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PDS / OPS Sampler - Operating instructions

Positive Displacement Sampler PDSshort One Phase Sampler OPS Operating Instructions

Picture Courtesy of the Petroleum Engineering Department at the Colorado School of Mines, Golden, CO USA

Sampling

short

The Positive Displacement Sampler PDS and the One Phase Sampler OPS provide representative samples of well fluid which can be transferred to sample bottles without the use of mercury.

PDS / OPS Sampler - Operating instructions

Contents 1 General Safe Handling Procedures......................................................5 2 The Sampler.......................................................................................6 2.1 Safe Handling Procedures..........................................................6 2.2 Description of the Sampler........................................................8 short 2.2.1 Positive Displacement Sampler PDS ...........................8 2.2.2 One Phase Sampler OPS.............................................. 10 2.3 Specification of the Sampler.................................................... 11 short 2.3.1 Positive Displacement Sampler PDS ......................... 11 2.3.2 One Phase Sampler OPS.............................................. 11 2.4 Schematic of the Sampler........................................................ 12 short 2.4.1 Positive Displacement Sampler PDS ......................... 12 2.4.2 One Phase Sampler OPS.............................................. 13 2.5 Assembly Drawings and Inventory........................................... 14 2.6 Sampler Clock.........................................................................25 2.7 O-Ring Seal and Back-up Ring Redress Kits..............................26 2.7.1 PDSshort Sampler...........................................................26 2.7.2 OPS Sampler...............................................................27 3 The Sample Cylinders........................................................................28 3.1 Safe Handling Procedures........................................................28 3.2 Description of the Sample Cylinders.........................................30 3.2.1 Cylinder Type 600........................................................30 3.2.2 Cylinder Type One Phase 600......................................30 3.3 Specification of the Sample Cylinders.......................................31 3.4 Assembly Drawing...................................................................32 3.4.1 Cylinder Type 600........................................................32 3.4.2 Cylinder Type One Phase 600......................................33 3.5 O-Ring Seal and Back-up Ring Redress Kits..............................34

2

4

The Transfer Bench...........................................................................35 4.1 Safe Handling Procedures........................................................35 4.2 Description of the Transfer Bench............................................35 4.3 Specification of the Transfer Bench..........................................36 4.4 Schematics of the Transfer Bench.............................................36

5

Operating Tools and Accessories.......................................................37 5.1 Tools for Samplers and Cylinders..............................................37 5.2 Tools for Cylinders only............................................................40 5.3 Tools for Transfer Bench........................................................... 41 5.4 Optional Tools.........................................................................44

6

The Nitrogen Booster Station............................................................47 6.1 Safe Handling Procedures........................................................47 6.2 Description of the Nitrogen Booster.........................................48 6.3 Specification of the Nitrogen Booster.......................................48 6.4 Schematics of the Nitrogen Booster.........................................49

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

7 Transfer Bench Assembly “Part One”................................................50 8

Preparation for Running the Sampler................................................ 51 8.1 Sample Chamber..................................................................... 51 8.2 Flow Regulator Prime Port Nipple - PDSshort only.......................60 8.3 One Phase Section...................................................................60 8.4 Flow Regulator........................................................................70 8.5 Air Chamber............................................................................72 8.6 Charging the N2 Chamber - OPS only.......................................76 8.7 Clock Coupling, Trigger Mechanism & Clock............................78 8.8 Assembling the Sampler .........................................................84 8.9 Priming the Sampler................................................................85

9 Before Sampling...............................................................................88 10 Transfer Bench Assembly “Part Two” - Pressure Test.........................89 11 Preparation of the Sample Cylinder...................................................90 12 Sample Validation.............................................................................97 13

The Transfer....................................................................................100 13.1 Preparing the Transfer............................................................100 13.2 Opening Pressure PDSshort only............................................... 103 13.3 Transfer Procedure................................................................. 103 13.4 Removal of the Air Lock from the Transfer Pump ................... 105

14 Bubble Point Analysis PDSshort only................................................... 107 15 Rigging Down.................................................................................109 15.1 Prepare the Sample for Dispatch............................................109 15.2 Rigging Down Transfer Bench................................................ 110 16

Periodic Workshop Test................................................................... 112 16.1 Shuttle Mechanism Assembly................................................ 112 16.2 Relief Valve ........................................................................... 113 16.3 Clock Testing Procedure......................................................... 116 16.4 Anti-Premature Closing Assembly.......................................... 116 16.5 Flow Regulator...................................................................... 117 16.6 Sample Chamber Assembly Pressure Test Procedure............... 118 16.7 Well Simulating Test.............................................................. 119

17 Preventing Tool Failure.................................................................... 122 17.1 PDSshort Operation.................................................................. 122 17.2 OPS Operation....................................................................... 124 18 Exploration Well Sampling.............................................................. 126

Friedrich Leutert GmbH & Co. KG

3

PDS / OPS Sampler - Operating instructions

Introduction This operating manual provides instructions on how to use this product correctly, effectively and safely for the intended purpose. Please, read all instructions carefully and familiarize yourself with all danger, warning, and notes. Please follow all safety instructions and precautionary notes in order to avoid damage to people or property during operation. LEUTERT can not be held responsible for damage or injury resulting from improper use, incorrect operation or lack of maintenance. This operating manual is designed mainly for technically trained personnel. If any questions arise regarding any safety or operational aspects, please do not hesitate to contact LEUTERT for assistance. Should you notice a faulty description or depiction, or, if you would like to suggest points for improvement, we are looking forward to hearing from you. Please keep the operating manual near the product to have it available if needed. Make sure that the manual is protected from dirt and moisture. Explanation of symbols:

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE is used to address practices not related to personal injury.

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Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

1

General Safe Handling Procedures

While handling the following items, always take into consideration that you are operating with high pressure. Its inherent danger is caused by the enhanced pressurized fluid. This energy varies depending on the volume, pressure and characteristics of the fluid. The compressibility of liquids is generally low, resulting in relatively low enhanced energy. Nevertheless caution is always advised. Pressure vessels containing gas enhance a very high energy. Damaged gas cylinders might break apart. Driven by escaping gases, exploding cylinders can be hauled several hundred meters (yards). Shrapnel inflicted injuries may also occur. As crude oil always contains gas, anyone using this product must be thoroughly familiar with these instructions and other applicable product instructions and manuals. According to this norm maintenance, repair and/ or reconditioning shall be performed by LEUTERT trained personnel only. Standard operating procedures for processes or procedures which use corrosive, toxic or highly toxic gases, such as H2S, shall be developed that include emergency response actions. All involved employees should be trained and be familiar with these procedures. Finally all users must comply fully with all local laws, rules or regulations in force.

DANGER Do not use flammable gases near to ignition sources. Ignition sources include open flames, sparks, and sources of heat, oxidizing agents and ungrounded or not intrinsically safe electrical or electronic equipment. Flames shall not be used for detecting leaks. A compatible leak detection solution shall be used. Use spark proof tools when working with or on a flammable compressed gas cylinder or system. Do not smoke near equipment.

WARNING Safety shoes are required when operating or moving the equipment. Safety glasses are required if pressure equipment is in use. Never allow the equipment to become part of an electrical circuit.

Friedrich Leutert GmbH & Co. KG

5

PDS / OPS Sampler - Operating instructions

Portable fire extinguishers should be available for fire emergencies. These fire extinguishers must be compatible with the apparatus and the materials in use. The tool should be located in a designated area, restricted to operating personnel and technicians. All safety guidelines pertaining to pressure testing of hydraulic units should apply. Care must be taken when testing/priming the sampling equipment. All seals and fittings should be original, inspected for wear and periodically pressure tested. Leutert will not except any liability if others but origin Leutert spare parts and consumable are used. Access doors to areas where flammable gases are stored or used should be clearly marked „No open flames”.

CAUTION Open valves only to the point where fluid can flow into the system with pressure. This will allow for quicker shutoff in the event of a failure or emergency.

2

The Sampler

2.1 Safe Handling Procedures DANGER The posi-lock pin should NOT be used for pressure or direct force retention. It was only designed to combat gravity, well vibration and to indicate the position of the needle valve body. The air chamber pressure must be bled down before removing the air chamber. The N2 gas pressure must be bled down before removing the OPS section.

WARNING Before commencing the transfer process the safe lock assembly should be checked for engagement. This is critical. Serious injuries could result. Also the sample could be lost during transfer.

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Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

The difference between the nose cone and the transfer lock should be recognized. While the nose cone prevents the needle valve assembly moving out of the sample chamber prior to running, the transfer lock when fitted prevents movement of the needle valve body after a sample has been taken, essential for safety when pressurizing or transferring a sample. The sampler should be handled with care avoiding any mechanical shock while the system is under pressure. Therefore the sample must not be transported within the sample chamber. It has to be transferred into a proper sample transport cylinder at the location.

CAUTION The relief valve within the shuttle assembly should be regularly checked by a hand-operated hydraulic pump. As the prime pressure of the tool at surface temperature will increase on exposure to downhole well temperature. The integrity of the tool particularly the shuttle assembly is protected by the relief valve. After the tool is retrieved from the well it should be kept in a secure area, accessible only to qualified technicians. Open the vent screw inside the air chamber immediately after the sampler is retrieved from well. Open the prime port valve and the prime port plug located in the flow regulator prime port nipple assembly immediately after the sampler is retrieved from well. Make sure not to open the N2 prime port valve and plug. Metals become brittle when used in corrosive gas service such as H2S. Check equipment and lines frequently for leaks. Disassemble the manifold after use and flush with dry air or nitrogen.

NOTICE For sampling wells with high H2S concentration special samplers machined from Inconel are available. The OPS section should be left connected to the sample chamber assembly and must only be disconnected immediately before transfer, therefore maintaining contact between sample and the nitrogen charge and compensating any further pressure change due to temperature change during transit.

Friedrich Leutert GmbH & Co. KG

7

PDS / OPS Sampler - Operating instructions

The Leutert bottom hole sampler is a precision instrument. Use the tools supplied i.e. quick clamp and OE spanner to make up joints (Fig. below). Never use pipe wrenches which damage tube walls and can cause galling of thread joints. Do not attempt to over tighten joints.

Quick Clamp Part-No. 5351.98.00015

2.2

Description of the Sampler

2.2.1 Positive Displacement Sampler PDSshort The LEUTERT Positive Displacement Sampler PDS downhole samples in oil wells.

short

is a device for taking

Positive displacement means that the synthetic fluid is replaced by the well fluid. The purpose of the tool is to provide high quality samples which when analyzed at reservoir conditions may provide data vital for the economic and technical evaluation of that reservoir. The tool has been designed to operate in all environments and consistently produce representative samples regardless of well fluid or hostile conditions. Premature sampling is prevented by a floating piston held at the bottom of the sample chamber by special synthetic oil under pressure in the air chamber. The piston is closing the inlet for the well fluid. When a mechanical clock at the top of the sampler has run the set time, the lever assembly drops into a cutaway in the clock cone, allowing the shuttle valve to move upwards, exposing a port in the shuttle assembly. The pressurized buffer fluid is then allowed to dump into the air chamber, its rate being metered by the flow regulator assembly. As the buffer pressure drops, the floating piston is pushed up the rod by well pressure and slowly draws in a sample. As the floating piston bottoms out on the premature closing assembly, the outer sleeve of the assembly is raised allowing the locking balls to release. The central core which is attached to the rod moves upwards when the floating piston fully bottoms out on the premature closing assembly, dragging the rod and needle valve body assembly upwards. The o-ring protector bottoms on the guide into the sample chamber and the needle valve body assembly slides the last part of its travel into the sample chamber. After the second o-ring has passed into the sample chamber the brackets of the split collets enlarge to lock the sampler shut.

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Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

The transfer system allows the sample to be validated prior to dispatch to the PVT laboratory where it will be analyzed. The data from the laboratory helps to determine such things as field development programs, oil and gas recovery factors, production forecasts and design of production facilities. short The PDS may also be used to retrieve sub-surface samples of water. It is an improper tool to sample condensates and gases. The mechanical version of the sampler is a wireline operated tool which is activated by a mechanical clock. The tool comprises of a sample chamber, and air chamber and the mechanical firing device. Other options available are: – Surface firing through electric line. – Pressure activated while run in a carrier integral with a tubing string (DST). When run on electric wireline it is only the top sampler that is triggered electrically, additional samplers are connected by a mechanical link that is activated when the sampler above completes the sampling process. As further option LEUTERT can supply a gauge by-pass carrier which provides electrical connection to an electronic gauge with surface read- out and simultaneously to the sampler. The electronic trigger system operates on the reverse polarity to the standard used to power and read electronic gauges. Running in combination with a gauge allows for the real time surface read out of downhole pressure. When the well is deemed suitably conditioned and ready for sampling, by the turn of a switch the polarity of the electric line is reversed and the sampler is activated to take a sample. A positive indicator shows that the sampler has been activated and the switch is reversed to continue monitoring the pressure. The operation to activate the sampler takes only a matter of seconds so that very little time is lost in the recording of the pressure readings. The mechanical tool may be run individually or in tandem with another. There is an additional safety device which is fitted to the needle valve body called the sure lock assembly which locks in the sample. After the sampler is returned to surface the sample can be transferred into any piston type sample cylinder by using the LEUTERT transfer bench.

Friedrich Leutert GmbH & Co. KG

9

PDS / OPS Sampler - Operating instructions

2.2.2 One Phase Sampler OPS While using the standard PDSshort sampler the sample will efficiently be restored to original sub surface conditions by heating if the fluid has a low heavy-component content. However, when the fluid contains asphaltenes and paraffins in a colloidal dispersion state, and when these products have been segregated, it is no longer possible to reintegrate them into the fluid. In such a case, the properties of the fluid on which the thermodynamic measures are taken in the laboratory do not any longer exactly correspond to those of the fluid in the deposit. Therefore, in such cases the sample must remain in monophasic condition during the complete sampling process. The OPS section may be attached to the LEUTERT PDSshort sampler in order to keep a fluid in a monophasic state. The OPS section is filled with compressed nitrogen gas prior to sampling. The OPS section is fitted between the sample chamber and air chamber of the PDSshort. The basic operation of the sampler with OPS section fitted does not change from that described for the PDSshort. However, once the sample chamber is filled and the sample trapped, a stinger assembly shuts off the communication to the air chamber. Simultaneously, nitrogen flow ports are exposed releasing the pressure of the nitrogen gas to act upon the top of the floating piston, thus maintaining the sample above reservoir pressure as it cools during retrieval from the well. This pressurized gas is allowed to act on the sample via a floating piston, thus compensating the volume changes, and keeping the sample pressure well above the dew point or bubble point at all times. By this process the sample cannot go through any phase change due to the lowering of temperature and subsequent shrinkage of the sample as the sampler is retrieved from the well. The One Phase Sampler is the right tool to obtain gas condensate samples.

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Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

2.3

Specification of the Sampler

2.3.1 Positive Displacement Sampler PDSshort Volume : Max. operating pressure : Test pressure : Max. operating temperature : Length : Diameter : Weight : Top connection : Material :

600 cm³ 15,000 psi (1,035 bar) 22,500 psi (1,550 bar) 360 °F (180 °C) 11.45 ft (3,491 mm) 1 - 11/16” (43 mm) 55 lbs (25 kg) 15/16-10 UN Seamless stainless steel according to NACE MR-01-75 bronze alloy

2.3.2 One Phase Sampler OPS Volume : Max. operating pressure : Test pressure : Max. operating temperature : Length : Diameter : Weight : Material :

Friedrich Leutert GmbH & Co. KG

600 cm³ 15,000 psi (1,035 bar) 22,500 psi (1551 bar) 360 °F (180 °C) 15.2 ft (4,632 mm) 1 - 11/16“(43 mm) 68 lbs (31 kg) Seamless stainless steel according to NACE MR-01-75 bronze alloy

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PDS / OPS Sampler - Operating instructions

2.4

Schematic of the Sampler

2.4.1 Positive Displacement Sampler PDSshort Part No. 5300.11.00000

Clock

Clock coupling

Shuttle mechanism Relief valve

Air chamber

Flow regulator Prime port Anti-premature closing assembly Travelling piston

Sample chamber

O-ring protector

Transfer port Guide pin

Needle valve

Safe lock

Fig. A

Priming fluid Well fluid

Fig. B

Fig. C

Fig. A – Primed-ready to take sample Fig. B – Triggered-taking sample Fig. C – Sample chamber filled and locked closed

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Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

2.4.2 One Phase Sampler OPS Part No. 5300.10.00000

Clock

Clock coupling Shuttle mechanism Relief valve

LEUTERT PDSshort

Air chamber

Flow regulator Prime port

OPS section

N2 chamber

N2 prime port

Sample chamber

Travelling piston

O-ring protector

Transfer port Guide pin

LEUTERT PDSshort

Anti-premature closing assembly

Needle valve

Safe lock

Fig. A

Friedrich Leutert GmbH & Co. KG

Fig. B

Fig. C

Priming fluid

Fig. A – Primed-ready to take sample

Well fluid

Fig. B – Triggered-taking sample

Nitrogen

Fig. C – Sample chamber filled and locked closed

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PDS / OPS Sampler - Operating instructions

2.5 Assembly Drawings and Inventory Sample Chamber Assembly / Part No. 5300.11.10000

Position of flow regulator prime port nipple assembly in PDS operation; not part of sample chamber assembly

Anti-premature closing assembly 5300.11.03000

Piston assembly 5300.11.02000

Sample chamber 5300.11.00003 Piston rod 5300.11.00002

Needle valve body assembly 5300.11.01000

Locking screw 5300.10.00012

Split collet assembly 5300.10.00015

Safe lock 5300.10.00011

Nose cone 5300.11.00001

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Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

Split Collet Assembly / Part No. 5300.10.00015 Lock spring 5300.11.01003 Split collets 5300.10.00014

Securing screw ISCHRBM05.08200 Lock spring 5300.11.01003

Needle Valve Body Assembly / Part No. 5300.11.01000

O-RingPA.202000 or 5300.10.00032

O-ring protector 5300.11.01005

Back-up ring 5300.11.01008 Transfer port plug 5300.11.01004 O-RingPA.041000 or 5300.10.00027 Guide pin 5300.11.01009

O-RingPA.041000 or 5300.10.00027 Back-up ring 5300.11.01007 Needle valve 5300.11.01002 Needle valve body 5300.11.01001

Friedrich Leutert GmbH & Co. KG

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PDS / OPS Sampler - Operating instructions

Piston Assembly / Part No. 5300.11.02000

Internal o-ring O-RingPA.092600 or 5300.10.00034

Piston pad 5300.11.02002

Internal back-up ring 5300.11.02004 O-RingPA.202000 or 5300.10.00032 Back-up ring 5300.11.02005 Piston 5300.11.02001 Back-up ring 5300.11.02005 O-RingPA.202000 or 5300.10.00032

Anti-Premature Closing Assembly / Part No. 5300.11.03000

Ball 5300.11.03006 Ball retainer 5300.11.03001 Brake collet 5300.11.03002 Rod connector 5300.11.03003 Compression spring 5300.11.03005 Spring retainer 5300.11.03004

Piston rod 5300.11.00002

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Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

Flow Regulator Prime Port Nipple Assembly / Part No. 5300.11.04000

Protection cap 5300.98.00029

O-RingPA.313500 or 5300.10.00038 O-RingPA.061600 or 5300.10.00028 Prime port valve 5300.11.04002 Prime port plug 5300.11.04003 O-RingPA.021700 or 5300.10.00026

Flow regulator prime port nipple 5300.11.04001 O-RingPA.313500 or 5300.10.00038 Back-up ring (2x) 5300.11.01008 PDS O-RingPA.202000 or 5300.10.00032 OPS: O-Ring 5300.10.00032

Flow Regulator Assembly / Part No. 5300.11.08000 Flow regulator body No. I: 0.010” 5300.11.08003 No. II: 0.013” 5300.11.08004 No. III: 0.020” 5300.11.08005

O-RingPA.183500 or 5300.10.00031

No. IV: 0.025” 5300.11.08006

Flow regulator piston 5300.11.08007

O-RingPA.121700 or 5300.10.00035 O-RingPA.061600 or 5300.10.00028

Flow regulator end cap LARGE: 0.156” 5300.11.08001 SMALL: 0.062” 5300.11.08002

Filter disc 5300.11.08008

Friedrich Leutert GmbH & Co. KG

Back-up ring 5300.11.05004 O-RingPA.183500 or 5300.10.00031 Internal circlip SEEG-RI.1903200

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PDS / OPS Sampler - Operating instructions

One Phase Section / Part No. 5300.10.00020 Position of flow regulator prime port nipple assembly in OPS operation; not part of N2 chamber assembly

N2 chamber assembly 5300.10.00025

N2 prime nipple & stinger housing assembly 5300.10.00024

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Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

N2 Chamber Assembly / Part No. 5300.10.00025

Protection plug 5351.98.01001 Male connector 1/16 NPT 9000.00.8862400 (Part of N2 chamber tube)

N2 chamber 5300.10.00001

N2 chamber tube 5300.10.00002

Male connector 1/16 NPT 9000.00.8862400 (Part of N2 chamber tube) O-ring 5300.10.00032 Retaining ring 5300.11.05003 N2 chamber plug 5300.10.00003 O-ring 5300.10.00031 Back-up ring (2x) 5300.11.05004

Friedrich Leutert GmbH & Co. KG

O-ring (2x) 5300.10.00029 Back-up ring (2x) 5300.10.00018

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PDS / OPS Sampler - Operating instructions

N2 Prime Nipple & Stinger Housing Assembly / Part No. 5300.10.00024 O-ring 5300.10.00028 Prime port valve 5300.11.04002 O-ring 5300.10.00026 Prime port plug 5300.11.04003 Internal circlip SEEG-RI.0120100 N2 valve stem 5300.10.00005 O-ring (2x) 5300.10.00027 Back-up ring (4x) 5300.11.01007 Back-up ring (4x) 5300.10.00017 Back-up ring (2x) 5300.11.01007

O-RingPA.313500 5300.10.00038 N2 prime nipple 5300.10.00004 O-RingPA.313500 5300.10.00038 Back-up ring (2x) 5300.10.00019 O-ring 5300.10.00033 N2 release stem 5300.10.00006 O-ring (3x) 5300.10.00027

Fixed plug 5300.10.00008 Back-up ring 5300.10.00021 Stinger housing 5300.10.00007

O-ring 5300.10.00033 Stinger back 5300.10.00010

O-RingPA.313500 5300.10.00038

O-ring 5300.10.00032 Back-up ring (2x) 5300.11.01008

Stinger front 5300.10.00009 O-ring 5300.10.00028

Protection cap 5300.98.00029

Back-up ring 5300.10.00022 Fixed plug 5300.10.00008

O-ring 5300.10.00030 Back-up ring 5300.10.00022 Internal circlip SEEG-RI.1903200

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Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

Air Chamber Assembly / Part No. 5300.11.05000

Shuttle mechanism is not a part of air chamber assembly.

Air chamber 5300.11.05001 Male connector 1/16 NPT 9000.00.8862400 (Part of air chamber tube)

Air chamber tube 5300.11.05100

Male connector 1/16 NPT 9000.00.8862400 (Part of air chamber tube) Back-up ring 5300.11.01008 O-RingPA.202000 or 5300.10.00032 Vent screw 5300.11.05005 Air chamber plug 5300.11.05002

Retaining ring 5300.11.05003 Back-up ring 5300.11.05004 O-RingPA.183500 or 5300.10.00031

Protection plug 5351.98.01001

Friedrich Leutert GmbH & Co. KG

21

PDS / OPS Sampler - Operating instructions

The following figure applies to Leutert samplers supplied up to July 2012 as well as MKII samplers. Shuttle Mechanism Assembly / Part No. 5300.11.06000 Protection cap 5300.11.06012 O-RingPA.263500 or 5300.10.00036 Back-up ring 5300.11.06014 O-RingPA.313500 (2x) or 5300.10.00038 Internal circlip SEEG-RI.0800800 Setting screw 5300.11.06002 O-RingPA.021700 or 5300.10.00026 Shuttle nipple body 5300.11.06001 Grub screw 90° turned STSCHR6-4031600 Relief valve system 5300.11.06006 Disc spring 5300.11.06015 Adjustable grub screw 5300.11.06007

Piston valve stem 5300.11.06018 Retaining bush 5300.11.06003 Trigger spring 5300.11.06005 Removal bush 5300.11.06011 O-RingPA.041000 (2x) or 5300.10.00027 O-ring spacer 5300.11.06010 Positioning bush 5300.11.06009 Retaining screw 5300.11.06008 O-RingPA.281000 or 5300.10.00037 Back-up ring 5300.11.06013

Shuttle Mechanism Assembly / Part No. 5300.11.06016 Protection cap 5300.11.06012 O-RingPA.263500 or 5300.10.00036 Back-up ring 5300.11.06014

Piston valve stem 5300.11.06018 Retaining bush 5300.11.06003

O-RingPA.313500 (2x) or 5300.10.00038

Trigger spring 5300.11.06005 Removal bush 5300.11.06011 O-RingPA.041000 (2x) or 5300.10.00027

Shuttle nipple body 5300.11.06017 Grub screw 90° turned STSCHR6-4031600 Relief valve system 5300.11.06006 Disc spring 5300.11.06015 Adjustable grub screw 5300.11.06007

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O-ring spacer 5300.11.06010 Positioning bush 5300.11.06009 Retaining screw 5300.11.06008 O-RingPA.281000 or 5300.10.00037 Back-up ring 5300.11.06013

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

The following figures applies to Leutert samplers supplied up to July 2012 as well as MKII samplers. Clock Housing Assembly / Part No. 5300.11.07000

Top nipple 5300.11.07002 O-RingPA.313500 or 5300.10.00038

Clock is not a part of the clock housing assembly.

O-RingPA.263500 or 5300.10.00036 Back-up ring 5300.11.06014

Clock chamber 5300.11.07001

Trigger mechanism assembly 5300.11.07100

Protection plug 5300.98.00028

Trigger Mechanism Assembly / Part No. 5300.11.07100 Pin

Lever housing Spring & pin Lever assembly Stop plate & screw Lever support

Screw

alternatively: Part No. 5100.0.11.01000 (not shown in this picture)

Friedrich Leutert GmbH & Co. KG

23

PDS / OPS Sampler - Operating instructions

Clock Housing Assembly / Part No. 5300.11.07004

Clock is not a part of the clock housing assembly.

Clock chamber 5300.11.07003

Clock coupling assembly 5300.11.07300

Protection plug 5300.98.00028

Clock Coupling Assembly / Part No. 5300.11.07300

Lever housing Spring & pin Lever assembly Stop plate & screw Lever support

24

Screw

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

2.6 Sampler Clock The following figure applies to Leutert samplers supplied up to July 2012 as well as MKII samplers. Clock 5300.51.00000 5 hrs 5300.52.00000 10 hrs

Clock protection tube 100106

Winding head 2300.01.00052 2300.02.00015

5 hrs 10 hrs

Clock 2300.01.00000 5 hrs 2300.02.00000 10 hrs 2300.03.00000 24 hrs

Clock protection tube 2300.01.00049

O-ring O-RINGBUN173000

Winding head 2300.01.00052 5 hrs 2300.02.00015 10 hrs 2300.03.00023 24 hrs

Friedrich Leutert GmbH & Co. KG

25

PDS / OPS Sampler - Operating instructions

2.7 O-Ring Seal and Back-up Ring Redress Kits NOTICE The standard o-rings and back-up rings are recommended for use when CO2 and only a small amount of H2S are present. If high quantity of H2S is present a special o-ring and back-up ring kit is required. The special kit is resistant to virtually all known fluids and combination of fluid.

2.7.1 PDSshort Sampler Kit Part No. 5311.98.03000 (standard), 5311.98.03300 (special) Item Qty 1 3 2 5 3 3 4 8 5 6 6 2 7 2 8 2 9 1 10 5 11 2 12 5 13 2 14 2 15 4 16 1 17 2

26

Part No. (standard) 5300.10.00026 5300.10.00027 5300.10.00028 5300.10.00031 5300.10.00032 5300.10.00034 5300.10.00035 5300.10.00036 5300.10.00037 5300.10.00038 5300.11.01007 5300.11.01008 5300.11.02004 5300.11.02005 5300.11.05004 5300.11.06013 5300.11.06014

Part No. (special) Description O-RINGPERL001 O-ring O-RINGPERL002 O-ring O-RINGPERL003 O-ring O-RINGPERL006 O-ring O-RINGPERL007 O-ring O-RINGPERL004 O-ring 5300.10.00035 O-ring O-RINGPERL008 O-ring O-RINGPERL009 O-ring O-RINGPERL010 O-ring 5300.11.01007 Back-up ring 5300.11.01008 Back-up ring 5300.11.02004 Back-up ring 5300.11.02005 Back-up ring 5300.11.05004 Back-up ring 5300.11.06013 Back-up ring 5300.11.06014 Back-up ring

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

2.7.2 OPS Sampler Kit Part No. 5300.98.00001 (standard), 5300.98.00058 (special) Item Qty 1 1 2 5 3 2 4 2 5 1 6 1 7 2 8 2 9 3 10 4 11 2 12 2 13 1 14 2 15 6 16 4 17 2

Friedrich Leutert GmbH & Co. KG

Part No. (standard) 5300.10.00026 5300.10.00027 5300.10.00028 5300.10.00029 5300.10.00030 5300.10.00031 5300.10.00032 5300.10.00033 5300.10.00038 5300.10.00017 5300.10.00018 5300.10.00019 5300.10.00021 5300.10.00022 5300.11.01007 5300.11.01008 5300.11.05004

Part No. (special) Description O-RINGPERL101 O-ring O-RINGPERL102 O-ring O-RINGPERL103 O-ring O-RINGPERL104 O-ring O-RINGPERL105 O-ring O-RINGPERL106 O-ring O-RINGPERL107 O-ring O-RINGPERL108 O-ring O-RINGPERL010 O-ring 5300.10.00017 Back-up ring 5300.10.00018 Back-up ring 5300.10.00019 Back-up ring 5300.10.00021 Back-up ring 5300.10.00022 Back-up ring 5300.11.01007 Back-up ring 5300.11.01008 Back-up ring 5300.11.05004 Back-up ring

27

PDS / OPS Sampler - Operating instructions

3

The Sample Cylinders

3.1 Safe Handling Procedures WARNING Secure cylinder caps during transport. Follow the local transport regulations. Prevent damage to cylinders. Store cylinders where they will be protected from physical damage by falling objects, corrosion or damage from public tampering. Cylinders shall not be subjected to artificially created low temperatures. Report damaged or leaking cylinders to the safety office immediately for repair or disposal. Never disassemble the valve from the cylinder when it is under pressure. Do not expose valves to any violent shocks. Do not use a deformed or damaged valve. Do not alter the markings. The valves shall never (i.e. cylinder/valves leak tightness checking) be in contact, neither externally nor internally, with any agent initiating stress corrosion on its components.

CAUTION Open valves only to the point where fluid can flow into the system at the necessary pressure. This will allow for quicker shutoff in the event of a failure or emergency. Metals become brittle when used in corrosive gas service. Check equipment and lines frequently for leaks. Disassemble the manifold after use and flush with dry air or nitrogen. Access doors to areas where flammable gases are stored or used should be clearly marked „No open flames”. All gases with a health hazarding component must be stored in a continuously mechanically ventilated gas cabinet, fume hood or other enclosure. Small quantities (e.g., lecture cylinders) or diluted concentrations of these gases may be stored outside of a ventilated enclosure. Audible alarms should be utilized in ventilated hoods that are dedicated to toxic gas usage or storage.

28

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

NOTICE Never apply excessive force to remove caps. Return to LEUTERT to remove “stuck” caps. Confirm gas tightness by using leak test solutions (e.g., soap & water) or leak test instruments. Never disassemble a valve. Do not expose the valves to bad weather conditions during transport and use. Keep the valve free of grease, plastic or metallic particles and corroding agents. To fulfill the requirements of the TPED certificate please follow the local transport regulations for pressurized vessels via road, rail or plane. Please note that the TPED certificate becomes invalid if product components are used within the sample cylinder which do not fulfill the requirements of the TPED directive.

Friedrich Leutert GmbH & Co. KG

29

PDS / OPS Sampler - Operating instructions

3.2

Description of the Sample Cylinders

3.2.1 Cylinder Type 600 The LEUTERT sample cylinders are shipping bottles designed to transport and store pressurized liquid samples, especially hydrocarbon samples. The construction of the cylinder is of a non-welded design with the body machined from a solid billet of a specified grade of stainless steel/titanium fully certified to required grade and heat treatment. Each billet received is stamped and numbered, surveyed at the mill supply source; confirmation and traceability of each billet is maintained by addition of a batch number and serial number prior to start of manufacture. To separate the sample fluid from a secondary driving fluid, the bottles are equipped with a floating piston. A mixing ball is incorporated. The bottles are designed with a minimum of dead volume. The two end caps are sealed with double o-ring seals and back-up rings. The piston has a single O-ring seal and a slider ring and is designed to minimize friction and reduce pressure load. Right angle needle valves with 1/4” NPT female port connections are fitted to the 10,000 psi cylinders. 7/16” female port threads are machined into the end caps of the 15,000 psi cylinders. Both end caps are held in place by strong circlips. A special valve is fit into the sample side which allows evacuation of the cylinder. Valve protectors on both ends protect the valves during handling and transportation. An aluminum transportation box is available.

3.2.2 Cylinder Type One Phase 600 The Sample Cylinder Type 600 One Phase is a shipping bottle designed to transport and store pressurized samples, especially hydrocarbon samples maintaining the sample in one phase. To separate the sample fluid from a secondary driving fluid, the bottles are equipped with a floating piston. A mixing ball is incorporated. The bottles are designed with a minimum of dead volume. The two end caps are sealed with double o-ring seals and back-up rings. The piston has a single o-ring seal and a slider ring and is designed to minimize friction and reduce pressure load. Right angle needle valves with 1/4” NPT female port connections are fitted to the 10,000 psi cylinders. 7/16” female port threads are machined into the end caps of the 15,000 psi cylinders. A special valve is fit into the sample side which allows evacuation of the cylinder. The non-sample end cap contains a reservoir, which can be filled with compressed gas (e.g. Nitrogen). After completion of the transfer process a valve can be opened allowing the gas to act on the piston from the nonsample side, keeping the sample under pressure and, thus, maintaining it in one phase. 30

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

Valve protectors on both ends protect the valves during handling and transportation. An aluminum transportation box is available.

3.3 Specification of the Sample Cylinders Capacity (nominal) : 600 cm³ standard, other capacities are available Volume

: 700 cm³

Weight – type 600 – type one phase 600

: 38.6 lbs (17.5 kg) : 50.7 lbs (23.0 kg)

Material – type 600, one phase 600 : Stainless steel, resistant to H2S and CO2 Operating pressure – type 600, one phase 600 : 10,000 psi (690 bar) standard, or 15,000 psi (1,035 bar) Operating temperature : -4 °F to 300 °F (-20 °C to 150 °C) Certificates – type 600 up to 10,000 psi

: TPED & Hydrostatic

– type 600 up to 15,000 psi

: Hydrostatic, PED on request

– type one phase 600

: Hydrostatic, PED on request

NOTICE All certificates becomes invalid if non-type-tested components are used. Upon replacement of components, the device must be retested for conformance. The test may only be conducted by LEUTERT or by personnel authorised by LEUTERT, respectively.

Friedrich Leutert GmbH & Co. KG

31

PDS / OPS Sampler - Operating instructions

3.4

Assembly Drawing

3.4.1 Cylinder Type 600 Part No. 5371.11.04000 (Cylinder incl. Transportation Box)

Vacuum port (hidden) 5371.0.11.01100 Internal circlip SEEG-RI.6802500

Plug 5300.98.00009 Sample end cap 5371.0.11.02002 Back-up ring (2x) 5371.0.11.01011 O-RingVIT533500(2x) or 5371.98.00025 Ball 9000.0.00.36489

Cylinder body 5371.0.11.04001

Back-up ring (2x) 5371.98.00028 T-ring 5371.98.00024 Floating piston 5371.0.11.02004 Slider ring 5371.0.11.01005 Non-sample end cap 5371.0.11.02003 Plug 5300.98.00009 Forged hand valve 9000.0.00.87156

Protection cap 9000.0.00.30367

Vacuum port 5371.0.11.01100

32

O-Ring 5300.10.00028 Nipple 5371.0.11.01101 Plug 5371.0.11.01102 O-Ring (hidden) 5300.10.00026

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

3.4.2 Cylinder Type One Phase 600 Part No. 5371.10.00000 (Cylinder incl. Transportation Box) Protection cap 9000.0.00.30367 Angle valve 5371.10.00014 Plug 5300.98.00009 Vacuum port 5371.0.11.01100 Back-up ring (2x) 5371.0.11.01011 O-RingVIT533500(2x) or 5371.98.00025 Internal circlip SEEG-RI.6802500 Ball 9000.0.00.36489 Back-up ring (2x) 5371.98.00028 T-ring 5371.98.00024 Floating piston 5371.0.11.02004 Slider ring 5371.0.11.01005 Locking device 5371.10.00004 Locking grub screw 5371.10.00012 N2 plug: Back-up Ring (4x) 5300.11.01008 O-RingPA.202000 (2x) or 5300.10.00032 N2 chamber 5371.10.00001 N2 filling connection: Plug 5371.10.00009 Gland 5371.10.00008 Angle valve 5371.10.00014

Sample end cap 5371.0.11.02002

Cylinder body 5371.10.00003

O-RingVIT533500(2x) or 5371.98.00025 Back-up ring (2x) 5371.0.11.01011

Protection cap 9000.0.00.30367

Headnut (2x) 5371.10.00013 Valve R Valve C

O-Ring 5300.10.00028 Nipple 5371.0.11.01101 Plug 5371.0.11.01102 O-Ring (hidden) 5300.10.00026

Friedrich Leutert GmbH & Co. KG

Vacuum port 5371.0.11.01100

33

PDS / OPS Sampler - Operating instructions

3.5 O-Ring Seal and Back-up Ring Redress Kits NOTICE The standard o-rings and back-up rings are recommended for use when CO2 and only a small amount of H2S are present. If high quantity of H2S is present a special o-ring and back-up ring kit is required. The special kit is resistant to virtually all known fluids and combination of fluid.

Kit Part No. 5371.98.00001 (standard), 5371.98.00023 (special) Item Qty Part No. (standard) 1 1 5300.10.00026 2 1 5300.10.00028 3 2 5300.10.00032 4 4 5300.11.01008 5 4 5371.11.0101190 6 1 5371.98.00024 7 4 5371.98.00025 8 2 5371.98.00028

34

Part No. (special) Description 5300.10.00026 O-ring 5300.10.00028 O-ring 5300.10.00032 O-ring 5300.11.01008 Back-up ring 5371.11.0101190 Back-up ring 5371.98.00024 T-ring O-RINGPERL109 O-ring 5371.98.00028 Back-up ring

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

4

The Transfer Bench

4.1 Safe Handling Procedures WARNING Do not remove the pre-set safety rupture disc. Inspect the transfer bench visually before each usage to detect any damage, cracks, corrosion or other defects. Even if the manifold passes visual inspection its components are still subject to failure. Therefore we strongly recommend recertification through LEUTERT every five years. Make sure that the related equipment of the transfer bench, such as gauges, adapters, hoses, and cylinders are of proper design regarding temperatures, pressures and flows. This has to be taken into consideration before replacing or combining any part. Pressurize the bench / the system slowly and ensure that valve outlets are pointed away from all personnel when opened. Release pressure from systems before connections are tightened, loosened or before any repairs.

CAUTION Make sure that valves are periodically re-packed or inspected. Valves and regulator maintenance histories should be known before usage. Close all valves of the system which are currently not in use. Remove all pressure from sections currently not used.

4.2 Description of the Transfer Bench The transfer bench is of stainless steel construction with a boxed tube framework. The LEUTERT transfer bench is designed to be used in conjunction with the Positive Displacement Sampler and One Phase Sampler, and piston Type Sample Cylinders. The purpose of the bench is to allow samples which are trapped in the sample chamber of the sampler to be transferred to a shipping bottle for transportation to the P.V.T. lab for analysis. The sample must be monophasic and homogeneous prior to transfer. The transfer bench allows a validation to be carried out after the transfer to ascertain a bubble point and comparison between samples.

Friedrich Leutert GmbH & Co. KG

35

PDS / OPS Sampler - Operating instructions

4.3 Specification of the Transfer Bench Max. operating pressure : Test pressure : Max. operating temperature : Dimensions : Weight : Material :

15,000 psi (1,035 bar) 22,500 psi (1,550 bar) 300 °F (150 °C) 18.5” x 17” x 13” (470 mm x 430 mm x 330 mm) 77 lbs (35 kg) Stainless steel

4.4 Schematics of the Transfer Bench Part No. 5351.01.00000

TRANSFER FLUID psi

WELL FLUID / OIL

psi

SECONDARY GAUGE

MAIN GAUGE psi

AIR PRESSURE V8 PUMP AIR SUPPLY FOR PUMP SAMPLER

OUTLET

INLET V1

CONSTANT VOL. ASSY.

TANK

AIR OUTLET

V7 AIR INLET CYLINDER V2

V4

V5

Schematic of field transfer unit showing sample transfer into sample bottle

CAUTION Previous versions of the Leutert transfer bench had additional valves (main gauge valve, V3 and V6). By changing the procedures we were able to eliminate those valves and simplify the operation. If the transfer bench in use is equipped with the above mentioned valves, those valves shall remain open during the whole operation.

36

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

5

Operating Tools and Accessories

5.1 Tools for Samplers and Cylinders Set Part No. 100108

Friedrich Leutert GmbH & Co. KG

100101 Toolbox

5300.98.000033 Accessory box

5300.11.01005 O-ring protector

5300.98.00022 O-ring sleeve (N2 release stem) aids the fitting of the o-rings onto the nitrogen release stem

5300.98.00049 Metal free anti-seize paste used in all threads

5300.98.00051 Vacuum hand pump c/w reservoir, adapters & 1/8“ dia tube

5300.98.00054 O-ring mounting tool

5300.98.00064 Transfer lock & setting tool an additional safety device to back-up the safe lock assembly to prevent the needle valve from being pushed out of the sample chamber.

5311.98.00001 O-ring sleeve (piston rod) for protecting the internal o-Rings on the floating piston when assembling with the piston rod

5311.98.00008 Filler funnel assembly holds measured amount of oil for filling sample chamber

37

PDS / OPS Sampler - Operating instructions

38

5311.98.00013 Evacuation adapter assembly to evacuate the dead volume within the sample end of the oil sample cylinder

5311.98.00014 Retaining fork to prevent air chamber plug springing back into air chamber

5311.98.00015 Small extractor to unscrew retaining bush for access to shuttle spring and piston valve stem to form back-up ring on needle valve for easy assembly

5311.98.00016 Large extractor (air chamber plug retaining ring) to unscrew retaining ring to access air chamber

5311.98.00019 Piston rod clamp to hold piston rod while tighten needle valve body and premature closing assembly

5311.98.00020 Cross tool removes needle valve assembly from sample chamber and chamber plug from air chamber

5311.98.00100 Transfer adapter Connection from sampler to sample cylinder

5341.01.00003 Flexible hose, drain

5351.98.00015 Quick clamp to hold sampler

5371.98.00012 Piston puller tool to remove piston from honed bore in piston type cylinders

5371.98.02200 Vacuum nipple to screw into cylinder valve to evacuate all small pockets of air at the bottom of the cylinders

9000.00.3932500 Set of files

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

Friedrich Leutert GmbH & Co. KG

9000.00.3933400 Adjustable pipe wrench make up autoclave connections and plugs

9000.00.3934400 OE spanners (38 mm) to tighten and untighten the tube components of the sampler

9000.00.3936400 OE spanner (11/16”) to be used with bottle valve adapter

9000.00.3938700 OE spanners (3/8” x 7/16”) for use on all tool joints

9000.00.3938800 OE spanner (1/2”)

9000.00.3940200 Needle valve key (3/16”) operates needle valve/transfer port/prime port plugs and all grub screw on transfer bench

9000.00.3941200 Prime port spanner opens/closes prime port valve

9000.00.3942200 Circlip plier to fit circlips on choke/filter and setting screw

9000.00.3942500 Circlip plier to fit circlips on cylinder

9000.00.3942700 Pin spanner to remove end caps of cylinder

9000.00.3950600 Brush to clean threads from sand

9000.00.7720800 Teflon tape

9000.00.8856400 Cylinder valve adapter to screw into 1/4 NPT valves on bottle

100033 Allen key (1/4”) to remove plug from cylinder valve

39

PDS / OPS Sampler - Operating instructions

5.2 Tools for Cylinders only Tools and Accessories / Part No. 5371.98.02000

40

5300.98.00013 Toolbox

5311.98.00013 Evacuation adapter assembly to evacuate the dead volume within the sample end of the oil sample cylinder

5341.01.00003 Flexible hose, drain

5371.98.00012 Piston puller tool to remove piston from honed bore in piston type cylinders

5371.98.02200 Vacuum nipple to screw into cylinder valve to evacuate all small pockets of air at the bottom of the cylinders

9000.00.3936400 OE spanner (11/16”) to be used with bottle valve adapter

9000.00.3938800 OE spanner (1/2”)

9000.00.3941200 Prime port spanner opens/closes prime port valve

9000.00.3942500 Circlip plier to fit circlips on cylinder

9000.00.3942700 Pin spanner to remove end caps of cylinder

9000.00.8856400 Cylinder valve adapter to screw into 1/4 NPT valves on bottle

100033 Allen key (1/4”) to remove plug from cylinder valve

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

5.3 Tools for Transfer Bench Set Part No. 5351.98.00000

Laminated piping schematic

5351.98.00003 Accessories Box

5351.98.08000 Main Gauge

5351.98.09000 Secondary Gauge

5351.98.04000 Prime Pump Assembly

Friedrich Leutert GmbH & Co. KG

41

PDS / OPS Sampler - Operating instructions

5351.98.00010 Sample Hose Assembly

5351.98.02000 Prime Pump Hose Assembly

5351.98.03000 Bottle/Bench Hose Assembly

42

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

Air connection 5351.98.00002

Pistol 9000.0.00.39101

Gland 9000.00.8856200 Collar 9000.00.8856100 Adapter 5351.98.00027 Air hose 5351.98.00014

5351.98.00001 Air Hose Assembly

5351.98.00015 Quick clamp (2x) to hold sampler

Friedrich Leutert GmbH & Co. KG

5351.98.00026 Clamp holder (2x) to hold quick clamp

5351.98.00024 & 5351.98.00025 Bolt & cylinder holder to attach sample cylinder to transfer bench

5351.01.00028 Rupture disc

9000.00.8485400 Measuring cup

5331.00.00009 + 9000.00.3910300 Plug-in coupling socket + hose clamp to attach any compressed air supply hose to the air inlet of the transfer bench

5351.98.00034 Redress kit - sample hose assembly

43

PDS / OPS Sampler - Operating instructions

5.4 Optional Tools

44

5100.0.99.04000 Clock maintenance kit

5300.98.00005 Flow regulator test unit

5300.98.00010 Well test simulator

5300.98.00052 Sand filtration sleeve

5300.98.00012 Tandem nipple

5300.98.00032 Knuckle joint

5361.01.00000 Heating jacket for sampler

5361.02.00000 Heating jacket for cylinder

5300.98.00025 Tandem firing mechanism

5300.98.00041 Maximum thermometer

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

Friedrich Leutert GmbH & Co. KG

5300.98.00050 5 liter Leusynth oil buffer fluid used to prime tool

5300.98.00053 Can for transfer fluid

5311.98.00002 Posi-lock holder to compress posi-lock pin to allow assembly

5311.98.00003 Push rod & setting tool (posi-lock setting / piston valve stem) pushes needle valve assembly into current position/ increases area of piston valve stem to allow setting by hand

5311.98.00011 O-ring sleeve (setting screw) helps to dress small diameter o-rings

5311.98.00018 Disc tool for depressing the posi lock pin

5300.98.00023 Safe lock tool to keep the safe lock collets compressed to fit into the safe lock assembly

5300.11.01009 Guide pin to locate needle valve body into sample chamber

9000.00.3931200 Screwdriver (5 mm) to fit setting screw

5341.00.00025 Laboratory vacuum pump 5341.00.00026 Workshop tool for Laboratory vacuum pump

45

PDS / OPS Sampler - Operating instructions

SAMPLE DETAILS CLIENT

WELL NO.

ZONE

FIELD

SAMPLE NO.

CYLINDER NO.

SAMPLE NATURE

SAMPLE DATE / TIME

SAMPLED BY FINAL PRESSURE

SAMPLING POINT

@

FINAL TEMPERATURE

5381.98.00007

COMMENTS

46

5381.98.00007 Label “Sample Details”

5341.01.00019 Label “READY FOR JOB - Filled with water/ glycol, N2”

5371.98.00003 Label “Flammable liquid”

5381.98.00005 Label “Toxic gas”

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

6

The Nitrogen Booster Station

6.1 Safe Handling Procedures WARNING Use ear protection. Watch out for orbiting ice particles coming from the sound absorber. Do not use other gases than N2 to be compressed by the booster. Do not use compressed air with a pressure above 145 psi (10 bar) to operate the booster. Do not modify the booster. Do not remove the pre-set safety rupture disc. Pressurize the Nitrogen Booster Station slowly and ensure that valve outlets are pointed away from all personnel when opened.

CAUTION The high-pressure couplings at the intake pipe socket and at the delivery end must never be loosened. The couplings must have an interference fit for preventing leakings and damages. Inspect the Nitrogen Booster Station visually before each usage to detect any damage, cracks, corrosion or other defects. Even if the manifold passes visual inspection its components are still subject to failure. Therefore we strongly recommend recertification through LEUTERT every five years. Make sure that valves are periodically re-packed or inspected. Valves and regulator maintenance histories should be known before usage. Make sure that the related equipment of the Nitrogen Booster Station, such as gauges, adapters, hoses, and cylinders are of proper design regarding temperatures, pressures and flows. This has to be taken into consideration before replacing or combining any part. Close all valves of the Nitrogen Booster Station which are currently not in use. Remove all pressure from sections currently not used.

Friedrich Leutert GmbH & Co. KG

47

PDS / OPS Sampler - Operating instructions

Release pressure from Nitrogen Booster Station before connections are tightened, loosened or before any repairs. Never allow the Nitrogen Booster Station to become part of an electrical circuit.

NOTICE Keep the sound absorber free from contamination of water and oil (grease).

6.2 Description of the Nitrogen Booster The Leutert Nitrogen Booster Station is used to compress nitrogen into the sample chambers of the one phase samplers and cylinders to a pressure rate above the well pressure. The sample chambers are pressurized across a piston from a nitrogen gas chamber. This compensates any temperature induced pressure drop (e.g. as the sample is returned to surface). The booster is driven by compressed air. The output pressure is controlled by an adjustable pressure regulator with build-in filter/water separator. The cycle speed of the booster is controlled by a ball valve. A build-in bleed valve is used to release the pressure. The supply pressure of the air driven booster, the pressure in the bottle and the pressure at the high pressure side can be monitored by liquid filled pressure gauges. A storage compartment for the hoses is also provided.

6.3 Specification of the Nitrogen Booster Air drive pressure : 14 to 100 psi (1 to 7 bar) Air input connection : ½” NPT female bulkhead Air drive pressure gauge : 145 psi (10 bar) ø 63

48

N2 supply pressure : N2 supply pressure gauge : N2 output pressure : N2 output pressure gauge : N2 input connection : N2 output connection :

1,200 to 4,350 psi (83 to 300 bar) 5,800 psi (400 bar) ø 63 max. 18,270 psi (1,260 bar) 23,000 psi (1,600 bar) ø 100 ¼” NPT female bulkhead 7/16”-20 UNF female bulkhead

Weight : Dimensions (L x W x H) : Gauges :

86 lbs (39 kg) 25.4” x 16.5” x 18” (645 mm x 420 mm x 460 mm) dual-scale psi, bar

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

6.4 Schematics of the Nitrogen Booster Part No. 5331.01.00000

N2 Prime Hose Assembly

5331.01.00001 Nitrogen Booster Station

5351.98.02000 N2 Prime Hose Assembly

Friedrich Leutert GmbH & Co. KG

49

PDS / OPS Sampler - Operating instructions

7

Transfer Bench Assembly “Part One”

The preparation for running the Sampler into the well is best done within the workshop. The transfer bench may be used as a carrier for easy strip down and assembly of the sampler. Remove the front cover of the transfer bench by releasing the four spring clips and unscrewing the two knurled safety nuts. Place the cover to the rear of the bench. With the cover turned upside down it has to be attached to the bench by screwing in the two knurled safety nuts to provide stability and for holding parts and tools during use. (Fig. 1)

Fig. 1

Loosen the four grub screws in the frame of the transfer bench. Fit the clamp holder into the two rearward facing holes at the top left and top right of the bench. Tighten all screws sufficiently so that most of the play has been removed, but small adjustments in position may be carried out. Insert the two body clamps into the clamp holders. To continue the assembly of the transfer bench please refer to chapter 10.

50

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

8

Preparation for Running the Sampler

8.1 Sample Chamber Position sample chamber into transfer bench clamps. NOTICE Large oval slot in sample chamber should face upwards. Unscrew the nose cone from the safe lock assembly. Unscrew the safe lock from the sample chamber. Remove the split collets. Unscrew the locking screw from the needle valve body.

PDSshort only: Unscrew the flow regulator prime port nipple in case it is connected to the sample chamber.

Screw the cross tool into the needle valve body.

The following procedure applies to Leutert samplers supplied up to July 2012 as well as MKII samplers. Depress the posi-lock pin into the recess by using the disc tool. (Fig. 2)

Fig. 2

Pull the needle valve body sharply. NOTICE Posi-lock pin must point centre upwards to avoid loss. Remove the posi-lock pin and spring. Store posi-lock pin and spring in a safe place to avoid loss.

Friedrich Leutert GmbH & Co. KG

51

PDS / OPS Sampler - Operating instructions

Pull the piston rod assembly out of the sample chamber. When the anti-premature closing assembly bottoms out on the piston, use a slight jarring action to free the piston from the sample chamber. Support the rod to prevent bending. Remove the cross tool. Unscrew the rod from the needle valve body. (Fig. 3) NOTICE To avoid damage of the rod, never use pliers. The piston rod clamp can be used to hold the rod while unscrewing the needle valve body.

Fig. 3

Remove the o-ring protector. Replace the o-rings and back-up rings on the needle valve body. NOTICE Unless the sampler has been exposed to high temperatures in excess of 150°C (300°F), the o-rings not in direct contact with well fluids can be replaced every two runs, or less frequently if conditions allow. However, the sampler should be completely stripped down following each run and the o-rings and back-up rings inspected as a matter of course. Experience is the only measure as to whether parts should be replaced, however, when in doubt replace parts and do not risk sampler failure. Return the o-ring protector, taking care not to damage the o-rings in doing so. Completely unscrew the needle valve from the needle valve body by using the needle valve key. Replace all o-rings and back-up rings. The needle valve can be redressed by using the o-ring sleeve. Before the needle valve is reinserted into the needle valve body the backup rings should be pre-compressed. To do so push the needle valve into the small extractor. (Fig. 4)

Fig. 4

52

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

Reinsert the needle valve into the needle valve body. Unscrew the transfer port plug. Use the needle valve key. Replace the o-ring. Return the transfer port plug. Using the needle valve key ensure that the needle valve and transfer port plug are fully tightened. (Fig. 5)

Fig. 5

Pull the piston of the rod. Replace the o-rings and back-up rings. To change the internal o-rings and back-up rings of the piston unscrew the piston pads by using the small extractor. Replace the internal o-rings and back-up rings. Return the piston pads. Use the piston rod o-ring sleeve to replace the floating piston back onto the rod. (Fig. 6)

Fig. 6

Screw the needle valve body assembly back onto the rod. Use the piston Rod clamp when tightening the needle valve body on the piston rod. Check that the rod is screwed fully into the anti-premature closing assembly and needle valve body. NOTICE Loctite can be used when connecting piston rod to anti-premature closing assembly. Do not use Loctite when connecting needle valve body.

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PDS / OPS Sampler - Operating instructions

Check that the piston is free to slide up and down the piston rod. (Fig. 7)

Fig. 7

Set the anti-premature closing assembly by holding the rod and gently pull on the top of the ball retainer. A clicking sound will be heard as this is done and the assembly will then become solid. (Fig. 8)

Fig. 8

A function test can be made by pushing the piston against the antipremature closing assembly, with the anti-premature closing assembly resting firmly against a solid surface.

Fig. 9

Set the anti-premature closing assembly.

The following procedures apply to Leutert samplers supplied up to July 2012 as well as MKII samplers. NOTICE: Any older sampler can be simply upgraded by replacing posilock pin with the new guide pin (5300.11.01009). Insert the posi-lock spring and pin into the needle valve body. NOTICE: Posi-lock pin must point centre upwards to avoid loss.

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PDS / OPS Sampler - Operating instructions

Return the complete rod assembly to the sample chamber. Do not insert completely. Slide the posi-lock holder over the needle valve body until it hits the posi-lock pin. Depress the pin and push the holder forward to cover the pin. (Fig. 10)

Fig. 10

Turn the needle valve body until the hole for the posi-lock pin is uppermost and in line with the slot and hole in the sample chamber. Guide the posi-lock holder into the sample chamber and continue to push forward as far as possible. NOTICE: A gap will remain between the sample chamber and the wider end of the posi-lock depressive tool. This gap serves to prevent injuries. Insert push rod & setting tool. Push slowly forward until the shoulder hits the end of the posi-lock holder. (Fig. 11)

Fig. 11

NOTICE: If resistance is met during this operation the posi-lock pin might not be in line with its groove in the sample chamber. The solution is to turn the posi-lock holder slightly to the left or right until the push rod & setting tool can be pushed forward easily. The front of the needle valve body has to be in line with the front end of the sample chamber.

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PDS / OPS Sampler - Operating instructions

Return the complete rod assembly to the sample chamber and slide the needle valve body assembly forward until guide pin makes contact with sample chamber edge. (Fig. 12)

Fig. 12

Carefully align the guide pin with oval transfer port slot in sample chamber. (Fig. 13)

Fig. 13

Gently push the needle valve body assembly forward until back end of needle valve is flush with sample chamber edge. (Fig. 14, 15)

Fig. 14

Fig. 15

If the needle valve body assembly overshoots use cross tool to readjust position. (Fig. 16)

Fig. 16

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PDS / OPS Sampler - Operating instructions

The following procedures apply to Leutert samplers supplied up to July 2012 as well as MKII samplers. Squeeze split collets and insert them into the safe lock tool. (Fig. 17)

Fig. 17

The complete unit can be inserted into front end (male thread side) of the safe lock. Push split collets into safe lock and remove safe lock tool. (Fig. 18, 19)

Fig. 18

Fig. 19

Squeeze split collets with circlip pliers. (Fig. 20)

Fig. 20

Fig. 21

Insert split collets into the safe lock. (Fig. 21) Remove circlip pliers.

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PDS / OPS Sampler - Operating instructions

Screw safe lock assembly onto the sample chamber until the holes of the split collets are in line with the holes of needle valve body. (Fig. 22, 23)

Fig. 22

Fig. 23

Secure split collets to the needle valve body by tightening the screw. Use needle valve key. (Fig. 24, 25)

Fig. 24

Fig. 25

Fully tighten the safe lock assembly. (Fig. 26, 27)

Fig. 26

Fig. 27

Tighten the securing screw fully. Screw on the nose cone and tighten fully. Clamp the sample chamber in a vertical position with the nose cone at the bottom. Fit the funnel into the top of the sample chamber. Pour 300 ml Leusynth oil into the funnel. Fit the filler funnel cap onto the funnel. Connect the vacuum hand pump to the metal tube of the filler funnel cap. Squeeze the handle of the vacuum pump to draw a vacuum within the assembly.

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PDS / OPS Sampler - Operating instructions

Release the vacuum from the assembly, the Leusynth oil will be sucked into the sample chamber. Repeat this procedure until the sample chamber is completely filled with Leusynth oil (300 ml).

Fig. 28

NOTICE For convenience hand-vacuum pump may be replaced by the electric driven vacuum pump. Clean the funnel. Remove the funnel. The top of the anti-premature closing assembly should be barely covered by the Leusynth oil. To check that the anti-premature closing assembly is still set correctly, measure the distance between the top of the anti-premature closing assembly and the end of the sample chamber. The distance should be no greater than 1¾ inch (45 mm). For OPS operation continue chapter 8.3

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PDS / OPS Sampler - Operating instructions

8.2 Flow Regulator Prime Port Nipple - PDSshort only Remove the protection cap from the flow regulator prime port nipple. Check the visible o-rings and back-up rings. Unscrew the prime port plug from the prime port valve. Check the o-ring. Return the prime port plug. Open the prime port valve by using the prime port spanner. NOTICE The o-ring sealing the prime port valve might be hidden in the valve body seat within the flow regulator prime port nipple. Remove the o-ring from the seat. Do not return the new o-ring into the seat, but fit it onto the valve before returning the valve. Return the prime port valve. With the sample chamber still held in vertical position, screw the flow regulator prime nipple assembly onto the sample chamber and tighten fully. NOTICE The reason for this method of assembly is to prevent the displacement fluid running out of the sample chamber and into the threads. If displacement fluid leaks into the threads it may get trapped between the double sealing o-rings resulting in a hydraulic lock. When subjected to increased temperature, the oil could expand sufficiently to damage the seals. For PDSshort operation continue chapter 8.4.

8.3 One Phase Section DANGER Make sure that the N2 chamber has been bled of pressure before disassembly of the OPS section. Unscrew the N2 prime port plug. Carefully open the N2 prime port valve by using the prime port spanner. Close the prime port valve. Return the prime port plug.

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PDS / OPS Sampler - Operating instructions

Separate the N2 prime nipple and stinger housing assembly from the nitrogen chamber. Fit the N2 chamber into the clamps of the transfer bench. Insert the large extractor into the end of the N2 chamber, and unscrew the retaining ring from the N2 chamber. (Fig. 29)

Fig. 29

Screw the cross tool into the end of the N2 chamber plug. Pull the cross tool until the pressure fitting is visible. (Fig. 30)

NOTICE: Do not over stretch the internal N2 chamber tube.

Fig. 30

Insert the retaining fork between the N2 chamber and the pressure coupling of the N2 chamber tube. (Fig. 31)

Fig. 31

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PDS / OPS Sampler - Operating instructions

Remove the cross tool. Remove the N2 chamber plug by unscrewing the coupling with spanners. Attach the cross tool to the threaded section on the gland of the N2 chamber tube. Pull the cross tool. Remove the retaining fork. Allow the N2 chamber tube to draw back into the N2 chamber. Remove the cross tool. Unscrew the flow regulator prime port nipple assembly from the N2 chamber on the other side. Disconnect the N2 chamber tube from the flow regulator prime port nipple assembly. Check the connection between the flow regulator prime port nipple and the N2 chamber tube. Replace the Teflon tape if necessary. Therefore the gland pin has to be disconnected from the flow regulator prime port nipple. The gland pin has to be cleaned from Teflon. The threads have to be covered with new Teflon tape. Remove the protection cap from the flow regulator prime port nipple. Check the visible o-rings and back-up rings. Unscrew the prime port plug from the prime port valve. Check the o-ring. Return the prime port plug. Open the prime port valve by using the prime port spanner. NOTICE The o-ring sealing the prime port valve might be hidden in the valve body seat within the flow regulator prime port nipple. Remove the o-ring from the seat. Do not return the new o-ring into the seat but fit it onto the valve before returning the valve. Return the prime port valve.

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PDS / OPS Sampler - Operating instructions

Return the protection cap to the flow regulator prime port nipple. Screw the gland pin back into the flow regulator prime port nipple. Connect the N2 chamber tube to the flow regulator prime port nipple assembly. Screw the flow regulator prime port nipple back into the N2 chamber. Attach the cross tool to the threaded section on the gland of the N2 chamber tube on the other end. Pull the gland nut until it passes the end of the N2 chamber. Slip the retaining fork between the gland nut and the end of the N2 chamber to prevent it from stringing back. (Fig. 32)

Fig. 32

Remove the cross tool. Check the o-rings and back-up rings of the N2 chamber plug. Check the connection between the N2 chamber plug and the gland pin of the N2 chamber tube. Replace the Teflon tape if necessary. Connect the N2 chamber plug to the N2 chamber tube and tighten. Screw the cross tool into the chamber plug. Pull the cross tool forward and remove the retaining fork. Let the N2 chamber plug draw back into the N2 chamber. Remove the cross tool.

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PDS / OPS Sampler - Operating instructions

To re-fit the plug into the N2 chamber screw the retaining ring into the end of the N2 chamber. Use the large extractor to tighten the N2 chamber plug fully. Unscrew the protection cap from the stinger housing. Screw the cross tool into the stinger front thread. Pull stinger assembly forward from the stinger housing. (Fig. 33)

Fig. 33

Remove cross tool. Separate the stinger housing from the N2 prime nipple assembly. NOTICE Be careful not to damage the N2 release stem. If there is any damage the stem must be replaced. Remove the fixed sleeve from the stinger housing by sharply striking the stinger housing onto a wooden surface. Remove the stinger from the stinger housing. Check the o-rings and back-up rings of the stinger housing. With the sample chamber still held in a vertical position screw the stinger housing into the sample chamber. (Fig. 34)

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Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

Fig. 34

NOTICE The reason for this method of assembly is to prevent the displacement fluid running out of the sample chamber and into the threads. If displacement fluid leaks into the threads it may get trapped between the double sealing o-rings resulting in a hydraulic lock. When subjected to increased temperature, the oil could expand sufficiently to damage the seals. Check the o-ring at the stinger front. Inspect both the inner and outer sealing diameters of the stinger assembly. (Fig. 35)

Fig. 35

NOTICE Both diameters should have a high polished finish. There may be particles of damaged o-rings and back-up rings in the inner diameter of the stinger, and these must be removed.

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PDS / OPS Sampler - Operating instructions

Fit the stinger into the stinger housing. (Fig. 36) Check that the stinger is fully inserted into the stinger housing. (Fig. 37)

Fig. 36

Fig. 37

NOTICE Great care must be taken not to damage or move the stinger, as this could cause failure due to a premature release of nitrogen. Use only your thumb to push the stinger fully into the stinger housing. Check the external o-rings and back-up rings of the fixed sleeve. The internal rings can be changed after the circlip has been removed with the circlip pliers. Insert the fixed sleeve into the stinger housing with the circlip facing downwards. (Fig. 38) Use the flat side of a large OE spanner (38 mm) to push the fixed sleeve into its final seat. Fill Leusynth oil into the stinger housing, until the oil level reaches the top of the fixed sleeve. (Fig. 39)

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PDS / OPS Sampler - Operating instructions

Fig. 38

Fig. 39

Check the visible o-rings and back-up rings of the N2 prime nipple. Unscrew the N2 prime port plug from the N2 prime port valve. Check the o-ring. Return the N2 prime port plug. Open the N2 prime port valve by using the prime port spanner. NOTICE The o-ring sealing the N2 prime port valve might be hidden in the valve body seat within the N2 prime nipple. Remove the o-ring from the seat. Do not return the new o-ring into the seat, but fit it onto the valve before returning the valve. Return the N2 prime port valve. Remove the internal circlip of the N2 prime nipple with circlip pliers.

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PDS / OPS Sampler - Operating instructions

Unscrew the N2 valve stem fully. The N2 valve stem can be redressed by using the N2 release o-ring sleeve. (Fig. 40)

Fig. 40

Before the N2 valve stem is returned into the N2 prime nipple the back-up rings of the N2 valve stem need to be pre-compressed. To do so push the N2 release stem o-ring sleeve over the N2 valve stem. Refit the N2 valve stem and the circlip. Check that the N2 release stem is not bent. Roll it over a flat surface to check eccentricity. Only remove and replace the stem if it is visibly damaged. If the N2 release stem has to be replaced, screw in the replacement stem just hand tight, then tighten with a spanner (1/8” of a turn only). (Fig. 41)

Fig. 41

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PDS / OPS Sampler - Operating instructions

Check the o-rings and back-up rings of the N2 release stem. The stem be redressed by using the o-ring sleeve. (Fig. 42)

Fig. 42

There are two sets of PEEK back-up rings on the rear grooves of N2 release stem. These back-up rings should only be replaced if they are damaged. Before the N2 prime port assembly is inserted into the stinger housing the back-up rings of the N2 release stem need to be pre-compressed. To do so push the N2 release stem o-ring sleeve over the N2 release stem. Insert the N2 prime port nipple assembly into the stinger housing. (Fig. 43)

Fig. 43



NOTICE: Ensure that the position of the stinger has not changed.

Connect N2 chamber including flow regulator prime port nipple to N2 prime port nipple assembly.

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PDS / OPS Sampler - Operating instructions

8.4 Flow Regulator Depending on expected bottom hole pressure and temperature, a flow regulator has to be chosen. The purpose of the flow regulator is to control the filling process of the sampler to avoid separation of the fluid to be sampled. For the correct selection of flow regulator end cap and body, please see table below. The numbers in the table refer to the body sizes 1 – 4. The body size only alters the fill time and has no bearing on the prime pressure. The exact prime pressure is needed to avoid premature filling before the sampler has reached the sampling depth. A safety valve in the shuttle mechanism may crack open, allowing displacement fluid into the air chamber prematurely. For this purpose there are two end caps. The end cap with the large port is for low pressure wells, and the end cap with the small port is for high pressure wells. The ratios of the two difference flow regulator end caps are as follows: – Low pressure (large front port) – High pressure (small front port)

5:1 16 : 1

It is very important that these ratios are maintained, and regulator testing is required, using the flow regulator test unit, see chapter 16.5. Example: Well pressure : Well temperature : Correct selection :

70

3,000 psi | 207 bar 257 °F | 125 °C End cap large port and flow regulator body no. 2

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

Flow Regulator Body Size No. 1 – 4 Well Temperature

End Cap Small Port Prime Pressure 300 psi (20.7 bar)

End Cap Large Port Prime Pressure 1,000 psi (69.0 bar)

Well Well Pressure Pressure 122°F 140°F 158°F 176°F 194°F 212°F 230°F 248°F 266°F 284°F 302°F 320°F 338°F 356°F 50°C 60°C 70°C 80°C 90°C 100°C 110°C 120°C 130°C 140°C 150°C 160°C 170°C 180°C (psi) (bar) 500 34.5 1,000 69.0 1,500 103.5 2,000 138.0 2,500 172.5 3,000 207.0 3,500 241.5 4,000 276.0 4,500 310.5 5,000 344.5 5,000 344.5 6,000 413.7 7,000 482.6 8,000 551.6 9,000 620.5 10,000 689.5 11,000 758.4 12,000 827.4 13,000 896.3 14,000 965.3 15,000 1,034.2

3 3 3 3 3 3 2 2 2 2 4 4 4 3 3 2 2 2 2 1

3 3 3 3 3 2 2 2 2 2 4 4 4 3 3 2 2 2 2 1

3 3 3 3 2 2 2 2 2 2 4 4 4 3 3 2 2 2 2 1

3 3 3 3 2 2 2 2 2 2 4 4 4 3 3 2 2 2 2 1

3 3 3 3 2 2 2 2 2 2 4 4 4 3 3 2 2 2 2 1

3 3 3 3 2 2 2 2 2 4 4 4 4 3 3 2 2 2 1 1

3 3 3 3 2 2 2 2 2 4 4 4 4 3 3 2 2 2 1 1

3 3 3 3 2 2 2 2 2 4 4 4 4 3 3 2 2 1 1 1

3 3 3 3 2 2 2 2 2 4 4 4 3 3 3 2 2 1 1 1

3 3 3 3 2 2 2 2 2 4 4 4 3 3 2 2 2 1 1 1

3 3 3 3 2 2 2 2 2 4 4 4 3 3 2 2 2 1 1 1

3 3 3 3 2 2 2 2 2 4 4 4 3 3 2 2 2 1 1 1

3 3 3 3 2 2 2 2 2 4 4 4 3 3 2 2 2 1 1 1

3 3 3 3 2 2 2 2 2 4 4 4 3 3 2 2 2 1 1 1

Flow Regulator Selection Guide for the LEUTERT PDS/OPS Sampler

Before assembling the flow regulator clean the filter of the flow regulator and also the innards of the flow regulator itself. NOTICE Ensure that on assembly there are no particles of dirt left that could block the small rear orifice. Blast dry with compressed air. Inspect the piston nose for signs of wear. Replace all o-rings and back-up rings if needed. Assemble the flow regulator assembly. (Fig. 44)

Fig. 44

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PDS / OPS Sampler - Operating instructions

Fit the flow regulator into the flow regulator prime port nipple assembly, ensuring that the wire mesh filter is facing towards the sample chamber or N2 chamber. (Fig. 45)

Fig. 45

Screw the protection cap onto the flow regulator prime port nipple. Put the assembly aside.

8.5 Air Chamber Fit the air chamber onto the transfer bench in a horizontal position. CAUTION Check that the air pressure has been released by opening the vent screw. The vent screw should be facing uppermost. Remove the protection plug. Insert the large extractor into the end of the air chamber and unscrew the retaining ring. (Fig. 46)

Fig. 46

Screw the cross tool into the end of the air chamber plug. NOTICE Do not overtighten.

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PDS / OPS Sampler - Operating instructions

Pull the cross tool until the pressure fitting is visible. (Fig. 47) NOTICE Do not overstretch the internal air chamber tube.

Fig. 47

Insert the retaining fork between the air chamber and the pressure coupling of the air chamber tube. (Fig. 48)

Fig. 48

Remove the cross tool. Tilt the tube to allow any Leusynth oil to drain. Remove the air chamber plug by unscrewing the coupling with spanners. Attach the cross tool to the threaded section on the gland of the air chamber tube. Pull the cross tool. Remove the retaining fork. Allow the air chamber tube to draw back into the air chamber. Remove the cross tool. Unscrew the shuttle mechanism assembly from the air chamber on the other side.

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PDS / OPS Sampler - Operating instructions

Disconnect the air chamber tube from the shuttle mechanism assembly. Check the connection between the shuttle mechanism assembly and the air chamber tube. Replace the Teflon tape if necessary. Therefore the gland pin has to be disconnected from the flow regulator prime port nipple. The gland pin has to be cleaned of Teflon. The threads have to be covered with new Teflon tape. Remove the protection cap from the flow regulator prime port nipple. NOTICE The inner parts of the shuttle mechanism assembly should not be serviced in the field unless exposed to very high temperatures or more than four runs in a well. In that case, please refer to chapter 15. Check the visible o-rings and back-up rings. Replace the o-rings and back-up rings of the shuttle mechanism assembly.

The following procedures apply to Leutert samplers supplied up to July 2012 as well as MKII samplers. Remove the internal circlip of the setting screw with circlip pliers. Unscrew the setting screw fully. It can be redressed by using the setting screw o-ring sleeve. (Fig. 49)

Fig. 49

Screw the setting screw back into the shuttle mechanism assembly and replace the circlip.

Connect the air chamber tube with the shuttle mechanism assembly. Screw the shuttle mechanism assembly back into the air chamber. Screw the protection cap onto the shuttle mechanism assembly.

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PDS / OPS Sampler - Operating instructions

Attach the cross tool to the threaded section on the gland of the air chamber tube on the other end. Pull the gland nut forward until it passes the end of the air chamber. Slip the retaining fork between the gland nut and the end of the air chamber to prevent the chamber coil from springing back. (Fig. 50)

Fig. 50

Remove the cross tool. Check the o-rings and back-up rings of the air chamber plug. Check the connection between the air chamber plug and the gland pin of the air chamber tube. Replace the Teflon tape if necessary Connect the air chamber plug to the air chamber tube and tighten. Screw the cross tool into the chamber plug. Pull the cross tool forward and remove the retaining fork. Let the air chamber plug draw back into the air chamber. Remove the cross tool and re-fit the plug into the air chamber. Screw the retaining ring into the end of the air chamber and tighten fully by using the large extractor. Connect air chamber to flow regulator prime port nipple.

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PDS / OPS Sampler - Operating instructions

8.6 Charging the N2 Chamber - OPS only Connect the air supply to the Nitrogen Booster. Connect N2 bottle to the Nitrogen Booster Connect the N2 prime hose assembly to the Nitrogen Booster Check that the N2 valve stem is closed.

Fig. 51

Hold the N2 prime port valve closed with the ring spanner. Unscrew and remove the N2 prime port plug.

Fig. 52

Screw the N2 prime port adapter into the N2 prime port valve while keeping the ring spanner in place so that the valve can be opened when all connections have been made.

Fig. 53

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PDS / OPS Sampler - Operating instructions

Tighten the adapter against the flat o-ring face. NOTICE Do not over tighten. Connect the lose end of the N2 prime Hose Assembly to the N2 prime port adapter.

Fig. 54

Open the N2 prime port valve one quarter turn.

Fig. 55

Fig. 56

CAUTION If the N2 chamber has been disassembled and redressed it is necessary to purge the nitrogen chamber with N2 gas 2 – 3 times by pressurizing to approximately 2,000 psi (138 bar). After that the N2 chamber may be pressurized as usual. The nitrogen chamber can now be pressurized with nitrogen gas to the required pressure.

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PDS / OPS Sampler - Operating instructions

NOTICE The recommended pressure is approximately 2,000 psi (138 bar) above the expected reservoir pressure. This over pressurization will compensate for the sample volume shrinkage as it cools during the retrieval to surface. Close the N2 prime port valve. Bleed N2 Prime Hose assembly Remove N2 prime hose assembly. Remove the N2 prime port adapter. NOTICE Take care to hold the N2 prime port valve closed with the ring spanner to avoid loss of internal N2 pressure. Replace the N2 prime port plug. Open the N2 valve stem. The sampler is now ready to be run into the well. NOTICE Run the tool into the well at a speed of approximately 200 ft/min (60 m/min). Leave the tool on sampling depth for one hour after clock has triggered. Remove sampling string from well.

8.7 Clock Coupling, Trigger Mechanism & Clock Unscrew the protection cap from the shuttle mechanism assembly.

The following procedures apply to Leutert samplers supplied up to July 2012 as well as MKII samplers. Slide the transfer lock & setting tool over the piston valve stem and push it forward until it hits the end of the thread. (Fig. 57)

Fig. 57

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PDS / OPS Sampler - Operating instructions

Hold the tool in this position and screw in the setting screw until you feel resistance. (Fig. 58) NOTICE The stem must still be moveable. If the stem is tightened it could be damaged.

Fig. 58

Remove the transfer lock & setting tool. As a function test, back off the setting screw. At this point, the piston valve stem should pop out the shuttle valve assembly. Set the mechanism again. Screw on the trigger assembly, hand tight only. Lift the trigger with a finger until it touches the sleeve to ensure that it has free movement. (Fig. 59)

Fig. 59

Screw on the empty clock housing and tighten fully.

Select an appropriate clock to suit the delay time required. NOTICE The clock’s protection tube is sealed in order to avoid any inappropriate repair or handling. Breaking the seal results in loss of warranty. Hold the clock body with the cone end facing and the scribed line on the body uppermost. Locate the pin in the winding head on to the slot in the cone and push fully forward. (Fig. 60)

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PDS / OPS Sampler - Operating instructions

Fig. 60

At this stage, the scribed line on the body and the zero mark on the winding head should be aligned. (Fig. 61)

Fig. 61

Hold the body steady and turn the collar until required delay time is aligned with the scribed line. (Fig. 62)

Fig. 62

While setting required delay time keep in mind that sampler should reach the sampling depth at least 20 minutes before the programmed time. NOTICE Do not overwind as the clock cannot be turned back. If accidentally overwound, the clock must be allowed to run off naturally. Remove the winding head. Check if the clock is ticking. If it is not ticking, slightly knock the clock into your flat hand to set the clock balance in motion.

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PDS / OPS Sampler - Operating instructions

The following procedures apply to Leutert samplers supplied up to July 2012 as well as MKII samplers. NOTICE The clock´s o-ring provides additional friction when connecting it to the advanced clock coupling. The o-ring needs to be removed if the old trigger mechanism is used. (Fig. 116A) Unscrew the top nipple from the clock chamber which is already attached to the shuttle mechanism assembly. Look into the open end of the clock housing and turn the tool until the locating pin in the end of the trigger sleeve is uppermost. Hold the clock with the coned end facing into the open end of the clock housing, and the scribed line uppermost. Rotate the clock as follows: A)

On a clock set for up to half of its full range, e.g. up to 5 hours on a 10 hour clock, rotate the clock approximately 30 degrees to the left.

B)

On a clock set for more than half of its full range, e.g. over 5 hours on a 10 hour clock, rotate the clock approximately 30 degrees to the right. (Fig. 63)

Fig. 63

Push the clock into the housing as far as it will go. Slowly rotate the clock i.e. to the right if set as in ‘A’, and to the left as in ‘B’. Maintain forward pressure as this is done. The clock will move forward another 6 mm, and then resist further rotation. (Fig. 64)

Fig. 64

Screw on the 5/8“ sucker rod top nipple, or the rope socket assembly and tighten fully. Unscrew the setting screw until it is backs against the circlip. (Fig. 65)

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PDS / OPS Sampler - Operating instructions

A „Click“ should be heard as this is done, indicating that the connector rod has come to rest on the trigger mechanism. NOTICE If operator fails to back-off the setting screw, the tool will not operate. Do not forget to change the setting screw o-ring before every run.

Fig. 65

Insert the clock carefully into the clock coupling and push gently forward. (Fig. 66)

Fig. 66



NOTICE: Do not connect the clock coupling to the clock before time has been set. Turning the clock inside the clock coupling will damage the clock coupling. (Fig. 67)

Fig. 67

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PDS / OPS Sampler - Operating instructions

Observe the procedure through the control window. At this point the clock cone and the trigger are not yet aligned. (Fig 68)

Fig. 68

Hold the clock coupling in one hand and turn the clock in a clockwise direction until the two groves are lined up. (Fig. 69)

Fig. 69

With a slight pushing motion drive the clock coupling home into the clock. (Fig. 70)

Fig. 70

Screw the clock and clock coupling assembly into the shuttle valve. (Fig. 71) Thereby the piston is pushed into the shuttle mechanism assembly. The valve inside the assembly is now set.

Fig. 71

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PDS / OPS Sampler - Operating instructions

Screw the clock chamber onto the shuttle mechanism. (Fig. 72)

Fig. 72

NOTICE Care must be taken that clock assembly is connected to the clock housing in a straight mode to avoid damage to the push rod. (Fig. 73)

Fig. 73

8.8 Assembling the Sampler The samplers should be assembled according to the assembly drawings.

Air chamber incl. clock housing

Air chamber incl. clock housing

84

OPS section incl. flow regulator nipple

Sample chamber incl. flow regulator prime port nipple

Sample chamber

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

8.9 Priming the Sampler The sampler needs to be primed with Leusynth oil prior to sampling. The purpose of priming the sampler is to have an internal pressure greater than the reservoir pressure. This will not allow the sample chamber to fill with reservoir fluid before the set sampling depth and time is reached. Check if the hydraulic pump is filled with Leusynth oil. Unscrew the plug from the prime pump assembly. Connect the prime pump hose assembly to the hand pump. Hold the prime port valve closed with the ring spanner. Unscrew and remove the prime port plug. (Fig. 74)

Fig. 74

Screw the prime port adapter into the prime port valve while retaining the ring spanner in place so that the valve can be opened when all connections have been made. (Fig. 75)

Fig. 75

Tighten the adapter against the flat o-ring face. NOTICE Do not overtighten. Connect the loose end of the prime pump hose to the prime port adapter. Do not tighten fully. (Fig. 76)

Friedrich Leutert GmbH & Co. KG

85

PDS / OPS Sampler - Operating instructions

Fig. 76

Bleed of the air from the prime pump hose by actuating the prime pump until Leusynt oil will leak from the connection between prime pump hose and prime pump adapter. Tighten the connection. Pressure test the assembly for 2 minutes. Bleed off pressure by opening the pressure relive valve within the prime pump assembly. Open the prime port valve one-quarter turn.

Fig. 77

Fig. 78

Pressurize the system.



NOTICE If the pressure does not build up, check that the internal valve of the shuttle mechanism assembly is closed, see chapter 8.6.

Operate the handle of the hydraulic pump until a test pressure of 4,000 psi (276 bar) has been reached. Check all joints for leaks. Wait until the pressure has been stable for approximately 2 minutes.

86

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

NOTICE Initially, there may be fluctuations in the pressure as the air in the tool is compressed. If the test is satisfactory, the correct prime pressure has to be chosen: WARNING Choose the correct prime pressure to avoid that the sampler will be exposed to a higher pressure than designed for due to the thermal expansion of the Leusynth oil. For wells with a bottom hole pressure below 5,000 psi (344.5 bar), a prime pressure of 1,000 psi (69 bar) should be used. For wells with a bottom hole pressure above 5,000 psi (344.5 bar), a prime pressure of 300 psi (20.7 bar) should be used. Close the prime port valve and tighten. Bleed off the pressure from the hand pump. Disconnect the prime pump hose from the prime pump adapter. Holding the prime port valve closed with the spanner, unscrew the prime pump hose, and screw in the prime port nipple plug. NOTICE The Leutert bottom hole sampler is a precision instrument. Use the tools supplied i.e. quick clamp and OE spanner to make up joints. (Fig. 116) Never use pipe wrenches which damage tube walls and can cause galling of thread joints. Do not attempt to over tighten joints.

Quick Clamp Part-No. 5351.98.00015

Fig. 116

The tool is ready to be run into the well.

Friedrich Leutert GmbH & Co. KG

87

PDS / OPS Sampler - Operating instructions

NOTICE Run the tool into the well at a speed of approximately 200 ft/min (60 m/min). Leave the tool at sampling depth for at least 40 minutes after clock has triggered. Remove sampling string from well.

9

Before Sampling

Insist that a gauge cutter is used to clear the tubing of the well to full depth. Information about bottomhole temperature and pressure are required for correct flow regulator (choke) and prime pressure to be chosen. With correct calibration of depth counter and by calculating the gradients of the well, the correct depth required for the sample can be ensured. Please note for tandem running (two samplers) a minimum of 5 lengths of lubricator tube and a large mast or crane (onshore) or tugger winch (offshore) will be required for a closed well sampling, pressure control assembly. Ensure that you have a flexible knuckle joint for times when you may be using string of other measuring tools, thus, this will make it very easy to insert the tool into the lubricator section. Please view optional tools and accessories. Information about well fluid is necessary. If sandy or salt particles are present, the sand filtration sleeve may be required. Please view optional tools and accessories. For cleaning and filling the sampler, porta-cabin or clean area is required if multiple runs and transferring is to be successfully completed. Check the operating tools and accessories.

88

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

10

Transfer Bench Assembly “Part Two” - Pressure Test

While the sampler is lowered into the well the operator has sufficient time to continue the assembly of the transfer bench. Fit the swivel cylinder holder into the side of the bench and tighten into place. Assure that all bulkhead fittings are tightened. Fit the main gauge and the secondary gauge onto the transfer bench. The transfer bench can now be pressure tested. Start the pneumatic pump stroking and bleed all the air from the system. Pressurize the entire system to 10,000 psi (690 bar). This figure should be a maximum for the duration of the test period. Keep V2 shut. Close V7 and open V8 and observe the main gauge for any indication of a pressure drop. Close V5 and open V2 and observe the main gauge for any indication of a pressure drop. Re-pressurize the system to 10,000 psi (690 bar). Close V4 and V1 and then open V2. At this point observe the secondary gauge for any indication of a pressure drop. Open the sampler port (bulkhead fitting plug) and observe the secondary gauge. It should maintain the same pressure reading. Open V4 to release the contained pressure. Now the pressure test is complete.

Friedrich Leutert GmbH & Co. KG

89

PDS / OPS Sampler - Operating instructions

11

Preparation of the Sample Cylinder

Before the sample cylinder can be used, it must be pre-charged with the displacement fluid on the non-sample side of the piston. The fluid normally used and recommended is a water/glycol mixture (2/1) with an applied back pressure on the fluid. NOTICE For convenience, the preparation of the cylinder is normally done in the workshop. Slip the piston sample cylinder into the holder and tighten the screws to lock the bottle. The valve ports on the bottle must be pointing towards the back of the bench. (Fig. 79)

Fig. 79

NOTICE Instead of using the transfer bench a bench vice can be used to hold the cylinder in a vertical and horizontal position. First, remove valve port plugs and check that the cylinder has been depressurized and the sample drained into a suitable container for disposal. Similarly, check and drain any residual displacement fluid from the cylinder. Remove the cage protectors. If need be, the external circlips holding on the valve protection cages have to be removed using the circlip pliers. Check the circlips for corrosion and replace if necessary. Remove the internal circlips securing the end caps, using the circlip pliers. Check the circlips for corrosion and replace if necessary. With the valves left in situ, remove the end caps with the special two-pin spanner. After removing the sample end, end cap, carefully roll the mixing ball from the cylinder.

90

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

From the non-sample end insert the piston puller tool and screw into the attachment hole in the centre of the piston. Pull the piston from the cylinder. The piston puller tool has a weighted knocker to aid the piston removal which can be hammered against the reverse of the handle while pulling on the piston. Remove all the o-rings and back-up rings from the end caps using o-ring picking tool. Care should be taken not to cause any damage to the o-ring recesses. Remove the T-ring and back-up rings from the piston. Take care not to damage the o-ring recess during the removal. In most cases, the slider ring does not need to be exchanged. All parts are ready for cleaning and inspection. Clean the cylinder bore thoroughly with a clean cloth and cleaning solvent. Check that the cylinder bore is smooth and clean, and that there are no scratches and markings. If the bore is marked in anyway, contact LEUTERT for advice. Clean the piston with cleaning solvent. Clean both the end caps. Fit the T-ring seal and back-up rings to the piston along with the slider ring. The back-up rings are contoured to fit the curvature in the T-ring. Make sure that the back-up rings are facing the correct way round. Apply a very small amount of silicon grease on the seal. Screw the piston puller tool into the piston. Insert the piston into the cylinder, taking care when pushing the piston past the end cap threads. NOTICE If you are not using a type 600 / type light 600 cylinder, it is important that the piston is inserted into the honed bore by the non-sample end. This end has a lead for the T-ring. Push the piston into the cylinder bore and work it up and down the bore checking that the piston is free in move. Push the piston down the cylinder, leaving about an inch of honed bore showing.

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91

PDS / OPS Sampler - Operating instructions

Type one phase 600 operation only: Fit o-ring and back-up ring to the reservoir end plug. Apply silicon grease on the o-ring diameter only, apply lubricating grease on the threads. Screw into the nitrogen cap with special spanner. (Fig. 80) The reservoir end plug should be tightened hand tight only.

Fig. 80

The first stage of testing can begin. It must be established that valves R and C seal 10,000 psi (690 bar) nitrogen gas into the N2 chamber. Set up as shown below with valve C (nitrogen chamber valve) closed, and valve R (nitrogen release valve) open. Pressurize through the N2 prime port) to 10,000 psi (690 bar) using a gas booster pump. Close valve R, thus trapping 10,000 psi (690 bar) nitrogen gas in the reservoir. Drop the pressure by shutting off the gas booster pump and releasing the pressure, remove the coupling from the prime port. To check for leaks, simply submerge the N2 cylinder body in water, or spray on leak detector. The first pressure test is now complete. NOTICE If the cylinder is to be used in the near future then it may be advisable to leave the nitrogen gas in the N2 chamber. ANGLE VALVE (T)

BALL

VACUUM PORT

FLOATING PISTON

ANGLE VALVE (T) CYLINDER BODY

N2 CHAMBER

PLUG

R C PLUG PROTECTION CAP

HEADNUT SAMPLE END CAP WELL FLUID / OIL

92

N2 PRIME PORT TRANSFER FLUID

NITROGEN

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

Fit the o-rings and back-up rings to the nitrogen end cap, apply a small amount of silicone grease onto the o-ring diameters. Apply some lubricating grease onto the threads. Slide the locking ring over the outer thread of the sample cylinder. Screw in the N2 end cap. Lift the locking ring and guide the cutaway over the pin of the N2 end cap. Tighten the N2 end cap fully. Screw the grub screw into the locking ring and tighten it. NOTICE The purpose of the locking ring is to prevent the N2 end cap from backing off its original position.

Type 600 operation only: Apply a small amount of grease on the threads of the non-sample end cap and a very small amount of Leusynth oil on the outer surface of the o-rings.

Screw in the non-sample end cap using the special pin spanner. Fit the internal circlip and back off the end cap until it touches the circlip. Turn the cylinder 90° and gently roll the mixing ball into the honed bore. Slowly rotate the cylinder a further 90° so that the sample end is now uppermost. The ball should now be located in the piston recess. Pour 100 ml of cleaning solvent into the cylinder. Similarly, grease the threads and smear Leusynth oil on the o-rings of the sample end cap. Screw in the sample end cap using the special pin spanner. Fit the internal circlip and back off the end cap, until it touches the circlip. Check valve is fully open. NOTICE Adjust the end caps so that connecting ports of the two valves are facing the same direction. Use the air line. Fit it to the cylinder valve and slowly open the air supply. This will push the piston to the bottom of the cylinder. Check that the vacuum port is closed. (Fig. 81)

Friedrich Leutert GmbH & Co. KG

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PDS / OPS Sampler - Operating instructions

Fig. 81

Connect a pressure hose from the top bulkhead fitting to the bottom of the cylinder. (Fig. 82) Check that V4 and V5 are open.

Type one phase 600 operation: Make sure that valve R is closed.

Operate the pump very slowly. Having left the connection on the bottom valve loose, when transfer fluid appears from the port, tighten the connection. Speed up the pump. When cleaning solvent appears through the evacuation nipple, stop the pump.

Fig. 82

94

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

Shut off the pump and open V2 to relieve the pressure. Shut V2 and fit the main gauge. Start the pump and pressurize the bottle up to the maximum working pressure. Wait for 15 minutes. If there are no leaks, the pressure test is complete. Relieve pressure by opening V2. Open the top valve on the piston sample bottle. Close V2, operate the pump to push the cleaning solvent out of the bottle. Disconnect the hose from the cylinder angle valve, checking that it is firmly closed. It is very important that there is no air trapped in the glycol/water mix (air bubbles), or in the chamber itself. This can be removed by turning the cylinder upside down, and allowing air bubbles to rise to the bottom of the cylinder. The small void can be filled with the following method. Screw the autoclave vacuum nipple into the bottle adapter. A cylinder valve adapter may have been used in conjunction with the autoclave vacuum nipple. Attach the vacuum pump and reservoir (half filled with glycol/water mix). (Fig. 83, 84)

Fig. 83

Fig. 84

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95

PDS / OPS Sampler - Operating instructions

Open the bottom valve and start evacuating the cylinder. When full vacuum is obtained, turn the vacuum pump and reservoir 90° on to its side. (Fig. 85, 86)

Fig. 85

Fig. 86

Release the valve on the hand vacuum pump to allow the glycol/water mix to be sucked into the cylinder. This should fill the bottle completely. Shut the bottom angle valve, remove the vacuum pump and reservoir, the vacuum nipple, the bottle adapter and fit the NPT plug. 6 ml of safety fluid will have to be flushed from the recess of the piston. This can be done by fitting the air line to the cylinder angle valve and blowing across the piston. This will evaporate the solvent from the evacuation port nipple. This operation should take approximately 15 minutes. NOTICE It is best to turn the bottle upside down for this operation, as gravity aids the removal of the fluid. When completed, disconnect the air line. Shut off both the valve and the vacuum port. Fit the NPT plug and the evacuation port plug. Fit protection caps. Return the cylinder to its transportation box ready for use. A useful procedure to adopt is to tag the cylinder and box when the above has been completed to identify that the cylinder is ready for use. Similarly, a tag system should also be used to identify when a cylinder is in use, charged with a sample and when the cylinder is ready to dump the sample and for cleaning.

96

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

12

Sample Validation

After the sampler has been retrieved from the well, remove the nose cone (Fig. 87) and replace with the transfer lock. (Fig. 88)

Fig. 87

Fig. 88

DANGER Do not stand in front of the open sampler end during this procedure until the transfer lock has been fitted correctly. The transfer lock should be fully screwed into the sample chamber until it is flush with the chamber end. (Fig. 89)

Fig. 89

This serves as confirmation that the safe lock collets have engaged and the sampler has functioned correctly and the sampler has closed.

OPS operation only: NOTICE The one phase section must remain connected to sample chamber and the N2 valve stem must be kept open until just before transfer. This will compensate for any pressure drop which may have occurred due to fluctuation in temperature, and ensure that the sample will remain in single phase. Remove N2 prime port plug from N2 prime port valve. Hold N2 prime port valve closed with the ring spanner. Unscrew N2 prime port plug (Fig. 90)

Friedrich Leutert GmbH & Co. KG

97

PDS / OPS Sampler - Operating instructions

Fig. 90

Screw validation adapter to N2 prime port valve whilst retaining the ring spanner in place so that N2 prime port valve may be opened when all connections have been made (Fig. 91)

Fig. 91

Tighten the validation adapter against the flat o-ring face. NOTICE Do not over tighten. Fit secondary gauge into validation adapter and tighten. Carefully open N2 prime port valve a quarter turn in order to read the pressure.

Fig. 92

NOTICE The system pressure must not be allowed to drop below the bubble point pressure as this could take the sample out of single phase.

98

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

NOTICE Ensure that the N2 valve stem remains open during this procedure. The subsequently indicated sample chamber pressure is considered „True Opening Pressure”. The purpose of determining the opening pressure of a bottom hole sampler is to verify the sample validity by comparing these pressures when multiple samples are taken from the same zone. Note down the true opening pressure and temperature (ambient or elevated via heating jackets). Close the N2 prime port valve. To bleed the manifold, remove the secondary gauge from the validation adapter. Remove the validation adapter.

To determine the opening pressure in PDSshort operation refer to chapter „Opening Pressure PDSshort only”.

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99

PDS / OPS Sampler - Operating instructions

13

The Transfer

13.1 Preparing the Transfer Before the air chamber is separated from the sampler, high pressure may have passed through to the air chamber, due to o-ring failure. Such pressure must first be released from air chamber. DANGER Release possible pressure from the air chamber by carefully opening the vent screw. The air chamber assembly can now be separated from the sampler and put aside.

OPS operation only: With the transfer bench and sample cylinder set up, close N2 valve stem on the N2 prime port nipple of the sampler and slowly bleed off the nitrogen from the N2 chamber through the N2 prime port plug. The N2 chamber can now be separated from the N2 prime port assembly. Fit the sample chamber assembly complete with the N2 prime port nipple and stinger assembly into the transfer bench clamps.

PDSshort operation only: Fit the sample chamber assembly into the clamps of the transfer bench. Remove the flow regulator from its housing nipple by inserting the cross tool into the small thread on the end of the flow regulator. The flow regulator may be withdrawn by pulling. (Fig. 93)

Fig. 93

100

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

Fit the sample hose assembly into the end of the flow regulator prime nipple assembly (PDS short), or the N2 prime nipple assembly (OPS). (Fig. 94) Fit the other hose to the bulkhead fitting, positioned next to the cylinder holder and connect it to the bottom valve on the piston sample cylinder. (Fig. 94)

Fig. 94

Before proceeding with the transfer air must be bled out of the connecting hoses and other parts of the system. Remove the prime port plug (PDS short) or the N2 prime port plug (OPS) and open the prime port valve one half turn. Close V2 and V4, open V1. Slowly stroke the pump. Flush the transfer fluid through the prime port valve until there is no air present. Close the prime port valve and open V4. Check that V7 and V8 are closed, open the hose connection to the bottom valve on the piston bottle, slowly stroking the pump by hand until all the air is flushed out, then tighten. Open the connection from the pressure gauge and secondary gauge slowly stroking the pump by hand until all the air is flushed out, then tighten. The system has to be pressure tested to 1,000 psi (69 bar) more than the anticipated transfer pressure. Close valve V2, V7 and V8. Open all other valves and the bottom valve on the piston sample bottle. Open the air supply valve. Slowly screw down the air pressure regulator. When the test has been completed, bleed the pressure down by opening V2.

Friedrich Leutert GmbH & Co. KG

101

PDS / OPS Sampler - Operating instructions

Push the o-ring protector down to expose the sample port and remove the transfer port plug. (Fig. 95)

Fig. 95

NOTICE Screw in the transfer adapter and tighten. Taking care not to overtighten. Slowly swivel the piston sample bottle towards the transfer adapter. Make sure that the port and stem are in line, then tighten. (Fig. 96)

Fig. 96

Evacuate the air from the top of the cylinder and the transfer adapter through the evacuation port on top of the cylinder using the vacuum hand pump. Attach the pump to the vacuum port assembly. Open the port by holding the body of the assembly with a spanner, turning the top part anticlockwise. Open the top valve on the piston sample cylinder and evacuate the transfer section. (Fig. 97)

102

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

Fig. 97

While this section is on maximum vacuum, close the vacuum port assembly and remove the hand pump.

13.2 Opening Pressure PDSshort only To determine the opening pressure in OPS operation refer to chapter „Sample Validation”. Check that V7 and V2 are closed, all other valves should be open. Pressurize up the entire system to 1,000 psi (69 bar) above the bottom hole pressure. Shut off the air regulator and allow the pressure to be stabilize. Lower the pressure in the system by slowly opening V2, observe for a kick in the main gauge reading as it lowers and note the pressure at which this occurs. The kick is caused by movement of the floating piston due to the presence of gas in the sample. It indicates the opening pressure. The purpose of determining the opening pressure of a bottom hole sampler is to verify the sample validity by comparing these pressures when multiple samples are taken from the same zone.

13.3 Transfer Procedure The transfer is made using the so called open-loop configuration. During the transfer 600 ml of water/glycol is allowed to escape through V8. A measuring jar indicates the progress of the sample transfer. This procedure is also most suited for occasions when bubble-point analysis follows sample transfer (PDS short). Place the empty measuring cup under the drain tube within the transfer bench.

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103

PDS / OPS Sampler - Operating instructions

Pressurize the system to 2,000 psi (138 bar) above bottom hole pressure. The valve configuration after initial pressurization of the system is as follows: All valves including sample cylinder valves are in the open position with the exception of V2, V5, and V8 which are closed. Align the transfer lock in such a way to enable the needle valve key to be inserted through the transfer lock into the needle valve stem within the needle valve body. (Fig. 98)

Fig. 98

Open the needle valve two complete turns. With the left hand carefully stroke the pump regulator whilst cracking V8 with the right hand allowing fluid to slowly drain into the measuring cup. Carefully control regulator and V8 in order to maintain stable drainage. NOTICE During this procedure ensure that pressure does not drop more than 1,500 psi (103.5 bar) above the bottom hole pressure. When transfer is complete the pump will stop and a sudden but slight pressure drop will be observed on the secondary gauge. V8 should be closed immediately to prevent the sample pressure from dropping too low. Observe the main gauge for any pressure drop. At this point check the volume of recovered transfer fluid in the measuring cup which should be 600 ml. If lesser volume has been recovered, the transfer is not complete. Shut off the air supply to the pump and bleed down the pressure in the transfer bench. Close the top valve on the piston sample bottle and the sampler needle valve. Disconnect the transfer adapter and remove from the cylinder.

104

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

Slip the sampler along the body clamps so that the piston sample bottle will be free to rotate 180° anti-clockwise. (Fig. 99)

Fig. 99

13.4 Removal of the Air Lock from the Transfer Pump During operation of the transfer bench, one might face a situation in which the pump does not build up any pressure. An air lock inside the pump might be the reason for the malfunction of the pump. An air lock will occur if the system was not bled of air correctly before the operation or if the supply transfer fluid was cut off. In this case the pump is sucking air through its seals. There are several reasons for a shortage in supply of transfer fluid:

–

The tank is empty.

–

Valves V2, V5 or the bottom valve of the cylinder were closed when starting the closed loop transfer procedure.

–

The air supply of the pump was not shut off immediately after the transfer in close loop mode had been completed. In such case the pump continues to suck the transfer fluid from below the piston until a vacuum occurs.

Such air lock can be removed easily in most of the cases by following the procedures below: NOTICE Step back from the bench and take a breath. It is critical not to open any valves in a hurry as that might result in a pressure drop of the sample leading to a separation of phases.

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PDS / OPS Sampler - Operating instructions

Procedure 1) Check the fluid level of the tank. Make sure there is sufficient transfer fluid in the tank. 2)

Close valve V1. If the problem has occurred during or immediately after the transfer, close the bottom valve of the cylinder to avoid loosing the pressure inside the sample cylinder.

3)

Open valve V4, V5, V7 and V8. Close valve V2.

4)

Remove both gauges from the transfer bench.

5)

Remove the bottle hose from the bottom valve of the cylinder and keep the hose end higher than the system. NOTICE If the problem has not occurred during or immediately after transfer, ignore item 5, attach a bottle hose to the cylinder connection of the transfer bench (right side), hold the open hose end into a separate container with transfer fluid and maintain the container higher than the system. Slowly stroke the pump carefully. The fluid in the bottle hose (or from the container) will slowly flow down and into the system.

6)

As transfer fluid exits the autoclave fittings (gauge connections on the top of the bench), one can very slowly open the air supply of the pump. The pump should not pump more than two strokes per second. After one minute, the frequency of strokes can be increased to four strokes per second.

7)

When steady fluid (without air bubbles) is observed exiting the autoclave fitting of the secondary gauge, fit the secondary gauge (and tighten) without stopping the pump.

8)

When steady fluid (without air bubbles) is observed exiting the autoclave fitting of the main gauge, fit the main gauge (and tighten) without stopping the pump.

9)

Close valve V7 first and then valve V5.

10)

Observe a pressure build-up on the secondary gauge.

11)

If no pressure build-up is observed, repeat the procedure and allow the transfer fluid to flow a little longer.

Continue with transfer procedure by reconnecting hose, bleeding off air and pressurizing complete transfer. If the problem has NOT occurred during a transfer, continue with intended procedure (i.e.) rig-up or pressure testing.

106

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PDS / OPS Sampler - Operating instructions

14

Bubble Point Analysis PDSshort only

NOTICE The Bubble Point Analysis should only be carries out if the Sample has not been obtained with the OPS sampler. During the bubble point analysis the sample will shift from single phase to dual phase. The purpose of using the OPS is to maintain the sample in single phase during retrieval. If bubble point analysis are carried out now the use of the OPS would have been without sense. Having transferred the sample into the piston sample bottle, we can begin to assess the bubble point. In the piston bottle an agitation facility has been built in to aid the mixing of the gas and oil. Agitate the sample by rotating the bottle 180° anti-clockwise watching for any pressure decrease. If a pressure decrease is observed then the sample is not monophasic. The pressure must be returned to the same pressure before agitation. Open V5 and operate the pump. Repeat the agitation process until there is no pressure drop. Check that V8 is closed, then quickly open and close V7 to allow the indicator rod on the constant volume assembly to reach its full 2 ml stroke. Pump the measured volume into the measuring cup by opening V8, then close again. The sampler pressure should be noted after two minutes and the process repeated on two minute steps. (Fig. 100)

Fig. 100

NOTICE In cases where the sample has a low G.O.R. and appropriate low bubble point is expected, it may be necessary to temporarily remove the constant volume assembly return spring as this will cause a back pressure and may affect the results, in confirming bubble point. After release of the transfer fluid through V8, the indicator rod has to be pushed back manually.

Friedrich Leutert GmbH & Co. KG

107

PDS / OPS Sampler - Operating instructions

Graph A: Sampler filled with formation water Graph B: Sampler filled with reservoir fluid

Pressure (psi)

Graph C: Sampler filled with gas

3,300

227.70

3,200

220.80

3,100

213.90

3,000

207.00

2,900

200.10

2,800

193.20

2,700

186.30

2,600

179.40

2,500

172.50

2,400

165.60

2,300

158.70

2,200

151.80

2,100

144.90

2,000

138.00

1,900

131.10

1,800

124.20

1,700

117.30

1,600

110.40

1,500

10

20

30

40

50

60

70

Pressure (bar)

The bubble point graph may now be plotted with volume or steps drawn on the X-axis and pressure on the Y-axis. The point where the two extrapolated lines joining the points intersect is the bubble point for that sample at ambient temperature. (Fig. 101)

103.50

Fig. 101 - Sub-Surface Sampler Bubble Point Graph

108

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

15

Rigging Down

15.1 Prepare the Sample for Dispatch Make sure that the top valve of the sample cylinder is closed.

PDSshort operation only: Bleed transfer fluid through V7 and V8 to required shipping pressure or until the pressure drops to zero. This will indicate, that the piston reached the bottom of the sample cylinder.

OPS operation only: Observe the pressure gauge. The pressure inside the cylinder should still read 2,000 psi above well pressure.

Close the bottom valve of the sample cylinder. Bleed of remaining pressure trough V7 and V8. Disconnect the bottle / bench hose assembly from the sample cylinder. Open the N2 communication valve of the sample cylinder. This will release the nitrogen to make contact with what remains of the transfer fluid and thereby maintaining the sample in one phase. NOTICE The N2 communication valve might be labeled with R in case older one phase cylinders are used. If Type 6 cylinders are in use open the nitrogen cylinder valve. This valve is color coded yellow. Plug the cylinder valve ports. Remove the sample cylinder from the transfer bench. Screw the valve protectors back onto the sample cylinder. Complete the label „SAMPLE DETAILS”.

SAMPLE DETAILS CLIENT

WELL NO.

ZONE

FIELD

SAMPLE NO.

CYLINDER NO.

SAMPLE NATURE

SAMPLE DATE / TIME

SAMPLED BY FINAL PRESSURE

SAMPLING POINT

@

FINAL TEMPERATURE

5381.98.00007

COMMENTS

Glue the label „SAMPLE DETAILS” to the cylinder.

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PDS / OPS Sampler - Operating instructions

Glue the hazard diamond label „FLAMMABLE LIQUIDS” to the cylinder and to the outside of the box.

In case the sample contains H2S glue the „TOXIC GAS” diamond label to the cylinder and to the outside of the box.

Put the sample cylinder and all transportation certificates into the box ready for dispatch to the P.V.T. lab. Remove the green status tag from the box or the sample cylinder.

15.2 Rigging Down Transfer Bench NOTICE Do not bleed the pressure within the transfer bench by opening V4 and V2. At his stage N2 is still present in the sampler. If V4 and V2 are opened N2 would get into the system and cause an air lock. Close the N2 valve stem. (Fig. 116)

Fig. 116

Disconnect the sample hose assembly from the transfer bench. The hose must stay connected to the sampler.

110

Friedrich Leutert GmbH & Co. KG

PDS / OPS Sampler - Operating instructions

Carefully open the N2 valve stem to drain the mixture of transfer fluid, Leusynth oil and N2 into a bucket. (Fig. 117)

Fig. 117

Connect the air hose assembly via the transport adapter to the sampler. (Fig. 118)

Fig. 118

Apply air to push the piston inside the sampler back towards the sample hose. This will drain the remaining transfer fluid through the sample hose. NOTICE It is advisable to dispose the transfer fluid from the sample chamber as it will be contaminated with Leysynth oil. The sampler can be disconnected from the transfer bench and redressed.

Friedrich Leutert GmbH & Co. KG

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PDS / OPS Sampler - Operating instructions

16 Periodic Workshop Test 16.1 Shuttle Mechanism Assembly With the shuttle mechanism separated from the air chamber, the internal valve seals can be replaced. Firstly unscrew the retaining bush using the small extractor. (Fig. 104)

Fig. 104

If the retaining bush is stiff and difficult to unscrew by hand, then a spanner can be used. Pull out the piston valve stem and trigger. (Fig. 105)

Fig. 105

Using the needle valve key unscrew the retaining screw. (Fig. 106)

Fig. 106

This will give access to the internal seals. Use the o-ring mounting tool and withdraw the complete assembly.

Fig. 107

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Replace seals and insert the seal assembly in the correct order and tighten retaining screw. NOTICE Apply a small amount of Leusynth oil to the o-rings before assembly.

16.2 Relief Valve The relief valve is built into the shuttle mechanism assembly allowing to bleed off the displacement fluid and prevent overpressure of the system from thermal expansion as the sampler is lowered into the well. To test the relief valve unscrew the protection cap from the shuttle mechanism assembly.

The following procedures apply to Leutert samplers supplied up to July 2012 as well as MKII samplers. Slide the transfer lock & setting tool over the piston valve stem and push it forward until it hits the end of the thread. (Fig. 57)

Fig. 57

Hold the tool in this position and screw in the setting screw until you feel resistance. (Fig. 58) NOTICE: The stem must still be moveable. If the stem is tightened it could be damaged.

Fig. 58

Remove the transfer lock & setting tool.

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Wind the clock. (Fig. 60)

Fig. 60

Connect the clock to the clock coupling. (Fig. 66)

Fig. 66

Screw the clock and clock coupling assembly into the shuttle valve. (Fig. 71)

Fig. 71

Screw the clock chamber onto the shuttle mechanism. (Fig. 72)

Fig. 72

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With the air chamber plug and the air chamber removed, attach the hydraulic prime pump to the air chamber coiled tube. (Fig.108) CAUTION When assembling the Swagelock compression fittings to the shuttle mechanism it is CRITICAL that the flats on the hex are parallel to the centre. (If not the fitting will damage the sealing bore in the air chamber & the locking screw cannot be removed). Slowly build up pressure until the relief valve opens.

Fig. 108

The pop-off pressure must be around 1,700 psi (117.2 bar). The closing pressure must be above 1,300 psi (89.6 bar). If an adjustment is required, slacken the lock screw with a 1/16“ allen key and turn the adjustable grub screw until the setting is correct.

Fig. 109

Tighten the lock screw and check the pop-off pressure. Disconnect the hydraulic prime pump and fit the air chamber and the air chamber plug.

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16.3 Clock Testing Procedure Wind the clock up to its full running time. This will depend on the range of the clock. Place the clock on a flat surface such that the clock body is supported but the cone and winding head are free to rotate. Record the time, and check clock time hourly against wrist. Repeat this procedure with the clock in horizontal, vertical and inverted position. NOTICE Should any problems occur with the clock, return the unit to LEUTERT for servicing.

16.4 Anti-Premature Closing Assembly With the anti-premature closing assembly attached to the rod, loosen the spring retaining nut from the brake collet and unscrew. This should be done in a vertical position. (Fig. 110)

Fig. 110

Lift the piston rod and rod connector, and the spring retainer and spring will come with it. Make sure that the four balls which may fall out do not get lost. With the assembly separated, inspect the rod connector, balls, and brake collet for signs of wear or damage. Check that the rod connector is tightly fastened to the Rod and nip up if required.

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Coat balls with a light film of grease and place them in their ports in the ball retainer. Gently lower the brake collet over the ball retainer taking care not to push the balls into the centre. Once this is completed, push the balls towards the outside of the ball retainer in order to allow the rod connector into place. Then tighten. Lock the assembly as described in an earlier section and check the operation. NOTICE The brake collet and the ball retainer should collapse leaving no gap. If a gap should occur, one or more of the balls have fallen into the centre of the ball retainer.

16.5 Flow Regulator Testing the operation of the flow regulator can be achieved by setting up a test unit. (Fig. 111)

NOTICE: This test unit can be supplied on request by the manufacturer. End cap large port outlet pressure 1,400 – 1,600 psi (96.5 – 110.3 bar)

End cap small port outlet pressure 300 – 500 psi (20.7 – 34.5 bar) 8,000 psi (551.6 bar)

Fig. 111

NOTICE The 1/4 NPT grub screw has a single purpose: When the prime hand pump is used in conjunction with the flow regulator test unit, the grub screw plugs the port when the 6,000 psi (413.7 bar) gauge is removed on the prime port adapter. Using the small front orificed end cap 5300.0.11.08002, flow regulator piston and any flow regulator body, apply 8,000 psi (551.6 bar), and the gauge should indicate between 300 psi (20.7 bar) and 500 psi (34.5 bar). NOTICE To prevent and air lock distorting the outlet side pressure, open the valve and allow a slight flow through, then the valve should be closed very slowly.

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Using the same set up as before, apply 8,000 psi (551.6 bar) to the large orificed end cap. Between 1,400 psi (96.5 bar) and 1,600 psi (110.3 bar) should be indicated on the gauge. If pressure rises above these given levels, the matching end cap and piston should be returned to the manufacturer for repair. NOTICE End cap and piston have been matched and tested. On no account should these be separated and used on non-matching pieces unless tested as described above.

16.6 Sample Chamber Assembly Pressure Test Procedure Dress the lower of the sampler as far as the flow regulator/prime nipple but DO NOT set the anti-premature closing assembly. Assemble as normal but use the transfer lock & setting tool sleeve to push the needle valve body onto its seat as though the tool had taken a sample. (Fig. 112)

Fig. 112

Screw the transfer adapter into the needle valve body and inject oil into the sample chamber until full. Close the needle valve and the prime port valve and disconnect the pump. Screw the transfer bench sleeve assembly onto the flow regulator/prime nipple assembly. (Fig. 113)

Fig. 113

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15,000 psi (1,034 bar) from Pump

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Pressurize to 15,000 psi (1,034 bar). If this test is satisfactory with no leaks, bleed off the pressure and redress the tool as described in an earlier section. NOTICE If a leak is discovered on the needle valve seat, the combined unit must be returned to the manufacturer for repair.

16.7 Well Simulating Test A function test can be carried out before despatching the tool to the well site. This will test the sampler’s function completely, but it also gives the operating engineer an opportunity to get familiar with the sampling equipment. Assemble the transfer bench as described in chapter 7. Assemble the sampler ready for running in the well except, that the nose cone is substituted by the tandem nipple. NOTICE The nose cone needs to be replaced with the tandem nipple prior to priming the sampler. This can not be done if the sample chamber is pressurized. Use the flow regulator body Nr. 4 with and the large end cap. Set the clock time for approximately 15 minutes. Put the Sampler into the clamps of the transfer bench. The sample chamber should be held by the clamps. Additional support below the air chamber is required to prevent the sampler from tilting over. Slide the well simulation tool over the inlet holes of the sampler and the tandem nipple. (Fig 114)

Fig. 114

Connect the bottle / bench hose assembly to the well simulation tool and the bulkhead fitting at the right back of the transfer bench.

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Bleed the air from the assembly before tightening the connections fully. Fit the main gauge onto the transfer bench. Bleed the air from the assembly before tightening the connections fully. Close V1, V2, V7 and V8. The bulkhead fitting for the secondary gauge must remain closed using a bulkhead fitting plug. Open V4, V5 and the flow line to the main gauge. Start the transfer bench pump and pressurize the system up to 2,000 psi. WARNING Do not exceed the maximum working pressure of the well simulation unit. The maximum working pressure is 3,000 psi. Do not shut off the air supply to the pump, once the system is pressurized but maintain the pressure coming from the transfer bench Wait until the clock has run down. A clicking sound should be heard as the clock coupling or trigger mechanism releases the piston valve stem within the shuttle mechanism. At the same time the pressure indicated at the main gauge will drop. The pump will start to stroke as the pressure drops. The main gauge will start to flicker as the piston runs up the tube. The sampler is now being filled with transfer fluid from the bench tank. The whole filling process might take several minutes. Unlike downhole operation the pressure in the well simulation unit drops every time the piston moves up a little further. To achieve constant pressure the well simulation unit may be connected to a nitrogen cylinder. No simulated transfer can be carried out if this method is used. (Fig. 115)

Fig. 115

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As soon as the floating piston reaches the top of the sample chamber the anti-premature closing assembly collapses, the sampler closes and the pressure indicated at the main gauge will jump up. The pump will stop to stroke. Shut off air supply. Open V2 and allow the pressure from the well simulation unit to bleed back into the tank. Remove the well simulation unit from the sampler. Remove the tandem nipple. Check if the safe lock collets have expanded inside the safe lock, when needle valve body assembly has moved up and the sampler has closed. If safe lock collets are expanded, well simulation test has successfully been completed and a simulated transfer can be carried out. Please refer to chapter 11. Fit the transfer lock & setting tool.

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17

Preventing Tool Failure

17.1 PDSshort Operation Below is a quick mental check before the tool is run and reasons that may cause the tool to fail. 1)

Check that the needle valve is closed. Reason for tool failure: Losing the sample when the transfer port plug is removed.

2)

Check that the anti-premature closing assembly has been function tested and set. Reason for tool failure: The sampler closing immediately after the tool has been fired.

3)

Check that there is no contamination in the flow regulator body. Reason for tool failure: A complete blockage or partial blockage due to dirt in the small back orifice. This would slow down or stop sampling.

4)

Check that the setting pin is fully backed off against the circlip. Reason for tool failure: The shuttle mechanism is still in the setting position preventing the mechanism from firing.

5)

Check that the flow regulator is facing in the correct direction. Reason for tool failure: The piston in the flow regulator would shut the flow off immediately after the tool was fired.

6)

heck if the clock coupling or trigger mechanism is free to move C upwards & downwards. Reason for tool failure: If clock coupling or trigger mechanism sticks, it will not drop down into the slot when the clock unwinds, thus preventing the piston valve stem from springing back releasing the flow.

7)

Check that the sampler clock is set for the correct duration. Reason for tool failure: The tool is firing prematurely, capturing a sample at the wrong depth. Or the tool is not firing at all, because the clock was set too long.

8)

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Check that the sampler clock has started before fitting it to the tool. Reason for tool failure: The tool will not fire.

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9)

Check that the sampler clock is serviced at regular intervals. Reason for tool failure: The sampler clock could stop before it has totally unwound.

10)

Check that the relief valve is set at the correct pressure. Reason for tool failure: The buffer fluid is bleeding into the air chamber through the relief valve (relief valve set too low), thus sampling at the wrong depth.

11)

heck that the seals in the shuttle mechanism assembly hold C pressure. Reason for tool failure: The buffer fluid is bleeding into the air chamber through the damaged seals. Thus, sampling occurs as soon as any external pressure is applied.

12)

Check that the piston valve stem is free to move before setting. Reason for tool failure: If the piston valve stem sticks, the tool will not fire.

13)

Check that the tool has been primed at the correct pressure. Reason for tool failure: A high build up in pressure in the sample chamber damaging the seals and causing the needle valve body assembly and piston to jam.

14)

heck that all excess thread tape is removed when assembling air C chamber parts (NPT Fittings). Reason for tool failure: The flow is being blocked by thread tape sticking in small orifices in the shuttle mechanism assembly.

The following procedure applies to Leutert samplers supplied up to July 2012 as well as MKII samplers. 15)

Check that the small pin in the trigger mechanism is not bent, damaged or missing. Reason for tool failure: A cam slot misalignment will cause premature tool firing, or prevent the tool firing.

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17.2

OPS Operation

Below is a quick mental check before the tool is run and reasons that may cause the tool to fail. 1)

T he split collets on the safe lock assembly are free to spring open while attached to the needle valve body by the securing screw. Reason for tool failure: Loss of sample will occur, due to the split collets not engaging into their recess, therefore, allowing the needle valve body assembly / floating piston assembly to be pushed back into their original position, by the nitrogen gas pressure when this is released, opening up the inlet ports.

2)

The stinger housing assembly is in the correct position. Reason for tool failure: If the stinger housing assembly is too far forward the flow of the dis placement fluid will be prevented and the Sampler will not operate.

3)

oth the valve stems on the N2 chamber assembly and the prime B port assembly are holding pressure and are not leaking past the o-rings or metal/metal seats. Reason for tool failure: Complete loss or low nitrogen pressure below the expected well pressure, resulting in a sample not in one phase.

4)

5)

T he safe lock collets are in good condition i.e. the edges are not rounded off, as they may not engage properly. Reason for tool failure: See item (1). oth the valve stems on the N2 chamber assembly and the prime B port assembly have been opened before the sampler is run into the well. Reason for tool failure: There will be no communication between the N2 chamber and the sample chamber, resulting in a sample which is not in one phase.

6)

The N2 chamber is primed to the required pressure. Reason for tool failure: If the nitrogen pressure is too low this will result in a sample which is not in one phase.

7)

F or damage or scratch marks on the stinger housing assembly sealing diameters. The o-rings on the N2 release stem could be damaged resulting in premature release of the nitrogen.

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8)

The nitrogen release stem is not bent before assembly. Reason for tool failure: The nitrogen release stem could damage the bore of the stinger housing assembly resulting in o-ring failure and premature release of the nitrogen.

9)

T he nitrogen release stem has been tightened properly into the prime port assembly. Reason for tool failure: Nitrogen gas will leak into the sample chamber prematurely. This causes a build up of nitrogen gas in the displacement fluid, when the sampler is triggered. The nitrogen gas in the air chamber will create too high a back pressure. The back pressure will prevent the sampler from closing, resulting in loss of sample.

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18 Exploration Well Sampling Accurate TWT data are crucial to well completion and production, formation, evaluation and reservoir characterization. Very often the slick line operator, who is sending to collect such a sample, does only know very little about sampling. The following instruction to exploration well sampling will put the operator and his supervisor into the position where he or she can decide which sampling procedure is the best to be followed.

18.1 Hydrocarbons Mineral oil and gas are known as hydrocarbons because they contain compounds predominantly from hydrogen and carbon, symbols H and C. As the number of carbon atoms in the molecule of a hydrocarbon increases, the boiling point increases. Compounds with to 4 carbon atoms per molecule are gases at normal ambient temperatures, those with 5 to 15 carbon atoms are generally liquids and with higher number generally solids (at ambient temperatures). Crude oils are complex mixtures and contain a very large number of different hydrocarbons and its properties reflect this composition. Three broad classes of hydrocarbons exist in crude oil. They are aliphatic compounds, cycloparaffins or naphthenes and aromatic compounds. Some of the molecular forms of these compounds are illustrated below: 1)

Aliphatic compounds (n-paraffins or alkanes) Methane......................................CH4 Ethane.........................................C2H6 Propane.......................................C3H8 Butane.........................................C4H10 These are distinguished by having the carbon atoms linked in open chains. C4 and higher paraffins have the possibility of branched chains, iso-paraffins.

2)

Cycloparaffins or Naphthenes These contain carbon atoms linked in rings of 5 or 6 atoms, with side chains on the rings. Cyclopentane...............................C5H10 Cyclohexane................................C6H12 Methyl-Cyclohexane....................C7H14

3)

Aromatics compounds These contain carbon atoms linked in rings of 6 atoms but with extra bonding between these atoms. Again with side chains on the rings. Benzone......................................C6H6 Toluene.......................................C7H8 Xylene.........................................C8H10

All three types of hydrocarbons are found in crude oil and the crude oil may be typified, as for example paraffinic, when it is predominantly composed

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of paraffin hydrocarbons, and alternatively, napthenic or aromatic. As the boiling point of these hydrocarbons increases the number of carbon atoms per molecule increases and hydrocarbons belonging to more than one class can and do co-exist. Other types of hydrocarbons such as olefins or alkenes do exist and are of great importance in petroleum processing and petrochemical manufacture. They are not however found in any significant amounts in crude oil.

18.2 Sulphur Sulphur is found in all crude oils normally in the range of 0.1 to 5.0 % weight. It is rarely present as free sulphur, but is either as hydrogen sulphide H2S in the gases and/or with carbon and hydrogen shown below. Ethyl Mercaptan..........................C2H5SH Diethyl Sulphide...........................C2H5S-C5H5 Thiophen.....................................C4H4S These compounds are normally only present when there is a relatively high concentration of H2S (>5000 ppmv). Apart from the mercaptans the other sulphur compound formulae can be derived from a corresponding hydrocarbon by replacing CH or CH2 by S. In most crude oils the percentage of sulphur in the oil increases with the boiling point, i.e. the naphtha fractions may have up to 0.1% sulphur, the gas fractions up to 1% and the residues up to 5% sulphur.

18.3 Other Substances Water and inorganic salts are often present in a reservoir, but are relatively easy to remove during processing by simple separation systems and are not, chemically speaking, part of the crude oil. Other elements present in crude oil in much smaller amounts than sulphur (ppm level), but of importance to the refining and/or use of the crude, are oxygen, nitrogen, nickel and vanadium. Oxygen is combined in what are known as naphthenic acids normally detected by determining the acid value of the crude oil and of products derived from it. Naphthenic acids are of importance for potential corrosion of handling and distillation equipment. If present in sufficient amounts, they can be recovered for chemical use. Nitrogen, if present, will be found in the higher boiling fraction of crude vacuum gas oils and residues and can be of importance to use of these products. Nickel and Vanadium, if present, will be found only in the residual fractions of crude oil. If present in more than a few ppm, they can be of importance to the use of these fractions.

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18.4 PVT Properties Changes of state In order to study the properties of gases and hydrocarbon liquids, we need to understand the relationship between them. This is best understood by considering molecular behavior and its effect on three physical properties. Please see below: Pressure (P) – which is a function of molecular attraction and repulsion Volume (V) – which is a function of the number of molecules present Temperature (T) – which is a function of the kinetic energy of the molecules When a material appears to be at rest, it is actually in dynamic equilibrium between the attractive and repulsive forces. If one of the physical properties is changed (P, V or T) then equilibrium must be established. For example, if heat is added to a liquid system the temperature rises, because of the increase in kinetic energy of the system and: EITHER Pressure increases in a closed system as a function of an increase in the number of impacts of the molecules on the surface of containment. OR In an open system the volume expands to accommodate the more excited molecules at the same pressure. In the extreme case, when enough heat is added, the forces become unbalanced (boiling liquid) and the material CHANGES STATE into the GAS PHASE. Phase behavior is best understood by considering phase diagrams.

Pure substances First we look at the simple phase diagram of a pure substance.

PRESSURE

C Solid

Liquid Gas

TEMPERATURE

Tc

Phase diagram for a pure substance

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The phase diagram is a plot of pressure against temperature. For the purposes of hydrocarbon chemistry, we can ignore the ‚Solid‘ part of the phase diagram and concentrate on the vapour pressure line TC with particular reference to C the critical point. The temperature and pressure at this point are defined as: CRITICAL TEMPERATURE (Tc): The temperature above which a gas cannot be liquefied, regardless of the pressure applied. CRITICAL PRESSURE (Pc): The pressure above which liquid and gas cannot co-exist, regardless of temperature.

PRESSURE

Two component systems Now consider a two component system.

TEMPERATURE

Phase diagram for a two component system

A phase envelope is developed. The line AC is the bubble point locus and BC is the dew point locus. Observe that the definition of critical point C applied to the pure component does not apply. Clearly liquid and gas can co-exist at temperatures and pressures above the critical point. The critical point is merely the point at which the BUBBLE POINT locus and the DEW POINT locus meet. This type of behavior becomes more exaggerated as the complexity of a hydrocarbon mixture increases shown in the next diagram. It now becomes necessary to re-define the pressure and temperature above which gas and liquid cannot co-exist. The CRICONDENBAR is the pressure above which liquid cannot be formed and the CRICONDENTHERM is the temperature above which liquid cannot exist.

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PRESSURE

PDS / OPS Sampler - Operating instructions

TEMPERATURE

Phase diagram illustrating the Cricondenbar and Cricondemtherm

Multi-component mixtures (reservoir fluids) Now consider ‘real’ complex hydrocarbon fluids. Below are typical phase diagrams for reservoir fluids under the normal classifications accepted in petroleum engineering.

PRESSURE

Mole %

TEMPERATURE

Phase diagram for a Low Shrinkage Black Oil

PRESSURE

Mole % Liq.

TEMPERATURE

Phase diagram for a High Shrinkage Oil

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PRESSURE

Mole %

TEMPERATURE

Phase diagram for a Wet Gas

PRESSURE

Mole %

TEMPERATURE

PRESSURE

Phase diagram for a Gas Condensate

TEMPERATURE

Phase diagram for a Dry Gas

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As previously stated, phase diagrams are plots of pressure against temperature, whereas in petroleum engineering it is more usual to consider pressure vs. volume (PV) at a fixed or perhaps one or two fixed temperatures. In this case it is interesting to consider the isotherm marked 1-2-3 on the phase diagrams which represents reservoir temperature. With a drop in pressure from 1 to 2,reservoir oil reaches the BUBBLE POINT (the point at which the first bubble of gas from the lightest component in the mixture appears). With progress from 2 to 3 the gas becomes progressively richer in heavier components, as the liquid becomes progressively depleted of light ends. With a drop in pressure from 1 to 2, condensate reservoir gas reaches the DEW POINT (the point at which the first drop of liquid appears). In this case it is termed RETROGRADE CONDENSATION, which is that the HEAVIEST components drop out first and the gas stream becomes progressively lighter as pressure drops. Now consider what happens when the reservoir fluid is brought to the surface, giving rise to both a drop in pressure and temperature. This is demonstrated by reference to the dotted line on the phase diagrams marked 2-Sep. The point marked ‘Sep’ denotes the separator pressure and temperature. With oils and condensate gases the system remains within the phase envelope where liquid and gas can co-exist. The actual point within the phase envelope defines the relative compositions of the oil and gas according to physico-chemical parameters which are explained later. What is interesting to observe is that the wet gas produces no liquid (in the reservoir) along the isotherm 1 to 2 but if the drop in pressure is accompanied by a drop in temperature, as happens during production, then liquid is produced at separator pressure and temperature. By definition a dry gas produces no liquid even at separator conditions, and any heavy components present have to be chilled out from the gas stream to bring the temperature within the phase envelope. When a reservoir should be sampled The aim of PVT sampling is to obtain a small sample of fluid under pressure, which is identical to the reservoir fluid under initial conditions. To achieve this several factors must be taken into account and decisions must be made: – Decide upon the condition of the well to be sampled. – Decide which sampling technique will give the best chance of obtaining a representative fluid sample. A field discovery well is usually subjected to relatively large drawdown pressures and considerable depletion in the production testing necessary to

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determine its extent. The second and third wells drilled will still encounter essentially virgin reservoir pressure, and the problems associated with conditioning, sampling and analysis will be minimized. Depletion of a reservoir below the bubble-point pressure, leads to extreme difficulty in obtaining a reliable sample. As the results from the analysis of reservoir fluids are generally used in material balance calculations, it is desirable that the analysis is performed on original fluid samples. Extra pollution of data from a current bottom hole pressure to a higher bubblepoint pressure is always hazardous and should only be attempted in extreme cases. Considerations for well sampling For the results of the fluid analysis to be of maximum value in the reservoir study, the sample must be representative of the phase that saturated the reservoir rock initially. In an oil reservoir it will be the gas phase. The well to be sampled should meet as many of the following conditions as possible: – The well should be centrally located in the field. – It should have as high a productivity index as possible. – The well should be completed in the section of the reservoir to be studied. In most cases this will be the oil zone. Care should be taken to eliminate any possibility of gas coning. – The well should be free from water production. – The flow in the reservoir should be single phase. – If bottom hole sampling is required, then the sample should be taken at or as close to the perforations as possible. Data required prior to sampling Before sampling is attempted it is important to obtain preliminary details of the reservoir and well characteristics. For example: – The type of fluid expected to be encountered. Oil, gas/condensate, or water – Whether it is saturated or under saturated. – Whether the formation has high or low permeability. In exploration wells standing’s correlations can be used to estimate the bubble-point pressure at formation temperature. To use these correlations the following data is required: – – – –

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Initial and present static reservoir pressure. Reservoir temperature. Oil and gas gravities. Stabilized gas-oil ratios at one or more flow rates.

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18.5 Oil Reservoirs Under saturated reservoirs These reservoirs are characterized by a constant G.O.R. equal to the maximum gas solubility in the oil. Bottom hole sampling and surface sampling can be carried out with the well flowing at any stabilized flow rate for which flowing reservoir pressure exceeds saturation pressure at reservoir conditions. Saturated reservoirs In these reservoirs the G.O.R. is only equal to the maximum gas stability in oil during a very short initial flow period. The G.O.R. then increases as the well is produced. Saturation pressure is equal to or near the initial static reservoir pressure, and, if an initial gas cap is present, it will always equal the initial pressure. Bottom hole sampling can be carried out if the following procedures are adopted. The flow rate should be progressively reduced and then the well finally shut-in. During this process the flowing bottom hole pressure will increase and the free gas produced into the well bore, or remain stationary within the oil phase until the well is shut in. Reservoir saturation pressure should be near to the initial static reservoir pressure. At this point the well should be opened on the smallest possible choke (e.g. 1/16”) and allowed to flow for 10 to 15 minutes before the sampler closes. During this short flow period draw down should be minimized and any liberated gas should be too small to affect the validity of the samples. The flow rate would be progressively reduced over a long period (depending on the permeability of the reservoir) and finally shut in. During this period the flowing bottom hole pressure will increase until it approaches the initial static bottom hole pressure. The movable free gas will be produced into the well bore and the stationary free gas will remain in the pore space of the reservoir. This remaining free gas reduces the effective permeability of the reservoir rock to single-phase reservoir fluid, and increases the pressure drawdown. Surface sampling Surface Sampling can only be carried out if at the minimum stabilized flow rate, the G.O.R. is very close to the initial G.O.R. Gas/Condensate reservoirs Since for these reservoirs it is difficult to determine from the well test data the exact nature of the reservoir, sampling should always be carried out assuming the worse case, i.e. a saturated reservoir with a dew point equal to the initial static pressure. Surface sampling should always be carried out for gas/condensate reservoirs. PDSshort bottom hole sampling is unsuitable for the following reasons:

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1)

PVT laboratory analysis normally requires a larger sample volume than the 600 ml available from bottom hole samplers.

2)

If a sample were taken, the effect of bringing the sampler to surface conditions would cause liquid to condense in the sample chamber. This liquid would in most cases be only a small amount and would remain behind, wetting the walls of the chamber, during a normal transfer at atmospheric temperature. The normal practice of heating the sample chamber at surface before transfer is no guarantee that single-phase equilibrium conditions can be achieved in the field.

Bottom hole sampling can be considered if the reservoir is known to be undersaturated and using a One Phase Sampler. In addition to the normal criteria for surface sampling in dealing with gas/condensate reservoirs, a further parameter has to be met. The liquid condensed in the tubing, between the bottom of the well and the surface must be produced into the separator. This requires a production rate that is sufficient to lift any condensed liquids to surface. The general rule is; gas/ condensate reservoirs are produced at a maximum stable production rate. Of course, this does not apply to every case, and exceptions arise when formation porosity is such that there is liquid condensed in the formation around the well bore during the clean up phase of the well test. In the most extreme case it could take months for a well under flowing conditions to produce representative equilibrium reservoir fluid at surface. Volatile oil reservoir A volatile oil is one with very high gas solubility in relation to its bubble point pressure. Because of its high G.O.R. and low relative density can be confused in the field with a gas/condensate reservoir. Because of these unusual characteristics, Standing’s correlations cannot be used to determine bubble point pressure, therefore, these reservoirs should be sampled as gas/condensates. If PVT analysis shows that it is an oil reservoir and the bubble point is established, bottom hole sampling can be employed on subsequent wells. Well conditioning The well should be flowed until a stabilized rate is achieved such that the G.O.R. is equal to the initial G.O.R. Stability should be achieved for a minimum of 4 hours for bottom hole sampling and 12 hours for surface sampling with a flowing bottom hole pressure greater that the bubble point pressure. During this period the oil and gas flow rates, well-head pressure, and flowing bottom hole pressure should all be constant. The latter gives the best indication of stability, but can only be used if electronic surface read-out gauges are available.

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© Friedrich Leutert GmbH & Co. KG, Adendorf, 2008 This document, including all of its parts, is protected by copyright. Any duplication or utilization outside of the copyright law is not permitted without explicit permission from LEUTERT and may be subject to prosecution. This applies in particular to duplications of any kind, translations and incorporation into electronic systems. – Original edition, manuals in other languages on request – Subject to change without notice Part-No. 101031 Issued 8 December 2014

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