SURGE TANK

Introduction

The "Surface Test Equipment" figure shows where the

surge tank is located in relationship to the other surface testing
equipment. On the upstream side, the surge tank is connected to
the separator by the separator oil line. On the downstream side, it
precedes the pump used to empty the tank and the burners that
burn off gas and oil. Unlike the gauge tank, the surge tank is a
pressurized vessel. It is always used, instead of the gauge tank,
when H2S is present in the well effluent. The surge tank is H2S
resistant. The gas leaving the surge tank is burned off, instead of
being vented to the atmosphere.
 The surge tank's functions are listed below:

• Low pressure separator

The surge tank was originally designed to work as a low-pressure separator, providing a secondary stage
of separation. It looks like a separator and, like the separator, it's pressurized and equipped with a pressure
regulation system and a safety relief valve. Although the surge tank is still used as a secondary separator,
today its primary use is identical to the gauge tank--volume measurements for calibrating oil meters.

• Storing liquids when pressure is low

When oil leaves the separator under low pressure, oil burners do not operate properly. To remedy this
problem, oil is stored in the tank where a pump is used to drive it to the burners under sufficient pressure.

• Storing liquids when large samples are required

It is unrealistic to take large samples of oil from a pressurized vessel, like the separator. For this reason,
the surge tank is used to store oil before it is sampled. From the tank, dead (degassed) oil can easily be
transferred to sample drums.

• Metering liquids when flow rate is low

Sometimes oil flow rates are so low that they do not register on the oil meter at the separator. When it's
impossible to measure the flow rate at the separator, the surge tank can be used to measure the flow rate.
The oil flow rate at the surge tank is calculated by measuring the volume of oil that accumulates in the tank
over a defined period of time.

• Calculating the volume correction factor at the tank to calibrate oil meters
The oil flow meter at the separator is not 100% correct. When oil leaves the separator, it still contains
some gas. In addition, the meter may not be correctly calibrated. By comparing the volume reading at the oil
meter with the actual volume measured at the tank, a correction factor can be obtained. This correction
factor, referred to as the "meter combined shrinkage" factor, reflects two adjustments:

• Meter factor
This is a calibration measurement that reflects the meter's inaccuracy.

• Shrinkage factor
The difference in the oil volume read at the separator and the volume measured at the tank is also due to
the loss of gas when the oil is exposed to the atmospheric pressure in the tank. This loss of volume is called
the shrinkage factor. The pure shrinkage factor is measured at the separator using a shrinkage tester.
Principles of Operation
This topic lists the main components of the surge tank and describes how the tank is used to calibrate
meters. Click on the graphic or scroll down for detailed information on each component.
Surge Tank Components

Safety Relief Valve

This valve is located on top of the surge tank. It's the same type of valve as the safety relief valve
used on the separator. The safety relief valve opens in case the pressure in the tank exceeds the tank's
working pressure--50 or 150 psi depending on the version of the surge tank. The outlet on the safety relief
valve is either connected to a separate vent line (recommended) or connected to the gas vent line on the
surge tank that goes to the gas flare, depending on client requirements and local regulations.

The safety relief valve incorporates a bellows seal that prevents surge tank fluid discharge from
entering the upper part of the valve that's exposed to the atmospheric pressure. The bellows has an effective
area equal to the area of the valve seat so the effect of any back pressure from the valve outlet on set
pressure is eliminated.

The set pressure is the pressure at which you want the safety relief valve to open. The set pressure is
adjusted by the force of a spring on a sealing disk that is exposed to surge tank pressure.

Sight Glass
The sight glass is a visual level indicator. A graduated scale permits level changes to be recorded and
volume changes to be calculated. The sight glass is made of transparent glass housed in a steel chamber to
resist the pressure inside the tank. In the event the glass ruptures, the safety glass is equipped with safety
valves that prevent fluids inside the surge tank from escaping.

The safety valve works using a ball that automatically seals off the tank from the sight glass using
the pressure differential between the tank and the atmosphere. After a broken glass is changed, the ball
needs to be pushed back in its groove so it can seal off the surge tank from the sight glass, in case another
failure occurs. Use the stem tip to push the ball back by moving the handle about one quarter turn. Once the
ball is in position, turn the handle back to return the stem to its original position.
Alarm Level System
This system has a low and a high level alarm system. A horn sounds if the liquid in the tank reaches
the low or the high level. Whenever an alarm sounds, the liquid levels are adjusted manually. So safe
operation of the surge tank requires constant supervision of liquid levels. To be able to run in fully
automatic mode, this alarm system must be connected to the ESD or to a pump.

Gas Vent Line

The surge tank is fitted with a gas vent or exhaust line that allows the gas in the oil to escape from
the tank. (Gas is sent to the gas flare where it is burned off.) The gas vent line for the surge tank must be
independent from the separator gas line. If they were connected, pressure from the separator gas line could
create back-pressure on the surge tank that's higher than the tank's working pressure.

Flame Arrestor
The job of this optional safety device, mounted on the gas vent line as close as possible to the surge
tank gas outlet, is to stop a fire from propagating inside the tank. It is equipped with steel wool to stop a
flame and to ensure that no oil droplets are carried away with the gas.
Butterfly Valves
The inlet and outlet manifold of the tank are equipped with butterfly valves. These valves are used to
fill or empty the tank.

Grounding Strap
The surge tank is grounded with a grounding strap, allowing static electricity to be discharged, so
flashes can be avoided. The build up of static charges of electricity may be caused by the friction from
flowing fluids. Onshore, the strap is connected to an iron stake driven into the ground. Offshore, it's
connected to a spot on the rig that's free of paint or grease.

Automatic Control Valve

The ACV in the gas vent line is used to maintain and regulate a positive pressure inside the surge
tank. This pressure is needed when using the surge tank as a second stage separator and, depending on the
pump used, may be necessary to prime the pump when emptying the tank. The ACV regulates the gas rate
by varying the diameter of the gas vent line in response to a signal received from a controller. The controller
reacts to any variation in the surge tank pressure. When the pressure rises, the controller opens the valve and
when the pressure drops, the controller closes the valve. Once the surge tank pressure is manually set at the
pressure controller, the operating pressure in the vessel is maintained close to the set value.

For safety purposes, the ACV is normally open. If for any reason the air pressure supply to the valve
is cut, the vessel will not be overpressurized. For a complete descripton of the system, see the gas pressure
controller in the Separator Training page.
Nonreturn Valve
This valve is fitted on the gas vent line. It is mounted downstream of the automatic control valve. It
is closed when there's no pressure in the surge tank. The nonreturn valve prevents any back-pressure from
entering the tank, causing the pressure inside the tank to increase above the maximum working pressure.

Calibration of Meters
Technical and economic considerations related to the development of a new reservoir may depend
on the accuracy of oil flow rates. Incorrect flow rates could cause the client to make incorrect decisions
about the well, which could have very expensive implications.

As explained in the introduction, the oil flow meters at the separator are not 100% correct. It is
important to verify their degree of accuracy. A simple method consists of pumping water through the meter
to be calibrated into a tank of known dimensions. A correction factor called the meter factor (f) is obtained
by dividing the volume of water in the tank by the volume registered on the meter.
 The meters on the oil flow line operate under pressure. Gas bubbles in the oil cause the oil meter to
register volume readings that are altered by the presence of the gas. To correct the volume reading at the oil
meter, a correction factor is derived by comparing the volume reading at the oil meter with the volume
measurement obtained at the tank. The volume correction factor is also referred to as the "meter combined
shrinkage" factor.

The following steps are needed to accurately and safely use the surge tank to calculate the volume
correction factor:

1. Read the initial level of oil in the tank.

2. Divert the oil flow to the tank and simultaneously take a meter reading at the oil flow line and record
the time.

3. Verify that the level of oil in the tank is rising. (This tells you that oil from the separator was
diverted and is flowing properly.)

4. Verify that there is no pressure build up in the tank.

5. Check frequently at the gas vent line outlets for liquid or foam carryover. To avoid carryover, do not
allow more than 80% of a tank compartment to be filled.

6. Divert the oil flow back to the burners and simultaneously take a meter reading at the oil flow line
and record the time.

7. Before taking the final tank reading, wait until all the gas has escaped from the oil.

8. The volume correction factor is simply the ratio between the volume obtained in the tank and the
volume registered by the meter.

Note:
At the time the final tank reading is taken, the tank temperature is also recorded. A correction for
temperature (temperature coefficient) is applied in order to report flow rates at standard conditions: 14.65
psi (atmospheric) and 60oF.
Equipment

Surge tanks are available in 80- and 100-barrel capacity, although the 80-barrel version is the most
common. The 80-barrel version has one compartment and a working pressure of 50 psi. The 100-barrel
version has two compartments and a working pressure of 150 psi. The range of surge tanks available makes
it possible to select a surge tank that accommodates the required well tests while not being larger, more
complicated or expensive than the overall project demands.

Surge Tank Selection Guidelines

The principal criteria for selecting a surge tank are:

1. If the project requirements specify that a gauge tank is required, a surge tank is usually not needed.
2. The service type required (operating environment) requires the use of a surge tank when H2S is
present.

Additional selection considerations are:

1. The surge tank needs less deck space than the gauge tank.
2. The surge tank needs an air supply for the valve controller.
3. Whether the surge tank will be used as a second stage separator.
4. An additional gas vent line is required for the safety relief valve.
5. A surge tank with two compartments may be required.

For current information, refer to the CNLC Equipment Guidelines.

Safety

1. Whenever H2S is expected to be in the well effluent, a surge tank must be used instead of a gauge
tank.

2. Before diverting the separator oil to the surge tank, you must check the ability of the gas vent line to
discharge the full volume of gas liberated without creating a back pressure greater than the
maximum pressure rating of the vessel.

3. Refer to the charts in the Tank Operations chapter of the Field Operating Handbook (FOH) for
Surface Well Testing.

4. When diverting the oil to the tank, always limit the flow rate to avoid filling the tank too rapidly. In
case of high flow rates, someone should constantly monitor liquid levels and be ready to divert flow
back to the burners to prevent overflow.

5. Prior to conducting any repair inside the tank, it must be steam cleaned and degassed. The person
repairing the tank must be in constant contact with a person on the outside of the tank.

6. Transport the surge tank when it is empty; even a partially full tank has a much higher weight than
an empty tank.

7. The exhaust for the safety relief valve must be connected to a 4-in. pipe landing that must be located
downstream and far away from the working area.

Self Test

1. Give three reasons for using a surge tank.

2. How is the volume of oil contained in the surge tank calculated?
3. What is the purpose of the ACV mounted on the gas line outlet?
4. How is it possible to prevent back-pressure from entering the surge tank?
5. Why is it important to prevent back-pressure from entering the surge tank?
6. What was the original purpose of the surge tank?