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Indirect Heater

Reference: InTouch content ID# 4229610


Version: 1.0
Release Date: 12-Jun-2007
EDMS UID: 1649507996
Produced: 13-Jun-2007 09:32:30
Owner: ELC Testing
Author: P. Quéré

Private Indirect air


burner, Heater,
ring , flameout
fi re tube, shutdown
diesel burner,
, flame
pilot
arresto r

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Indirect Heater
Reference: InTouch content ID# 4229610
Version: 1.0
Release Date: 12-Jun-2007
EDMS UID: 1649507996
Published: 13-Jun-2007 09:32:30
Owner: ELC Testing
Author: P. Quéré

Private Indirect air


burner, Heater,
ring , flameout
fi re tube, shutdown
diesel burner,
, flame
pilot
arresto r

Copyright © 2007 Sophia, Unpublished Work. All rights reserved.


TS Technology Based Training — Well Testing — Surface Testing — Equipment — Indirect
Heater / Legal Information

Legal Information

Copyright © 2007 Schlumberger, Unpublished Work. All rights reserved.

This work contains the confidential and proprietary trade secrets of Schlumberger
and may not be copied or stored in an information retrieval system, transferred,
used, distributed, translated or retransmitted in any form or by any means,
electronic or mechanical, in whole or in part, without the express written
permission of the copyright owner.
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Trademarks & Service marks

Schlumberger, the Schlumberger logotype, and other words or symbols used


to identify the products and services described herein are either trademarks,
trade names or service marks of Schlumberger and its licensors, or are the
property of their respective owners. These marks may not be copied, imitated
or used, in whole or in part, without the express prior written permission of
Schlumberger. In addition, covers, page headers, custom graphics, icons, and
other design elements may be service marks, trademarks, and/or trade dress
of Schlumberger, and may not be copied, imitated, or used, in whole or in part,
without the express prior written permission of Schlumberger.

A complete list of Schlumberger marks may be viewed at the Schlumberger


Oilfield Services Marks page: http://markslist.slb.com

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Heater / Document Control

Document Control
Owner: ELC Testing
compass-support@slb.com

Author: P. Quéré

Reviewer: C. Rojas

Approver: P.Chaigne

Contact Information
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Name: ELC Testing


Email: compass-support@slb.com
LDAP Alias: SRPCDoc-TBT

Revision History
Rev Effective Date Description Prepared by

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Heater / Document Control
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v TS Technology Based Training — Well Testing — Surface Testing — Equipment v
— Indirect Heater / Table of Contents

Table of Contents

1 Overview
1.1 Introduction __________________________________________________ 1-1
1.2 Features and Benefits ________________________________________ 1-1
1.3 Applications _________________________________________________ 1-2

2 Full Training Package


2.1 Introduction __________________________________________________ 2-1
2.2 Objectives ___________________________________________________ 2-2
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2.3 Principle of Operation ________________________________________ 2-3


2.4 Equipment __________________________________________________ 2-12
2.5 Safety ______________________________________________________ 2-13
2.6 Maintenance ________________________________________________ 2-14
2.7 Summary ___________________________________________________ 2-14
2.8 Posttest ____________________________________________________ 2-14
2.9 References _________________________________________________ 2-14
2.10 Other Useful Links __________________________________________ 2-15

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— Indirect Heater / Table of Contents
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vii TS Technology Based Training — Well Testing — Surface Testing — Equipment — vii
Indirect Heater / List of Figures

List of Figures

1-1 Indirect Heater ____________________________________________________ 1-1


2-1 Surface Test Equipment____________________________________________ 2-1
2-2 Indirect Heater ____________________________________________________ 2-4
2-3 Firetube___________________________________________________________ 2-5
2-4 Cut View of Diesel Burner __________________________________________ 2-6
2-5 Diesel Burner _____________________________________________________ 2-7
2-6 Thermostatic Valve ________________________________________________ 2-8
2-7 CMA Flameout Shut Down System (CMA Controlled Mercury Assist) 2-10
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2-8 Flame Arrestor ___________________________________________________ 2-11


2-9 Indirect Heater 5K, 2MMBTU (IHT-BAG) ___________________________ 2-12
2-10 Indirect Heater 5K, 0.9MMBTU (IHT-AEH)__________________________ 2-12

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Indirect Heater / List of Figures
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1-i TS Technology Based Training — Well Testing — Surface Testing — Equipment 1-i
— Indirect Heater / Overview

1 Overview
1.1 Introduction ____________________________________________________ 1-1
1.2 Features and Benefits __________________________________________ 1-1
1.3 Applications ___________________________________________________ 1-2
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1-1 TS Technology Based Training — Well Testing — Surface Testing — Equipment 1-1
— Indirect Heater / Overview

1 Overview Indirect
ring, fl ameout
Heater,shutdown,
firetube, diesel
fl ame burner,
arrestorpilot burner, air

1.1 Introduction
The indirect heater is used to raise the temperature of the well effluent to prevent
hydrate formation, reduce fluid viscosity, and breakdown emulsions before the
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well effluent enters the separator. The well fluid being heated flows through
tubes that are surrounded by water in a vessel. A diesel burner heats the water
via a firebox.

Figure 1-1: Indirect Heater

1.2 Features and Benefits


The indirect heater has the following features and benefits:

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— Indirect Heater / Overview

• A choke assembly to control the well at the indirect heater instead of the
choke manifold. The fluid is heated before it passes through the choke.
• An inlet manifold made of three gate valves (see Glossary) to control the fluid
flow and to bypass the indirect heater if necessary.
• The diesel flame is regulated by an automatic control valve (ACV) to maintain
a preset temperature.
• A diesel shutdown valve actuated by pilot light stoppage.
• A flame arrestor on the burner air inlet.
• A spark arrestor on the chimney exhaust
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The indirect heater permits testing of wells with effluent characteristics that would
normally impair the separation and metering process if the effluent were not
heated.

1.3 Applications
An indirect heater is used whenever the well effluent needs to be heated up
before it enters the separator.

As safety regulations become more and more stringent, the indirect heater is
progressively being replaced by the steam exchanger.

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Indirect Heater / Full Training Package

2 Full Training Package


2.1 Introduction ____________________________________________________ 2-1
2.2 Objectives _____________________________________________________ 2-2
2.3 Principle of Operation __________________________________________ 2-3
2.3.1 Fire-tube ____________________________________________________ 2-4
2.3.2 Diesel Burner ________________________________________________ 2-5
2.3.3 Pilot Burner __________________________________________________ 2-6
2.3.4 Air Ring _____________________________________________________ 2-7
2.3.5 Stack _______________________________________________________ 2-7
2.3.6 Flame Ignition System ________________________________________ 2-7
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2.3.7 Temperature Control System _________________________________ 2-8


2.3.8 Flameout Shutdown __________________________________________ 2-9
2.3.9 Flame Arrestor ______________________________________________ 2-10
2.3.10 Spark Arrestor ______________________________________________ 2-11
2.3.11 Choke Box _________________________________________________ 2-11
2.4 Equipment ____________________________________________________ 2-12
2.4.1 Indirect Heater Selection Guidelines __________________________ 2-12
2.5 Safety _________________________________________________________ 2-13
2.6 Maintenance __________________________________________________ 2-14
2.7 Summary ______________________________________________________ 2-14
2.8 Posttest _______________________________________________________ 2-14
2.9 References ____________________________________________________ 2-14
2.10 Other Useful Links ____________________________________________ 2-15

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2 Full Training Package Indirect


ring, fl ameout
Heater,shutdown,
firetube, diesel
fl ame burner,
arrestorpilot burner, air

2.1 Introduction
The indirect heater is an optional piece of surface testing equipment that may
be required, depending on the characteristics of the well effluent. This training
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page describes the purpose of the indirect heater, shows where it is located in
relationship to other surface testing equipment, examines how the indirect heater
works, and describes its main components.

Figure 2-1: Surface Test Equipment

An indirect heater is used to raise the temperature of the well effluent for the
following reasons:

Hydrate Prevention - Natural gas contains water vapor. Under certain choked
flow conditions, sufficient expansion occurs to lower the temperature of the flow
and cause hydrate formation. Hydrates are formed when particles of water and
some light hydrocarbons in the natural gas become solid. Hydrate formation is a
serious hazard; if particles freeze and accumulate in the surface equipment, the
chokes and flowlines could be plugged and the valves could become inoperative.

Natural gas hydrates resemble granular snow. These chemical compounds of


hydrocarbons and water form at temperatures above the normal freezing point of
water when certain hydrocarbons are dissolved in water under low temperature
and high pressure conditions. High velocities, pressure pulsations, and agitation
accelerate this phenomenon. H2S and CO2 promote the formation of hydrates.

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Viscosity Reduction - High viscosity impairs the flow of an effluent through a


pipe. The combined effects of changes in composition as the reservoir fluid is
brought to the surface ambient temperature may rise the viscosity and affect
testing efficiency. Because viscosity is temperature-dependent, using an indirect
heater to raise the effluent temperature decreases its viscosity.

Emulsion Breakdown - Under certain conditions, the oil and water in the
effluent emulsify and do not separate unless chemicals are injected or the
effluent temperature is raised with an indirect heater.

Foam Reduction - For certain types of crude oil, a reduction in the flow rate
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pressure causes some gas bubbles to become encased in a thin film of oil,
instead of being liberated from the oil. This results in the dispersion of foam or
froth throughout the oil, creating what is known as foaming oil.

Foaming greatly reduces the flow rate capacity of oil and gas separators and
makes it difficult to accurately measure the oil flow rate. These problems,
combined with the potential loss of oil and gas because of improper separation,
emphasize the need for special equipment and procedures to handle foaming oil.
Heat is one of the main methods used to eliminate or reduce foaming.

Increased Burner Efficiency - Reducing the oil viscosity improves the


atomization of oil at the burner head.

2.2 Objectives
Upon completion of this package, you should be able to:

• Explain the operating principles of the indirect heater.


• Explain how the temperature regulator works.
• Explain how the CMA flameout shutdown system works.
• Draw a diagram of the indirect heater circuits displaying the well effluent,
propane, compressed air, water, mercury, and diesel line.
• Write down a list of the safety rules to be observed when operating the
indirect heater.

Upon completion of the Compass Tasksheets for the indirect heater, you should
be able to:

• Identify all the components of the indirect heater by visual inspection.


• Complete the steps required to prepare the indirect heater to flow fluids
through the coils.

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• Write down the steps required to pressure test the coil assembly.
• Follow recommended safety procedures when operating an indirect heater.
• Divert the flow to bypass the indirect heater.

2.3 Principle of Operation


The indirect heater shown in the "Indirect Heater" diagram consists of a
non-pressurized water vessel that contains two coils through which well fluid
passes and is heated up. The diesel burner is contained inside a fire-tube. This
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system causes the water to conduct heat to the coiled tubes, warming up the
effluent. There is no direct contact between the tubes carrying the fluid to be
heated and the flame used as a heat source. This system is intrinsically safer
than a direct heater in which the tubes containing the well effluent are in direct
contact with the flame. A common example of a direct heater is a domestic boiler.

After the well fluid passes through the first coil section, a choke assembly
between the coils allows the well to be controlled at the indirect heater instead of
at the choke manifold. An inlet manifold with three gate valves (see Glossary)
controls fluid flow and provides a way to bypass the coils and choke. To maintain
a preset temperature, the diesel flame is regulated by a thermostatic valve. A
shut down valve (ASV) cuts the diesel supply if the pilot light is extinguished.
The internal design of the vessel is such that convection currents prevent any
localized heating of the water because boiling would impair the performance and
life span of the indirect heater.

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Figure 2-2: Indirect Heater

The parts of the indirect heater are shown in the "Indirect Heater" diagram and
are described below.

2.3.1 Fire-tube
The fire-tube is shaped like a "U" tube. Combustion occurs on one side of the "U"
and the chimney is located on the other side. The fire-tube is mounted on a flange
and inserted inside the vessel. This configuration allows the fire-tube to be easily
removed for repair or replacement. It has brackets on the bottom or on the side

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(or both) to prevent it from touching the vessel. Because the tube is immersed in
the water, its temperature is approximately the same as the water, even though
the combustion temperature inside the tube may be greater than 165ºC (300ºF).

If the tube touches the vessel, a hot spot will develop that can distort or melt the
tube and the vessel. To prevent this from occurring, a liner is located inside the
fire-tube in the combustion area. This protective device, made of a heat resistant
metal, prevents the flame from striking the tube wall, which could cause the tube
to overheat and fail. In the event the fire does strike the liner, it will eventually
melt and have to be replaced. If the damaged liner is promptly replaced, the
fire tube will not be damaged.
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Figure 2-3: Firetube

2.3.2 Diesel Burner


The burner of an indirect heater, located at the inlet of the fire-tube, is designed
to produce a long, narrow flame pattern so the flame will not touch the walls. It
is centered in the fire-tube. It is made up of a mixing chamber where air under

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pressure sprays the diesel into tiny droplets before it burns. The amount of air
passing through the flame arrestor (necessary for the diesel combustion) can be
adjusted with a flap. When the proper volume of diesel and volume of air are
mixed in the fire-tube, a blue flame results. The diesel is sent to the burner with
an air driven pump that typically sits on top of a diesel drum. The flow rate of the
diesel supplied to the burner is controlled by adjusting an air pressure regulator
(see Glossary) on the pumping unit.
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Figure 2-4: Cut View of Diesel Burner

2.3.3 Pilot Burner


The pilot burner is similar to the main burner, but it is much smaller. It does not
require compressed air because it burns propane gas. To maintain a constant
flame pattern, a pressure regulator (see Glossary) is fitted on the propane line to
the pilot burner. A sight glass permits to check if the pilot is on or off.

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Figure 2-5: Diesel Burner

2.3.4 Air Ring


Located inside the firetube, the air ring sweeps out the firetube with fresh
compressed air before the pilot light is ignited. If any gas vapors are present
inside the firetube when the pilot light is ignited an accidental explosion could
occur.

2.3.5 Stack
The stack or chimney is a piece of pipe that fits over the outlet end of the
fire-tube. The chimney dissipates the unused heat and combustion remnants to
the atmosphere. Its height varies from 2 to 6 meters, depending on the length of
pipe required to properly vent the smoke in the area where the heat exchanger
is located. It is equipped with a spark arrestor to prevent sparks from being
released to the atmosphere through the chimney.

2.3.6 Flame Ignition System


This system consists of a high voltage coil and a spark plug to light the pilot. A
push button is used to create the spark that lights the pilot.

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2.3.7 Temperature Control System


A temperature controller senses the temperature of the water bath and signals
the diesel valve to open or close as required to hold the water temperature at
the set point on the controller.

The temperature control system consists of a thermostatic valve and a


temperature bulb. The thermostatic valve is designed to maintain the temperature
of the water bath at the desired value. A temperature bulb immersed in the water
activates the valve. When the burner is off, the temperature bulb is cold and
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the valve is open. When the burner is lit, the water bath temperature heats the
bulb. The fluid inside the bulb and the valve chamber expands, exerting a force
on the valve stem and the spring proportional to the temperature. At a certain
temperature, the force of the expanded fluid is higher than the force of the return
spring so the valve closes, cutting off the diesel supply. This extinguishes the
flame in the diesel burner. When the burner flame goes out, the water bath and
the bulb cool down. This heat loss causes the fluid in the expansion chamber to
contract and the valve opens by means of the return spring, restoring the diesel
supply to the burner.

Figure 2-6: Thermostatic Valve

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The temperature controller is set for a delayed response of the diesel valve.
The delayed response setup allows the diesel burner to burn continuously,
and the intensity of the flame varies in response to temperature changes. In
contrast, when the temperature controller is set for a quick response, the diesel
burner burns at full rate when the diesel valve is fully open and is completely
extinguished when the diesel valve is fully closed. This on/off action increases
the likelihood of firetube burnout at full-rate. Consequently, the delayed response
setup is desirable because it stabilizes the firing rate and avoids full firing even
for short periods.

The following paragraphs describe how the diesel valve delayed response works.
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• If the temperature of the water begins to fall, the temperature controller reacts
by opening the diesel valve more, increasing the intensity of the flame in the
diesel burner. It takes a few minutes to heat the volume of water in the vessel
to the set temperature. When the set temperature is reached, the diesel
valve does not return to its original position immediately. This delay allows
the water temperature to rise slightly above the set point.
• If the temperature of the water begins to rise, the temperature controller
reacts by closing the diesel valve more, decreasing the intensity of the flame
in the diesel burner. It takes a few minutes to cool down the volume of water
in the vessel to the set temperature. When the set temperature is reached,
the diesel valve does not return to its original position immediately. This delay
allows the water temperature to fall slightly below the set point.
• The drawback to the delayed response system is that the temperature is not
perfectly constant. As described in the previous paragraphs, it cycles around
the set temperature. This variation around the set temperature can affect
pressure readings at the separator.

2.3.8 Flameout Shutdown


This safety system, known as the CMA control box, consists basically of a
three-way switch operated by the thermal expansion of mercury. The purpose
of this system is to shut off the diesel flow to the burner when the propane gas
pilot goes out.

When the heater is started, a manual knob opens the propane inlet orifice,
causing propane gas to flow to the ASV and to the pilot simultaneously. This
opens the ASV and allows the pilot to be lit. Once the pilot is lit, the mercury in the
sensor and capillary tube expands (as it is heated by the flame), pushing down
the stem inside the control box. In this position, the stem causes the propane
inlet orifice to remain open even when the manual reset knob is released. If the
pilot flame goes out, the mercury will cool down and contract, releasing the
pressure on the stem and causing the stem to retract. Under the action of the

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return spring, the propane inlet will close. Because the ASV is no longer supplied
with propane, it will close by means of the return spring. Consequently, there is
no danger of diesel being supplied to the main burner when the pilot is not lit.
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Figure 2-7: CMA Flameout Shut Down System (CMA Controlled Mercury Assist)

2.3.9 Flame Arrestor


The flame arrestor is mounted on the inside of the door that permits access to
the burner. If a flame tries to move to the outside of the tube, the flame arrestor
will stop the flame. The flame arrestor is made of a thin aluminum sheet wound

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in a spiral coil. The flame arrestor is also designed to let air from the outside into
the fire-tube for diesel combustion. If the indirect heater was not equipped with
a flame arrestor, a gas leak or the presence of a flammable liquid outside the
heater could be ignited by the flame and cause a major fire or explosion.
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Figure 2-8: Flame Arrestor

2.3.10 Spark Arrestor


Located on top of the chimney, the spark arrestor is made of a wire mesh. Sparks
from the diesel burner flame that may travel up the chimney are stopped by the
spark arrestor before they can escape to the atmosphere.

2.3.11 Choke Box


The choke box is designed to receive either a fixed or an adjustable choke. It
is located between the two coils in order to have the fluid pre-heated before
passing through the choke. This helps to prevent the formation of hydrates in
the fluid; or in the case of gas, it prevents freezing.

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2.4 Equipment
The indirect heaters are available in 5,000 psi pressure ratings. The heating
capacity expressed in Btu/hr (British thermal unit per hour) is also a main
characteristic of the indirect heaters. The range of indirect heaters makes it
possible to select one that accommodates the well test needs, while not being
larger, more complicated, or expensive than the overall project requirements.

The following datasheets show the most common types of indirect heaters
available and their respective specifications. For additional information, please
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refer to InTouchSupport.com.

Figure 2-9: Indirect Heater 5K, 2MMBTU (IHT-BAG)

Figure 2-10: Indirect Heater 5K, 0.9MMBTU (IHT-AEH)

2.4.1 Indirect Heater Selection Guidelines


The principal criteria for selecting an indirect heater are:

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• Pressure rating requirements


• Heating capacity
• Safety regulations (an indirect heater is not accepted in some locations)
• Available space (an indirect heater must be located in a safe area)

Additional considerations are:

• Air supply for the diesel burner and sweep system of the indirect heater.
• The indirect heater needs electricity for the ignition of the pilot light.
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• The indirect heater needs diesel supply and a diesel pump for the burner.
• The indirect heater needs propane to supply the pilot light.
• Water and corrosion inhibitors are needed to fill up the vessel of the indirect
heater.

2.5 Safety
The key safety considerations for indirect heaters are listed below:

• A perfect understanding of the diesel, propane, and air circuits is a


prerequisite to a successful and safe job.
• Before starting or restarting the indirect heater, sweep out the firetube with
fresh compressed air. In the event that gas or diesel vapors are present, this
practice can avoid an accidental explosion.
• Do not touch the water vessel with bare hands when the indirect heater is
working
• Verify that the spark arrestor is installed on the chimney.
• After the job, flush the coils thoroughly with soft water and fill them with
corrosion inhibitor before storage.
• Never flow the well through the coils if a choke is not installed. Sand particles
or corrosive fluids can erode the threads in the choke box.
• Do not use the adjustable choke to stop the flow, as the stem tip can be
broken.
• Do not use the gate valves on the indirect heater as chokes.
• Do not transport the indirect heater when it is full of water. The frame cannot
support this extra weight.

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• Before starting the indirect heater, verify that the outlet valve and the choke
are open. If the coils are filled with liquid and the valves and choke are
closed, the thermal expansion that results can generate enough pressure
to burst the coils.

2.6 Maintenance
For information about indirect heater preparation and functional checks, see the
recommended steps in the Field Operating Handbook (FOH) for Surface Well
Testing.
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For information about equipment maintenance, refer to the relevant maintenance


manual and to the Field Operating Handbook (FOH) for Surface Well Testing.
For this type of equipment, it is quite common to implement some modifications
issued by the product center (Modification Recaps-MR).

Some MR can be mandatory and are listed under the Technical Alerts in InTouch.
Up to date information are available under the InTouch Indirect Heater Reference
Page.

2.7 Summary
In this training page, we have discussed:

• The purpose of the indirect heater and five reasons (see Introduction) to
use it.
• The general description (see Principle of Operation) of the indirect heater.
• The function of the parts (see Fire-tube) of the indirect heater.
• How the temperature regulation (see Temperature Control System) and
flameout systems (see Flameout Shutdown) work.

2.8 Posttest
To access the posttest, click the link below.

Test your understanding

2.9 References
• Indirect Heater Reference Page

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• Field Operating Handbook II (FOH II) (Feb 1994). M-073899 2-1


• Pressure Operations Manual rev. 5.2
2-2
• Testing Services Catalog (2002). SMP-7086-1

2.10 Other Useful Links


• LMS Login Page
• LMS Reference Page
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• COMPASS Reference Page

2-1. Schlumberger publication order number

2-2. Schlumberger publication order number

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