SPE 74106

Environmentally Friendly Well Testing

Y. El-Khazindar,SPE, Schlumberger, M. Ramzi Darwish, ADMA-OPCO, and A. Tengirsek, Schlumberger

Copyright 2002, Society of Petroleum Engineers Inc.

Introduction
This paper was prepared for presentation at the SPE International Conference on Health, Conventionally, during cleanup and well-testing operations,
Safety and Environment in Oil and Gas Exploration and Production held in Kuala Lumpur,
Malaysia, 20–22 March 2002. both oil and gas are burned away into the atmosphere. The
This paper was selected for presentation by an SPE Program Committee following review of
combustion efficiency of fully atmospheric oxidation is
information contained in an abstract submitted by the author(s). Contents of the paper, as insufficient. Oil- and gas-flaring operations create significant
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
correction by the author(s). The material, as presented, does not necessarily reflect any amounts of emissions that contain unburned hydrocarbons,
position of the Society of Petroleum Engineers, its officers, or members. Papers presented at
SPE meetings are subject to publication review by Editorial Committees of the Society of
carbon monoxide and nitrogen oxides, which produce acid
Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper rain, smog, ozone at ground levels, and greenhouse gases in
for commercial purposes without the written consent of the Society of Petroleum Engineers is
prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 the upper atmosphere.
words; illustrations may not be copied. The abstract must contain conspicuous
acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O.
Acid rain depletes soil, pollutes water, damages forests,
Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435. endangers animal habitats and food chains, and corrodes
human-made structures, such as buildings, statues,
Abstract automobiles, and other artifacts made of stone or metal. Smog
Burning hydrocarbons during cleanup and well-testing and ozone cause human respiratory ailments, such as asthma,
operations produces toxic gases, soot, acid rain, unburned bronchitis and emphysema. Most scientists believe that
hydrocarbons and noise. Not only do these emissions have a greenhouse gases are a major cause of global warming.
damaging impact on the environment, but they also impose an Increased concentrations of water vapor, carbon dioxide,
economic impact: the cost of the oil and gas flared and the cost methane and other greenhouse gases trap heat energy in the
of the equipment used during the flaring operations. earth’s atmosphere. A gradual rise in the earth’s surface
A joint task force between two offshore operating temperature is expected to melt polar ice caps and glaciers,
companies in Abu Dhabi, United Arab Emirates (U.A.E.), expanding ocean volume and raising sea level, flooding some
with the help of the contracted service provider, worked to coastal regions and even entire islands.
implement innovative solutions to achieve flaring-emission Middle Eastern countries, including the U.A.E. with its
elimination targets and eliminate environmental risk. low-lying coastal areas, are concerned about rising sea levels
Innovative equipment modifications and design, coupled and potential flooding caused by global warming. They are
with new operational procedures, were implemented to concerned about increased radiation of heat and light from
neutralize the fluids used to prepare the well for production global warming, leading to regional desertification. As major
(allowing well effluents to flow through the test separator producers of oil and gas, they are concerned about the
during the cleanup phase) and to use a boosting system to deterioration of air quality from inefficient combustion of a
pump the oil into the sealine (fully eliminating oil flaring). sour gas supply.
The initial stages of the solution neutralized the acid Abu Dhabi is blessed with a charming environmental
flowed back to surface and eliminated the oil flaring. A heritage. Nevertheless, the environment in this part of the
multiphase flowmeter was then introduced to the system. Not world is no less fragile than anywhere else.
only did the multiphase flowmeter enhance operation Recognizing mounting international concerns over
flexibility, confidence in the information acquired, and environmental issues, a joint task force was formed in June
accuracy of the results, but it also eliminated gas flaring after 1997. The Abu Dhabi Marine Operating Company and the
the cleanup period. The minimal pressure drop across the Zakum Development Company, with the assistance of
meter and the high-pressure rating of the meter allow well Schlumberger, the testing services provider, worked to
effluents to flow naturally through the sealine without implement pioneering solutions for optimizing acid
separating the well-effluent phases. Deployment of the neutralization, reducing flaring operations in the short term,
multiphase flowmeter in the system reduced the gas flaring by and ultimately achieving zero hydrocarbon flaring to eliminate
about 60% during the overall job. environmental risk during well-testing operations(1-2).
2 Y. EL-KHAZINDAR, R. DARWISH AND A. TENGIRSEK SPE 74106

Environmentally Friendly Well Testing The PhaseTester multiphase flowmeter simultaneously

This paper describes the equipment and processes used to measures the total mass flow rate of the stream passing
achieve zero hydrocarbon flaring. through, with a venturi meter, and the individual phase
fractions, with a dual-energy gamma fraction meter. Working
The First Stages: Acid Neutralization and Oil Reinjection. on the multiple-energy principle, the detector picks up the total
The separation and reinjection of oil was introduced in June count of photons hitting the sensor, as well as the energy of
1998 (see Fig. 1). In this process, single-phase oil-reinjection each hit. The high-speed detector produces a signature count
pumps, specially designed to overcome high sealine pressures rate, over the two peak energy bands, which is a function of
of up to 1300 psi, were used to reinject the oil back into the the measured medium. Hits at two different energy levels are
production sealine. They covered the range from 12,000 filtered out and used for the fraction of oil, water and gas
BOPD at 410 psi to 3500 BOPD at 1300 psi. The use of calculations. The sampling frequency of 45 Hz is sufficient to
reinjection pumps, which eliminated the need for oil flaring define the continuous variations in the process flow.
during postcleanup operations, reduced the total oil flared The measuring section includes the venturi meter and the
by 65%. dual-energy gamma fraction meter. Both measurements—
To stimulate wells after drilling or workover operations, performed at the same time and place—eliminate anomalies or
10 to 15 gal/ft of 15% HCl are pumped downhole. The spent inaccuracies associated with meters that have a series of
acid flowing back to surface typically has a pH of 2 to 3. In sensors implemented along a pipe and that do not detect the
February 2000, an acid neutralization system was introduced same flow instantaneously.
(see Fig. 2). In this process, neutralizing agents are used to The PhaseTester multiphase flowmeter uses a blind tee in
keep the pH of the effluents flowing back to surface after an the flowline upstream of the measuring section to impose a
acid job between 5.5 and 6. Na2CO3 was chosen because it is predictable flow shape onto the flowstream. Effectively
soluble in water, cost effective and generally available on removing flow anomalies imposed by downhole conditions
well sites. and surface piping, this tee eliminates high-frequency flow
The neutralization system keeps the pH of water dumped instabilities in the measuring section.
overboard the rig between 5.5 and 6. Furthermore, it allows oil With an American Petroleum Institute (API) 6A rating,
separation from the start of flowback operations so that the the PhaseTester multiphaseflowmeter does not require
reinjection pumps can inject 100% of the oil back into the additional shutdown and pressure-relief systems. The
production sealine. PhaseTester Vx* multiphase well testing technology can be
The neutralization system involves pumping demulsifying used to accept fluids directly from the flowline and, after
agents upstream of the choke manifold and pumping the measurement, flow them back naturally to the production
neutralizing agent, Na2CO3, downstream of the choke sealine without any boosting services. Pressure loss across the
manifold. The neutralizing agent then flows into a test system is typically 3 to 30 psi, much lower than for a
separator, a 100-bbl dual-compartment skimmer, where conventional test-separation system.
chemical treatment reduces the oil-in-water content to 100
ppm before the water is dumped overboard. Testing. Between May 15 and October 1, 2001, 23 wells were
Introducing the neutralization system and the reinjection cleaned up and tested using the reinjection, neutralization
pumps eliminated the need for oil-flaring operations. Even system and PhaseTester multiphase flowmeter combination.
though initial stages considerably reduced emissions to The operation involved 36 postcleanup flow tests. Flowing
atmosphere, improving the system to eliminate gas flaring conditions during the flow periods were
during cleanup and well-testing operations remained • wellhead flowing pressure range: 90–1300 psi
a challenge. • oil flow rate range: 400–5500 BOPD
• gas flow rate range: 0.3–4.0 MMscf/D
The PhaseTester multiphase flowmeter. In May 2001, the
• gas volume fraction (GVF) range: 60–98%
PhaseTester* portable multiphase periodic well testing
• CO2 range: 1.5–8.0%
equipment(3-5) was introduced to the setup (see Fig. 3). The
PhaseTester’s high working pressure of 5000 psi allows • H2S range: 0–4%
placing the tool upstream of the choke manifold (see Fig. 4). • basic sediment and water (BS&W) range: 0–34%
This tool was selected to Figs. 5 through 11 plot the distribution of these parameters
• reduce the amount of gas flared by against the number of flow periods.
approximately 60% The 36 flow tests were compared to a traditional test
separator(6-7). Various authors have mentioned the difficulty of
• eliminate unnecessary shut-ins and flow disturbance
making comparisons with test separators (for example, Ting8
during testing operations (for example, during a
or Amdal et al.9). Separators are limited to performing a
helicopter landing)
reasonable liquid-to-liquid separation. In most tests the water
• provide a reliable, stand-alone flow rate
cut is calculated from in-line sampling from the choke
measurement.
manifold. The PhaseTester tool obtains reliable water
* measurements with the dual-energy spectral gamma-ray
Mark of Schlumberger
SPE 74106 ENVIRONMENTALLY FRIENDLY WELL TESTING 3

composition meter because this nuclear determination is not tool into the production sealine. Separating, boosting and
sensitive to the distribution of the phases. flaring operations were not required. The extremely low
Uncertainties are not limited to those of the individual oil pressure drop across the PhaseTester tool helped to achieve
and gas meters installed on a test separator. Other factors that gas-flaring reduction.
can affect the separator uncertainties are Confidence in the PhaseTester multiphase flowmeter’s
• meter factor drift caused by gas entrainment in the measurement reliability and flexibility was developed during
liquid leg of the test separator its evaluation over 36 flow tests. The PhaseTester multiphase
• slugging of the wells, which affects flowmeter was then deployed on three tests to reduce gas
test-separator performance flaring. Table 1 shows the reduction in gas flaring when the
• an operator-dependent process PhaseTester multiphase flowmeter was integrated into the
• poor liquid-to-liquid separation system. (Gas is typically flared during the initial
• overall accuracy affected by the whole system (back cleanup phase.)
pressures, lines, controls, etc.)
• frequency of data gathering. TABLE 1—[Summary of gas flaring reduction results]
For a calibrated separator operated by a dedicated crew, Well no. 1 Well no. 2 Well no. 3
the uncertainties are expected to be Total job duration, hours 75 80 41
• gas uncertainty in the range of 5 to 8% Total gas produced, MMscf 13.6 8.3 3.6
• total liquid uncertainty in the range of 5 to 8%. Gas flared, MMscf 3.20 0.54 0.77
Comprehensive preparation of the reference separator was Gas flared, % 24 7 21
performed in advance, ensuring a proper conclusion. A
Gas injected, MMscf 10.4 7.7 2.9
comparison of flow rate results between the PhaseTester tool
and the reference separator indicated that the PhaseTester tool Gas Injected, % 76 93 79
performed within its operating specifications, yielding the
Future Plans. Various studies have been carried out to define
PhaseTester multiphase flowmeter uncertainty figures +/- the
practical and economical means of fully eliminating the gas
separator uncertainties.
flaring. A multiphase pump is currently being considered as a
The flow rate uncertainties(10) for the PhaseTester flowmeter
solution. The challenges to designing a multiphase pump for
are as follows:
this application include the pump capability to cover a wide
Liquid:
range of flow conditions, as well as size and power
The larger of 2.5% of the reading, or 300 bbl/d, for
requirements. The joint task force is currently studying
GVF between 0 and 98%
technical details and performance of a multiphase pump
Gas:
specifically designed to suit a wide range of flow conditions.
The larger of 1% of the reading, or 140 scf/d, for
The current water treatment skimmer system is capable of
GVF between 0% and 30%
achieving an oil-in-water level of approximately 100 ppm.
The larger of 3% of the reading, or 420 scf/d, for
Different options were considered to achieve an oil-in-water
GVF between 30% and 60%
level of less than 15 ppm, the environmental emissions
The larger of 10% of the reading, or 1410 scf/d, for
guidelines limit specified by Abu Dhabi National Oil
GVF between 60% and 90%
Company’s Health, Safety and Environment policy. The joint
The larger of 15% of the reading, or 2120 scf/d, for
task force proposed an integrated water deoiling package. Full
GVF between 90% and 95%
feasibility and Hazardous and Operability studies were
Water-Liquid Ratio (WLR):
performed. The water deoiling unit, currently being
± 3% absolute for GVF between 0% and 70%
manufactured, is planned for utilization in January 2002.
± 4% absolute for GVF between 70% and 80%
The water deoiling unit was designed to meet the
± 5% absolute for GVF between 80% and 90%
following criteria:
± 8% absolute for GVF between 90% and 95%.
• a compact integrated solution including a degasser,
Toward Zero Gas Flaring. The ultimate goal is to achieve a hydrocyclone, reject oil tank, pumping units and
flaring-free operation. As a step toward this goal, the control panel, all on one skid that can be
PhaseTester multiphase flowmeter was deployed to reduce gas accommodated easily on the rig/barge without
flaring to a minimum. The PhaseTester flowmeter was inflicting space limitations
expected to decrease gas flaring by approximately 60% during • the ability to recycle the liquids within the system to
the overall job, as well as eliminate unnecessary shut-ins and ensure an optimum oil-in-water level
flow disturbance during the testing operations. • the ability to cover a wide range of flow rates and
After the flowback and acid neutralization, once the cope with changing flowing conditions. The system is
wellhead pressure increased to overcome the production capable of handling up to 6,000 B/D of water with
sealine pressure, well effluents bypassed the conventional oil-in-water levels of up to 1% at the inlet of
separator system and flowed naturally through the PhaseTester the system.
4 Y. EL-KHAZINDAR, R. DARWISH AND A. TENGIRSEK SPE 74106

Figure 12 is a schematic for the proposed future setup. 2. Hassan, M.M., Fadaq, A.S. and Beadie, G.: “Reduction of
Well Emission During Clean Up and Testing Operations by
Conclusions Rig,” paper SPE 68151, presented at the 2001 SPE Middle
East Oil Show and Conference, Bahrain, March 17–20.
During the initial stages of the project, utilizing acid
3. Kontha, I.N.H, Weimer, B, Retnanto, A., Azim A and
neutralization and oil-reinjection systems achieved zero oil Martinon, D.: “Monitoring Well Performance Using
flaring. After integrating the PhaseTester multiphase Multiphase Flow Meters,” paper SPE 68718, presented at
flowmeter into these systems, the following benefits the 2001 SPE Asia Pacific Oil and Gas Conference and
were observed: Exhibition, Jakarta, Java, Indonesia, April 17–19.
• When the wellhead pressure is high enough to 4. “Multiphase Flow Meters: A New Way to test Wells in
overcome the production sealine pressure, the well Production,” Hart First Look (September 1999).
effluents flow naturally through the PhaseTester 5. Mus, E. A, Toskey, E.D and Bascoul, S.J.F: “Added Value
multiphase flowmeter (bypassing the separator) into of a Multiphase Flow Meter in Exploration Well Testing,”
paper OTC 13146, presented at the 2001 Offshore
the production sealine. Gas flaring is eliminated
Technology Conference, Houston, Texas, USA, April 30–
(because of the minimal pressure drop across the May 3.
PhaseTester flowmeter), reducing the amount of gas 6. Atkinson, D.I, Berard, M and Segeral, G.: “Qualification of
flared during the whole job by more than the a Nonintrusive Multiphase Flow Meter in Viscous Flows,”
targeted 60%. paper SPE 63118, presented at the 2000 SPE Annual
• The PhaseTester multiphase flowmeter results, Technical Conference and Exhibition, Dallas, Texas, USA,
compared to a reference test separator, showed that it October 1–4.
performed within its operating specifications and 7. Theuveny, B.C., Segeral, G. and Pinguet, B.: “Multiphase
Flowmeters in Well Testing Applications,” paper SPE
provided reliable, stand-alone flow rate
71475, presented at the 2001 SPE Annual Technical
measurements. Conference and Exhibition, New Orleans, Louisiana, USA,
• Shut-ins to accommodate helicopter landings were September 30–October 3.
eliminated because fluids flow directly through the 8. Ting, V.C.: “Effects of Non-Standard Operating Conditions
PhaseTester multiphase flowmeter into the on the Accuracy of Orifice Meters,” SPE Production &
production sealine. Furthermore, helicopter flights are Facilities (February 1993) 58.
no longer dependent of the flow programs. 9. Amdal, J., Danielsen, Dykesteen, E, Flølo, D., Grendstad,
J., Hide, H.O., Moestue, H., and Torkildsen, B.H.:
Eliminating the risk to the environment posed by flaring Handbook of Multiphase Metering, Norwegian Society for
Oil and Gas Measurement, (1997).
hydrocarbons during well testing operations is a challenge. 10. Retnanto, A.: “Production Optimization Using Multiphase
Keys to achieve environmentally friendly well Well Testing: A Case Study from East Kalimantan,
testing operations: Indonesia,” paper SPE 71556, presented at the 2001 SPE
- understanding the flow conditions and Annual Technical Conference and Exhibition, New
operational constraints. Orleans, Louisiana, USA, September 30–October 3.
- setting reasonable targets to achieve flaring
free operations.
- examining and revising the existing
operational procedures. Metric Conversion Factors
- looking for areas in which a significant value could cp x 1.0* E–03 = Pa·s
be achieved by implementing innovative ideas bar x 1.013 25* E+05 = Pa
and solutions. psi x 6.894 757 E+00 = kPa
The deployment of an acid neutralization system and oil bbl x 1.589 873 E–01 = m3
reinjection pumps to completely eliminate oil flaring as well B/D x 6.624 471 E–03 = m3/h
as the utilization of the PhaseTester multiphase flow meter to ft3 x 2.831 685 E–02 = m3
3
reduce the gas flaring by more than 60% are examples of ft /D x 1.179 869 E–03 = m3/h
solutions that can be implemented to achieve environmentally lb/ft3 x 1.601 846 E+01 = kg/m3
friendly well testing operations.
*Conversion factor is exact.
Acknowledgments
The authors would like to thank the management of ADMA-
OPCO and Schlumberger for permission to publish this paper.

References
1. Messiri A., Al Attas, M.O., and Mohamed, N.: “Towards
Zero Flaring Emission,” paper ADIPEC 0964, presented at
the 2000 Abu Dhabi International Petroleum Exhibition and
Conference, Abu Dhabi, UAE, October 15–18.
SPE 74106 ENVIRONMENTALLY FRIENDLY WELL TESTING 5

Fig. 1—Schematic of the surface well testing setup and

reinjection pump Fig. 4—The PhaseTester multiphase flowmeter

12

10
Number of tests performed
8

0
90-200 200-500 500-750 750-1000 1000-1500 1500-1800
Wellhead Flowing Pressure (Psi)
Fig. 2—Schematic of the surface well testing setup,
reinjection pump and neutralization package Fig. 5—Wellhead flowing pressure distribution versus the
number of tests

14

12
Number of tests performed

10

0
>400 400-1000 1000- 2000- 3000- 4000-
2000 3000 5000 5500
Oil Flow rate (bbl/d)

Fig. 3—Schematic of the surface well testing setup,

reinjection pump, neutralization package and PhaseTester Fig. 6—Oil flow rate distribution versus the number
multiphase flowmeter of tests
6 Y. EL-KHAZINDAR, R. DARWISH AND A. TENGIRSEK SPE 74106

10.0 18

9.0 16

Number of tests performed

Number of tests performed

8.0 14
7.0 12
6.0 10
5.0 8
4.0
6
3.0
4
2.0
2
1.0
0
0.0
0 0.2-1 1-1.5 1.5-2 2-4
>0.3 0.5-0.75 0.75-1 1-1.5 1.5-2 2-3 3-4
H2S (%)
Gas Flow Rate (MMscf/D)

Fig. 10—Hydrogen sulphide distribution versus the

Fig. 7—Gas flow rate distribution versus the number number of tests
of tests

14
16
12
Number of Tests performed
14
Number of tests performed

12 10

10 8
8
6
6
4
4
2
2

0 0
60-70 70-80 80-90 90-95 95-98 0 1 2 3 4 5 6 7 8 9 10 24 34

GVF (%) BS&W

Fig. 8—Gas volume fraction distribution versus the Fig. 11—Basic sediment and water distribution versus the
number of tests number of tests

18

16
Number of tests performed

14

12

10
8

0
1.5-2 2-3 3-5 6-8 Fig. 12—Schematic of the reinjection pump, neutralization
CO2 (%) package, PhaseTester multiphase flowmeter, water
deoiling unit and multiphase pump
Fig. 9—Carbon dioxide distribution versus the number
of tests