Well Test Manual 1

Section 7

Introduction to Well Testing

Equipment
Table of Contents
Introduction…………………………………………………………………… 7-2
Objectives…………………………………………………………………….. 7-2
Well Test equipment…………………………………………………………. 7-4
Identification and Operations of Well Test Equipment …………………… 7-5
• Surface Test Tree………………………………………………………….. 7-5
• Coflexip Hoses..…………………………………………………………….. 7-7
• Emergency Shutdown Panel…..………………………………………….. 7-8
• Chemical Injection Pumps…………………………………………………. 7 - 14
• Sand Filters………………………………………………………………….. 7 - 15
• Pipe Work....…………………………………………………………………. 7 - 16
• Surface Safety Valve……………………………………………………….. 7 - 20
• Data Headers………………………………………………………………… 7 - 21
• Choke Manifold………………………………………………………………. 7 - 22
• Heat Exchanger. ………………………………………………………… 7 - 34
• Separator. ……………………………………………………………………. 7 - 36
• Calibration Tank....…………………………………………………………… 7 - 39
• Pumps....………………………………………………………………………. 7 - 42
• Diverter Manifold....………………………………………………………….. 7 - 46
• Burner Booms....…………………………………………………………….. 7 - 47
• Burner Heads....……………………………………………………………… 7 - 49
• Other Auxiliary Equipment....……………………………………………….. 7 - 51
1. Flame Arrester
2. Compressors and Hoses
3. Steam Generators
4. Propane Racks
5. Ignition System
Well Test Manual 1

Introduction
The section contains an introduction to Well Test Equipment

Objectives
After completing this section, you should be able to
• Know what equipment is required on a basic Well Test
• Know in what position you would find this equipment.
• Know what each piece of equipment does.

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What kind of equipment might you find on a typical rig up?

Sub Sea Test Tree (1)

Retainer Valve (2)
Lubricator Valve (3)
Stiff Joint (4)
Lower Master Valve (5)
Swivel (6)
Surface Test Tree (7)
Check Valve (8)
Line to Kill Pumps (9)
ESD Control Panel (10)
Chemical Injection Pump (11)
Surface Safety Valve (12)
Chemical Injection Pump (12)
Sand Filters (14)
Data Header (15)
Choke Manifold (16)
Steam Heat Exchanger (17)
Steam Generator (18)
Separator (20)
Flow Diverter Manifold (21)
Multi-sensor Relief Valve (MSRV) (22)
Pipework (23)
Calibration Tank (24)
Pump (25)
Compressors (26)
Propane (27)
Burner Boom Diverter Manifold (28)
ESD Pull Stations (29)
Burner Booms (30)
Burners (31)

We do not completely cover the Sub Sea Test Tree (SSTT) on this course but be
aware that one will be fitted if the rig is either a Semi-Submersible or Drill Ship. The
SSTT, allows for a safety system to be placed inside the BOP on the ocean floor and
this in turn enables the rig to be disconnected and moved show it be necessary.

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Identification and operational uses of the different equipment

Surface Test Tree

Operational Uses of Surface Test Tree

The Surface Test Tree is a temporary Christmas Tree and is used to isolate the
produced fluids from the formation from escaping at the surface. It acts as an
emergency shut in and there is the ability to kill the well through the STT. It allows for
remediation work to be carried out.
It has the following parts:

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Coflexip Hoses

Operational Uses of the Coflexip Hose

It is made up of several layers of materials for strength and durability

It has two main uses:

• Allows for the movement of the rig up and down

• Has no sharp bends should solids be returned

The Coflexip hoses are normally connected from the STT and hang down to the rig
floor, where they are then connected to the Choke Manifold or fixed pipe. Make sure
that the bend radius of the Coflexip is not outwith the designated guidelines. The
hoses should be supported where necessary.

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Emergency Shutdown Systems (ESD Systems)

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ESD Systems are made up of several pieces of equipment:

ESD Control Panel Surface Test Tree

Quick
Exhaust

Shut Down Pilots

Liquid Level Pilots

Shutdown Stations Pressure Pilots

ESD Shutdown Valve

If offshore this valve will be found on the Surface Test Tree, Flow Wing Side. It is
the primary means of shutting in at the surface. If onshore then there may be a
shutin valve on the Christmas Tree or if not then we can use a SSV (Surface Safety
Valve).

In many cases now the SSV is use as a secondary surface shut-in. The ESD
Shutdown valve is connected to the ESD Panel by a hydraulic hose, offshore and
sometimes onshore by an air hose when using Pneumatic Surface Safety Valve.

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Quick Exhaust

Depending on the time it takes for the valve to shut in, it may be necessary to fit a
quick exhaust.

Quick exhausts can either be hydraulic or pneumatic. They allow for the quick
release from the ESD valve of operating fluid or air, depending of the type of valve.
This can vastly reduce the time it takes for the valve to close.

ESD Panel

ESD Panel is usually positioned close to the Emergency Shutdown Valve. This
allows for much quicker operation. The panel works with Air over Hydraulics. This
means that air is controlling the hydraulics which means it works perfectly as an
emergency shutdown control.

The panel comes in many different styles, above is only one of the styles. It is
designed so that there is an air pilot system that can be run to different areas of the
rig. From any of these positions the air can be vacated from the pilot system which
operates the panel shutting in the ESD Valve.

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1. Connect the inlet air to the panel, making sure that the supply is enough to
operate the panel, normally around 90 to 130 psi.

NOTE: Some panels only allow 100psi maximum pressure. You must check this
before fitting area to panel and regulate as necessary.

2. Check the level of hydraulic fluid in the panel. You should start of with a full
tank.
3. Connect the hydraulic hose from the panel to the ESD Valve. Make sure that
the hose and fittings are of the right pressure rating.
4. Turn the pilot system to override and open the valve.
5. Operate the emergency shut in on the panel. This will evaluate the amount of
time it takes for the valve to shut when relieving the operating fluid back to the
panel. You can then decide whether to fit a quick exhaust.
6. Connect up the pilot line/s to the panel and run to ESD shutdown stations,
pilots etc. Shutdown stations should be strategically placed around the Well
Test Equipment and in places like the rig floor and if necessary at the
beginning of the burner boom.

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7. Once all the stations and pilot have been fitted you can add air to the system.
This will normally be around 30 psi. Sometimes however it may be more or
less, this is dependant on the shutdown instruments fitted. If you have a leak
of air in the system it may be necessary to use a mixture of soapy water to
determine where the leak is situated.

8. Each shutdown station must be checked for reaction time on the valve. The
maximum shut-in time for the valve is 10 seconds. Should the pilot system
take to long to shut in then it may be necessary to vacate the air from the
system quicker. You may have to fit pneumatic quick exhausts within the
system to allow the system to drop air pressure sooner.
9. It may be necessary at times to lock the ESD Valve open. This could be due
to Wire Line or Coil Tubing Operations. A cap on the ESD Valve may have to
be fitted.

Shutdown Station, Pilots etc.

Shutdown stations can consist of PULL, PUSH OR TURN to operate.

HI/LO Pressure and Liquid Pilots

Pressure: There are many different types available here are some of them.

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Where would you position Pressure HI/LO pilots:

1. Upstream of Choke.
2. Downstream of Choke
3. On Separator
4. On Tanks
5. At Diverter Manifolds
6. Any place where you have a chance of over/under pressure.

Liquid Pilots: They also come in many different styles, here are a couple.

Where would you position Liquid HI/LO pilots:

1. On Separators
2. On Tanks
3. Anywhere where you have a chance of high or low levels.

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Chemical Injection Pumps

MACH 24 Pump TEXSTEAM PUMP

Haskel Pump

Operational Uses for Chemical Injection Pumps

Injection of chemicals is often necessary for many reasons:

Hydration
Foaming
Emulsions
Waxing
Chemicals are normally injected either at the STT or Choke Manifold.

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Sand Filters

Operational Uses of Sand Filters

There are two basic reasons for having a sand filter:

1. Solids produced directly from the formation

2. Solids that have been either introduced to the Well Bore or Formation.

Solids produced directly from the formation

Sand is a problem in many oil and gas fields throughout the world. This is directly
related to the accelerated production of water, the unconsolidated nature of some
reservoirs, and the properties of some heavy and viscous crudes. As a result, many
operators are experiencing large quantities of sand in the well fluids, accompanied
by problems or erosion and solids accumulation, and/or equipment blockage.

Solids that have been either introduced to the Well Bore or Formation

These solids could have been introduced during the drilling i.e. Drilling Mud. They
could also be frac sand. This method is used to enhance the permeability of the
formation.

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Pipe Work

They come in many different sizes and lengths and Fittings. The most common
connections are:

Weco - 602 and 1502

How do we identify the pressure rating, standard of service and end

connections.

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End Connections

End Connections are identified with a colour coding system. Do not assume that if
the ends are not coloured you know what they are. You must always check.

Type

This is the new colour coding

for Expro pipework as from 1st
October 2008. On post job
inspections the colour coding
must be changed.

Type of Service

Standard service pipework does not have any colour on the pipe.
Sour Service will have a green band on the centre of the pipe.
All of our pipework should be rated to Sour Service. Do not assume that it is, always
check if there is no colour band on the pipe. Report this to your supervisor.

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Pressure Rating

Pressure rating is identified in three ways:

• Stamped clearly on the pipe
• Marked on the metal band on the pipe
• Welded on the wing.

If all three are not shown on the piece of pipework do not assume that it is of a
certain pressure always check. Report this to your supervisor.

Remember! Always flow into the thread

NOTE: It is imperative that a piece of pipe should adhere to all of the above
characteristics.

Thickness Testing of Pipework

During certain operations it is necessary to take thickness checks on pipework. This

would be any time solids are to be flowed back.

How often should we carry out a thickness check?

During these operations it will be necessary to carry out thickness checks on

designated spots where erosion could occur. This should take place at least once
per shift.

Where should I take these thickness tests during operations.

Initially a thickness test should be carry out on each spot before flowing occurs and a
check made against initial thickness of pipework. The place where the thickness
should be measured would be any position where a increase in velocity of the
material passing through the pipework could occur. This would be on elbows, tees
and bends.

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Thickness
Check to be
carried out here

It is necessary that these thicknesses are recorded and kept for reference purposes.
Make sure that you use the right form for submission.

How to carry out a thickness Check

Hand held ultrasonic thickness testers come in many different styles, but they all
work in the same way, by sending out a ultrasonic pulse which bounces back to the
instrument which then measures the response time, and thereby determines the
thickness of the metal. Some thickness testers as in the one on the previous page
can take into consideration the paint on the pipe. If the one you are using does not
then you must clean off the paint to the bare metal before testing.

Each tester comes with its own calibration block. Before switching on you must have
the calibration block ready with some ultrasonic gel placed on each thickness of the
block. Switch on the tester and press calibration, then place the probe on each of
the thicknesses of the block it should read that thickness.

When you are ready to do the pipework then place a spot of gel on each position that
you are going to test and then place the probe on that position. The gel acts as a
buffering agent allowing for good communication between the probe and pipe.
If you do not have any ultrasonic gel you can use a mixture of silicon gel and solvent.
(Not to much solvent) 10 – 1 mix usually works well.

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Surface Safety Valve

Two Types of valves are used:

Pneumatic Surface Safety

Valve. (Operated with air
only.) This is normally
used

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Operational Uses of Surface Safety Valve (SSV)

Due to more awareness to the possibility of damage to the environment, by the

discharge of fluid to the atmosphere, surface safety valves are now being
incorporated into the systems to isolate the equipment from the surface test tree.
In some areas of the world this is the only safety shut in fitted. This is mostly on land
jobs, where a permanent Christmas Tree has been fitted.
It is connected to the main ESD system and is operated when shutdown occurs.

Data Headers

Operational Uses of Data Headers

Data Headers are fitted upstream and downstream of the choke manifold. This
allows for the necessary instrumentation to be fitted.

What Instrumentation?

Upstream: Pressure Gauges, Pressure Recorders, Pressure Transducers, Chemical

Injection point, Sand monitoring, Deadweight Testers and Hi/Low Pressure Pilots.

Downstream: Pressure Gauges, Temperature Gauges, Pressure and Temperature

Transducers, Sampling.

When fitting all instrumentation to the data headers upstream, they must have
double isolation.

Fittings on data headers if over 10,000psi must be autoclave.

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Choke Manifold

Operational Uses of Choke Manifold

In this section we will cover the choke manifold more thoroughly than all of the other
pieces of equipment. The reason behind this, being, that during your early working
experience most of your practical experience will be on this piece of equipment.

What is a choke used for?

It is the primary means of controlling the flow from the well.

What does it do?

Reduces the flow by means of a reduction in the size of orifice flowing through.

What does it consist of?

A series of blocks, spools, valves, fixed orifice and adjustable orifice. This allows
should any part of the choke be damaged, it can easily be replaced.
There are two types of choke fitted to the manifold:

Adjustable Choke.

It primary function is to allow for the fixed choke to be changed during flowing
operations. Secondly should be used during clean up operations.
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The adjustable choke operates by a cone shaped end sliding in and out of a fixed
Adjustable choke been which has a tapered inside lip to allow for more accurate flow
control. By turning the wheel anti clock wise you pull the cone away from the Choke
Bean allowing a larger area for the fluid to pass by the cone.

To set the size of the Adjustable Choke there is a sleeve with a scale marked on it.
The sleeve is attached to the stem of the Adjustable Choke and as the stem moves
in and out so does the sleeve showing the scale. Before use this scale must be
zeroed to calibrate. To do this you must loosen the allen screw holding the sleeve in

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place. Shut in the adjustable all the way and turn and fix the zero point on the sleeve
to the zero point on the outer casing.

Indicator Barrel in 64ths

of an inch.

Bolt or Wing nut to stop

adjustable from moving off
set point due to vibration.

This will have to be carried out during every shut in.

During clean up operations it may be necessary to rock the adjustable choke handle
back and forward, should the choke block up. Before doing this you must inform the
scan operator and supervisor. So that they are aware of the problem and also to
make a note of the in the sequence of operations.

There is a screw on the outside housing of the stem that can be used to secure the
stem in position should there be excessive vibration. This must be loosened when
altering the adjustable choke size.

During each shutdown period the Adjustable choke should be pulled out and the
cone/Adjustable choke bean examined for wear. Also check the “O” ring and
threads on the cap and seat. Grease the threads with a high temperature grease.
When putting back together do not over tighten. This is not necessary as it is an “O”
ring seal.

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Damaged adjustable
Choke Stem and Seat

Undamaged adjustable
Choke Stem and Seat

Master Flo Adjustable Choke

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Fixed Choke.
Its main purpose is to provide a more accurate means of controlling
the well.

What do we can the insert we put into the fixed side? It is called a choke bean. It is
sized in 64ths of an inch. E.g. 32/64ths is 1/2inch choke 16/64ths is a 1/4inch choke.

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What should be on the choke before insertion into the housing?

Each choke bean should have a gasket fitted. This gasket can be a metal seal,
Teflon seal or “O” ring seal. MAKE SURE IT IS FITTED.

If this seal is not in place then there is more than a fair chance that you will cut out
the choke and the threads on the housing. Should this occur, not only will you have
to throw away the choke bean, but you will have to replace the whole Fixed choke
assembly.

There should always be a fixed choke bean in the fixed side. If there was no choke
bean fitted and the valve was passing there is every chance of damaging the internal
threads.

Before the choke goes offshore all choke beans should be checked for size and
make sure that they are marked accordingly. A full range of chokes should be
available when going offshore. Always carry spare gaskets.

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Standard Choke Bean Table (3” Choke Manifold)

Choke Bean Size Imperial Choke Bean Imperial Choke Bean Metric Choke Bean
64ths Size (Fractions) Size (Inches) Size (mm)
4 1/16 0.0625 1.5875
8 1/8 0.125 3.175
12 3/16 0.1875 4.7625
16 1/4 0.25 6.35
20 5/16 0.3125 7.9375
24 3/8 0.375 9.525
28 7/16 0.4375 11.1125
32 1/2 0.5 12.7
36 9/16 0.5625 14.2875
40 5/8 0.625 15.875
44 11/16 0.6875 17.4625
48 3/4 0.75 19.05
52 13/16 0.8125 20.6375
56 7/8 0.875 22.225
60 15/16 0.9375 23.8125
64 1 1.0 25.4
72 1 1/8 1.125 28.575
80 1 1/4 1.256 31.75
88 1 3/8 1.375 34.925
96 1 1/2 1.5 38.1
104 1 5/8 1.625 41.275
112 1 3/4 1.75 44.45
120 1 7/8 1.875 47.625
128 2 2 50.8

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Pressure Testing

Just after rig up the equipment has to be pressure tested here are the guidelines for
pressure testing the choke manifold.

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What position should the valves be in when getting ready to open up?

• Both front valves closed.

• Both back valves open.
• Sample point needle valves closed.
• Needle valve to downstream gauge open.
• Adjustable choke set off zero.
• Positive choke installed - choice dependent on well performance.

Opening the well through the choke.

An opening choke size is agreed upon and usually a small size.

Adjustable choke set to predetermined size.

Open front valve on adjustable choke monitoring upstream and downstream

pressure continually.

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Problems associated with Flowing through the choke!

It is necessary that you understand what is happening when working at the choke
manifold. Here are some problems, causes and solutions.

1. Upstream and downstream pressure rising:

• You may have a blockage downstream of the choke. Investigate

where the problem is occurring and fix. It may only be a valve partially shut, the
heater choke on a smaller size than the choke. If you cannot fix the problem it
may be necessary to shut in and sort out the problems. As soon as this problem
occurs inform the supervisor.

• If you are flowing during a clean up, this may be an indication that the
well is cleaning up. You will know this by the increase in back pressure to the
burners.

2. Upstream pressure rising and downstream pressure falling:

• You may have a blockage at the choke, solids packing around the adjustable
choke. To cure this rocks the choke. It may be necessary to rock it quite
severely. Inform supervisor and scan before carrying out this operation.
• This could be caused by hydrates forming at the choke (freezing). To solve
this you can start injecting methanol before the choke. If this does not cure the
problem then you can either increase the choke to increase the temperature
or shut in to clear the blockage.

3. Upstream pressure dropping and downstream pressure dropping.

• You have a blockage upstream of the choke. This could be caused by solids
or hydrating. Inject methanol at the STT for hydrating. If it is solids then it is
likely that you will have to shut in and clear the problem.
• When flowing back during a clean up it is possible to have a drop in pressure
due to liquid (water) coming to the surface. Once the water has reached the
surface, the pressure to rise back to normal, or until the next slug of water
comes to the surface.

4. Upstream pressure dropping and downstream pressure rising.

• This is a sure sign that your choke is cutting. Change sides and remove,
inspect and replace choke if necessary.

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How to change fixed chokes

• Check that the sample points/bleed valves are closed.

• Set adjustable choke to same as on the fixed side.
• You will need two men to do this.
• Check to make sure the downstream valve on the adjustable side is open.
• The person on the adjustable side will crack open the upstream valve unti he
feels the well.
• At this stage the person on the fixed side will start to shut in at the upstream
fixed side.
• Both persons will work together with one person controlling the operation, by
looking at the upstream gauge to try and maintain a stabilized pressure
throughout the operation.
• Once the sides have been changed then the operator on the fixed side will
shut the downstream valve on the fixed side.
• He will then bleed of the pressure by opening the bleed valves.
• Once there is no pressure coming from the bleed valves he will loosen the
cap on the fixed side, only by two turns.
• He will then make sure that there is no pressure trapped by pushing in the
plug on the cap. If it moves freely then there is no pressure.
• Remove the cap completely. Make sure that there is a catchment tray
positioned under the end of the fixed choke.
• Once the cap is removed, check the threads on the cap/choke body. Check
that the seal (“O” ring or other) is intact. Place carefully at the side. Be aware
that the cap is heavy.
• Using the proper equipment and PPE remove the Choke Bean from Choke
Manifold. Inspect for damage and clean. When removing the choke bean
there is every likelihood that a large amount of fluid will be trapped behind it.
This will come out as you remove the bean.
• Inspect inside of the housing for damage.
• The new bean will be inspected for size, gasket and to make sure that there is
no damage to it. Have someone else inspect the bean for size.
• Grease the new bean with a high temperature grease. Then insert the bean
into the housing. Make sure that it goes all the way in. If it doesn’t then this
can cause gas/fluids to pass on the outside and will cut the bean and housing.
• Grease the threads on the cap and choke body with high temperature grease.
• Turn the cap until it is hand tight. Several light taps should secure the cap if it
is an “O” ring seal. If it is a metal seal then it will require substantial tightening.
Be very careful with the instrumentation during this operation. It may be
necessary to remove it.
• Close the bleed valves.
• Slowly open the downstream valve on the fixed side to equalize the pressure
across the fixed side upstream valve.

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• During this time the person on the adjustable choke has been slowly opening
it up to the new size of fixed been. The Data acquisition should be informed of
this operation.
• Now reverse the operation of changing sides.

NOTE: DO NOT IN ANY CIRCUMSTANCES TAKE SAMPLES, BS&W’S OR

GRAVITIES FROM THE UPSTREAM SIDE OF THE CHOKE. ALL THESE MUST
BE TAKEN AT THE DOWNSTREAM (LOW PRESSURE SIDE).

Well Stream Heaters

These fall into two categories:

• Direct – Steam Heat Exchangers

• Indirect – Diesel, Gas or Electric fired Heat Exchanger

Steam Heat Exchangers

Normally fed by either the rig steam system or by Steam Boiler/Generator.

Whichever supplies the steam they are used to heat the Well Stream Fluids and
should be placed as near after the choke as possible.

Indirect Heater (Gas, Diesel or Electric)

Used to heat up the Well Stream Fluids. The coils sit in a bath of water (Not Salt
Water) and heat from the burner heats the water and the water then transfers the
heat to the coils, therefore indirectly. Great care must be taken when positioning this
piece of equipment, as it has an ignition source. The stack must have a flame
arrester fitted to the top.

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Separator

Operational Uses of a Separator

A separator designates a pressure vessel used for separating well fluids produced
from oil and gas wells into gaseous and liquid components.

How many phase’s will a normal separator have?

Three phase’s.
Gas
Oil
Water
It is usually a 1440 psi rated, but can go to 2000 psi.
It is usually horizontal, but can be vertical.

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What are it’s Internals?

Explanation of how it Operates

The oil enters the separator and either hits a deflector plate or mini cyclone. This
helps separate the liquids from the gas. The liquids fall to the bottom of the
separator and travel along the separator where near the far end is a weir plate. As
the liquid inside the separator has a certain retention time. The gas breaks out of the
liquid and the oil and water separate. As the oil is on the top, the levels are set so
that only oil will pass over the weir plate into the oil compartment. A pressure must
be maintained within the separator to push the fluids out. This pressure is
dependant on many factors. These will be covered in future courses.
Where the oil and water leave the separator there is a Vortex Breaker. This stops
the fluids from swirling down the pipe as you would see in a kitchen sink when you
empty the water out. The levels are maintained by controllers which are air
operated. A float system allows the controllers to adjust the levels accordingly.

On the side of the Separator you will see sight glasses. These give the operator a
visual display on how much Fluids (either oil or water) are contained in each
compartment. On the water side you will be required to see an interface between
the oil and the water.

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Meters on the lines provide the operator and Data Gathering Software a meaning of
measuring the flow rate.

As the Gas flows along the top of the separator it passes a set of plates positioned in
the centre of the separator. As the gas passes over the plates small droplets of oil
which is entrained in the gas forms on the plates. As the oil collects it then runs
down the plates and falls into the liquid below.

Before the gas leaves the separator is passes through a mist extractor which is
basically a wire mesh (like wire wool). Oil collects on the mesh and then falls into
the oil compartment below.

The pressure within the separator is maintained by a valve on the outlet of the gas
line. This is set at a prescribed pressure setting and maintained by a pressure
controller which monitors the pressure on the outlet line.

For measurement the gas passes through an orifice (small hole in a metal plate).

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The difference between the upstream and downstream pressure as it passes

through the plate and is measured. This is used in part to calculate the gas rate.
During clean up operations the separator is bypassed until such time as there are
not solids and a sufficient amount of gas to run the separator.

Further instruction on the separator will be given in the next course.

Surge Tank
This can be called Calibration Tank, Pressure Tank. In some areas they use
Atmospheric Tanks to calibrate there meters.

Operational Uses of a Surge Tank

The main reason for having a Surge Tank is to allow for the calibration of the meter
during flowing operations.

Although the meters at reasonably accurate it is required that they be calibrated

against a known amount of fluid.

During each flow rate the flow to the burner boom is diverted into the tank for a
specified period. Two people are required for this operation.

Before diverting to the tank a reading is taken on the level inside the tank. It is better
to have a level showing in the tank so that you know what the starting amount is.

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At the moment of diverting to the tank the operator on the separator will take a meter
reading. Flow should continue to the tank for as long a period as possible. This will
allow a more accurate meter calibration.
When time to divert back to the flare, the operator at the separator will take a reading
at the same time as diverting back to the flare. An extra man must be present at the
flare to make sure that ignition takes place.

The pressure inside the tank is then bled off and together with other factors the tank
reading is compared to the meter reading and then a correction factor for the meter
is set for that flow rate.

The Surge Tank is then emptied ready for the next calibration.

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What is the normal pressure range of a tank?

Pressurized tanks are normally rated at 50 psi, maximum allowable working pressure
(MAWP). Although the MAWP is 50 psi, the tank will normally be set at around 35
psi. This is carried out by a back pressure valve and controller fitted to the tank.
These tanks will also be fitted with a relief valve and rupture disc.

Atmospheric Tanks

These tanks can be cylindrical upright or box type tanks. Some of the box type tanks
have two chambers allowing to divert the flow from one side to another. These tanks
are not pressurized. Make sure that no pressure build up occurs in these tanks. The
relief line normally goes straight over the side. They can also be used as calibration
tanks. As these tanks are open to atmosphere, they must be placed in such a
position that when they vent (which is constantly), the gas does not discharge into a
hazardous area, or near vents, entrances and air intakes. These types of tanks are
commonly used in land jobs.

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Other uses for tanks!

Tanks can also be used for storage of oil. In some areas, it is not allowed to burn oil.
The oil therefore, is stored and then transported from rig/site for disposal.
They can also be used to extraneous materials coming from the well. This could be
frac sand, mud, brine, acid water mix or reservoir solids. These are normally stored
in the tank until the end of the job then send for cleaning.

Pumps

Pumps fall within two categories Centrifugal Pumps and Positive Displacement
Pumps.

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Centrifugal Pumps

These pumps operate by an impellor system, as the fluid enters the pump an
impellor pushes the fluid outward where it leaves the pump. These are normally low
pressure pumping systems, with a high volume rate.

Positive Displacement Pumps

These can be broken down into different categories:

• Reciprocating – using a piston system to push the fluid out. These are very
high pressure pumps and commonly used for pressure testing and chemical
injection.

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Gear/Lobe pumps

These pumps use a set of gears to push the fluid through the pump. They are high
pressure but lower volume pumps.

Screw pumps (seepex)

The screw action of the pump pushes the fluid through the pump and out the
discharge. Again this is a high pressure pump and can discharge much more fluid
than the gear or lobe pumps.

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Radial Pumps

These pumps are very similar in operation to the centrifugal pump, but they are
positive displacement pumps and can pump at high pressure and medium flow rates.
Do not mistake them for centrifugal pumps.

What is the important difference between a centrifugal pump and a positive

displacement pump?

The positive displacement pump must always have the suction open! If not, then the
pressure inside the pump will build up instantaneously and can blow the seal on the
pump.

NOTE: Always make sure that the discharge flow path from the pump is open.
Positive displacement pumps can build up very high pressures and could
cause at the minimum discharge to the atmosphere, or it could prove FATAL.

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Diaphragm Pumps
Commonly used to transfer fluids from the Calibration Tanks to Flare or to stock
tanks.

Diverter Manifolds

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Diverter Manifolds are normally fitted in the lines to the burner booms. This allows
the flow direction to be altered according to operational requirements. Gas and oil
lines can then be diverted to either boom due to changes in wind direction. Loading
and unloading at the rig.

They can also be fitted at the tanks, either used as bypasses to the tank or maybe if
you have more than one tank, to divert the flow to the different tanks.

Burner Booms

Burner Booms are placed at the corner of rigs to allow the burners to be fitted at
there ends. They are connected and slung from the King Post on the rigs. In many
areas EXPRO supply the King Posts. The Burner Booms hang from the side of the
rigs and can be different lengths. This is dependent on the heat radiation coming
from the burner heads.

They allow the operator safe access to the burner heads when not flowing, and they
keep the burners far enough away from the rig so that no damage can occur. They
have fixed lines attached to the Burner Booms, for, Oil, Gas, Air, Water, and ignition.

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Types of Burner Booms

TX600

U Type

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There is a set procedure for working on Burner Booms and this should be followed
strictly.

Burner Heads

SuperGreen

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Sea Emerald

Vulcan Burner

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Burners allow for the oil and air to mix as they pass through Burner Head. This
causes the oil to form a fine mist which is in turn easier to ignite and burn.

Other Auxiliary Equipment

Flame Arrester

Compressors and Hoses

Steam Generators

Propane Racks

Ignition Control System for Burner Head

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Flame Arrester

Flame arresters are passive, mechanical device installed in a flammable vapor

piping system. The arresters' functions are: (1) to allow the passage of vapor under
normal operating conditions and (2) to stop and extinguish any flame front
propagating through the flammable vapor/air mixture under emergency conditions.
Stopping the flame protects the equipment located in the piping system, from the
catastrophic damage that may result from an uncontrolled ignition. A variety of
arrester designs are available. The choice of a proper arrester depends on factors
such as the location of the arrester with respect to the ignition source and the
flammable properties of the vapor/air mixture.

Compressors and Hoses

Air compressors are normally used to supply the air necessary for the burner to give
a clean burn. They can put out as much as 750 scf/min at 100 psi.
They may also if necessary be used to supply air to the instrumentation and ESD
system.
Hoses must be of the right size to supply enough air to the burners. They should be
meticulously inspected before use.

NOTE: AIR – PRESSURE – DANGER (even 100 psi is enough to cause severe
injury)
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Steam Generators
It is commonly necessary to use Steam Boilers/Steam Generators to supply steam to
the Well Stream Heater. These will be run by a qualified operator only.

Propane Racks
Propane racks are fitted near the burner boom to supply the ignition system with a
fuel for the pilots. They should be strategically placed so that they are easily
accessed during flowing operations and not subject to ambient heat from the burner.

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Ignition System for Sea Emerald Burner Head

The control Box for this burner sits close to the Burner Boom but not on it, and in an
area easily accessible.

Ignition System for Super Green Burner Head

The control for this will be placed as with the Propane in an area of easy access.
They require an electrical source.
EQUIPMENT OPERATIONS AND MAINTENANCE WILL BE COVERED MORE
THOROUGHLY IN THE NEXT COURSE.

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