Ultrahigh Rate Well Testing with Zero-Flaring Solution: An Innovative and Sustainable Approach

Abstract A gas project was facing a unique requirement to test the wells to the maximum sand-free rate. The major challenge was to identify the maximum sand free flow rate with low well head flowing pressure. The max flow rate is expected to be 300% more than standard well testing job in similar flowing pressure. Zero flaring and zero discharge are also among the critical requirements. An innovative solution was developed to address the project's unique requirements. Parallel operation of four solid handling and flowback trains minimized pressure losses. The compact, modular system facilitated rapid mobilization between well pads, expediting the test campaign and unlocking the gas project's full potential. A unique choke increasement strategy was employed to ensure that the sand-free rate can be targeted correctly and avoid any excessive sand production from downhole to protect the production piping and the receiving gas plant.A well-orchestrated choke operation among the 4 trains simultaneously.Real-time monitoring of upstream and downstream pressure and temperature change.A highly sensitive technology for detection and removal of solids were deployed to make sure any small amount of solid production is detected and capture before the flow is passed through the downstream production line.An acoustic solid detection system was installed on the pipeline at the first change in flow direction. To constantly monitor acoustic signal and analyzed for solid presence in the flow stream.Multi-cyclonic desanders were used at the wellhead to separate any solid return.Flow rate measurement is always of paramount importance for any well testing application. In this case, the multiphase flow with high gas volume fraction was accurately measured in real time by a large bore 88mm Multiphase flow meter. The operation was performed using the four-train set-up with large bore Vx Multiphase flowmeter. Below are the key results and observations during the operation. The rig-up of the well testing system with a lot of equipment was the first of its kind, but thanks to the optimize design of the footprint and modularity of the well testing assets, the rig-up time was kept to a minimum of 4 days.Maximum sand-free rate was achieved safely without any damage to the equipment thanks to an accurate choke increasement plan at small steps of 2/64" inch. Solid recovery was accurately measured down to 0.1 kg and enabled highly accurate correlation of the sand-free rate.Highly accurate measurement was obtained to help determine the optimal strategy for future production. Sudden changes in the flow regime and the CGR were captured in real time and help greatly with the operation of the whole system.Zero flaring and zero discharge operation was achieved during the entire duration of the project. This was enabled by the 5000 psi working pressure of the whole system while most common well testing equipment are limited by the 1440 psi working pressure of standard well test separator. Thanks to the high-pressure rating, there was no requirement for a pressure relief or venting system, which help to eliminates any hydrocarbon discharge to the environment. As the challenge was unique in terms of requirements, this solution was designed uniquely to address the main aspects of a modular and mobile system that is typically used in well testing applications. Large bore 88mm Multiphase Flowmeter, with its expansive turndown, high accuracy at high gas fractions, compact footprint, and high-pressure rating, enabled precise flow measurementLine sizing and piping arrangements optimization software was used to predict and minimize the pressure loss in the system.Sensitive solid detection system helps to correlate solid recovery result with future well testing