vessel.

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 5) Separator and Transfer Pump
 TRANSFER PUMP

• The transfer pump is used to pump oil from a tank to a burner or from a tank to an available flowline. Transfer pumps can be either electrically

or diesel driven and are used to pump the oil from the surge tank to the disposal point, e.g. burner, stock tank or flare pit.

 Design Requirements

• Provide sufficient pressure to successfully atomize the oil when burners are used

• Re-injecting oil into the flow line from separator or stock tank (high capacity/high pressure pump may be required)

• Transfer of oil between tanks

• well testing surge tanks or gauge tank transfer

• reinjection of separator oil into a flowline

• Flushing through system with water.

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 6) Heat Exchanger
• The heater is used to heat up the produced well fluids to prevent the formation of hydrates or wax. Some gas or high GOR oil wells are

susceptible to hydrate formation particularly when first opened up from closed in.

• Direct fired heaters that burnt diesel to heat up water surrounding the coils through which the well fluids flowed on their way to the separator

used to be quite common.

• Nowadays for safely reasons, they have been replaced on offshore locations by "steam heat exchangers" and onshore by indirect heaters. These

are heated with steam supplied from a self contained steam generator.

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 7) Gauge and Surge Tanks
 Gauge Tank:

• It is a non-pressure vessel with an open venting system, used mostly for storage purposes and to allow measurement of volumes and the flow

rates of produced fluids (hence the name Gauge Tank)

• It has fell into disuse mainly because it is not a safe option when flowing back H2S producing wells

 Surge Tank:

• It is a more versatile version of the Gauge Tank, it is used to measure liquid flow rate and the combined shrinkage and meter factor, and can

be used as a second stage separator and also used for calibrating flow meters, also can be used for storage.

• It is a H2S service pressurized vessel with a relief valve and a back pressure valve fitted on the gas outlet valve which can be preset to

maintain backpressures in the tank up to 45 psi (250 psi tanks are also available)

• The gas outlet is vented away from the well test area of particular safety interest for a H2S well.

• Some reservoir engineers will ask for a Daniels Junior Box to be fitted on the gas outlet line to ensure all produced gas is measured for

accurate GOR measurements.

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 7) Surge Tanks
 General Features:
• Surge tanks can be split vertically providing 2 X 50 bbl
compartments, others are 100 bbl tanks.
• Tank is pressurized so no gases are vented to
atmosphere near the test area
• Fitted with sample point and pressure and temperature
ports
• Measures liquid flow rates, shrinkage and meter factors
• Sight glasses level indicators
• Fitted with a bypass manifold to enable isolation
• Fitted with access man-ways for internal inspection and
debris removal

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 Hatem Hussein
Senior CWI Engineer

Thank you
[email protected]

00201003607896 – 00201275177448

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