Well testing is an important tool for field appraisal, field development, reservoir surveillance and management. Some key measurements during well testsareflow rates of individual phases, fluid properties, fluid composition, flowingsurface, down hole pressure and temperature etc. Analysis of this datahelps in pinpointing where improvements can be made, how the productive potential of the reservoir can be enhanced and where the future investments are to be focused. So production testing campaigns of wells are to be conducted and should be conducted annually or bi-annually to get the aforesaid vital information of the well and the reservoir.

While gathering vital data during production testing, an apprehensionis that the hydrocarbon produced and separated on surface should notbe flared, as it can cause a huge financial loss and environmental harm. Therefore, a zero flaring concept was adopted during production in which the separated gas was safely and effectively injected back to the production line and the fluids to the storage facility.

In Pakistan, production testing is generally carried out using conventional 1440psi separator andimplementing zero flaring concepts. But there are certain limitations associated with the conventional 1440 psi separators available in the country. A few of them are that they cannotbe used on wells whose downstream pressure or injection line pressure is greater than the safety limit of 1440 psi separator. They cannot be used on wells with high gas rates greater than the maximum limit of conventional 1440 psi separator which is 60 MMSCFD and the same limitation applies to condensate/oil/water rate as well. For this reason there are certain fields in Northern Pakistan where production testing campaigns with zero flaring cannot be carried out due to the above mentioned limitations of 1440 psi separator.

This paper describes the introduction of the first ever High Pressure (HP) separator in Pakistan. This separator has overcome the limitations due to its high design pressure of 2160 psi and high gas and oil flow rate capacity which in 90 MMSCFD and 13000 bpd respectively. Successful field applications at three different fields in Pakistan are discussed in this paper covering lesson learned and best practices during the operations. Producing wells were tested without flaring or wasting any hydrocarbon which is harmful to environment. All the separated gas was injected back to the high pressure production line which resulted in a huge financial advantage. The application of the non-conventional high pressure separator and implementing zero flaring is proven to be a beneficial solution with huge potential for future applications in Pakistan.

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