BP COLOMBIA WEO JOB CRITICALITY SHEET
OPERATIONAL PROCEDURES ELMAR PANELS Original Issue Document WOM 2.1.8 No.: J. C. Agudelo Original By: First Issue: 17th May 2002
Last Revision Revision Original No.: By: Date:
1.0 BACKGROUND AND PURPOSE
This Procedure covers the use of the Elmar Hydraulic Control Package. It is used to avoid installing a fusible cap during all Wellsite operations where tools, wire, or Coiled Tubing is to be run across master valves. Making it necessary to take local control of the valve, in order to prevent accidental shut-ins. Any intervention is planned and executed with the aim to always maintain the pressure envelope of the Well and upon the "fail safe" criteria. The current practice of installing a fusible cap on the SSV has proven to have faults in other locations when a fire occurred within the Production Tree boundary but not at the Tree itself. The only way to then shut the Well in is to physically remove the fusible cap from the Upper Master valve (UMV), which entails risk to personnel. The Elmar Panel is a dual Haskel AW-100 pump design, capable of supplying hydraulic fluid up to 10,000 psi, which is used to hold a designated valve open. This then provides a means of shutting the Well in if an emergency occurs by releasing the hydraulic pressure. An independent output is fitted for each pump. 2.0 APPLICATION OF THIS PROCEDURE
This Procedure applies for every Well intervention where any tool, wire or Coiled Tubing is run into a Well. The intention of using Elmar panels is to have remote control of the Upper Master Valve at a safe area from the Wellhead.
Note: In some cases such as injection Wells, it will only be necessary to assume control of the SSV. In these cases, all reference to control of the DHSV in this Procedure should be ignored. This Procedure covers: installation, function tests, operation, removing, emergency shut down and maintenance. 3.0 JOB CONSIDERATIONS AND SAFETY
The Wellsite PE is responsible for taking control of the Well with the Elmar panel. He is also responsible for ensuring that all site personnel are aware of the action to be taken in the event of an emergency. Except in an emergency, the Elmar panel will normally be operated under supervision of the Wellsite PE. However, all relevant personnel should be familiar with its operation, particularly with action to take in the event of an emergency. The Wellsite PE must be satisfied that the unit has been serviced and checked on a regular basis (every 3 months). Any faults or repairs needed to the Elmar panel should be immediately reported and resolved. Be aware that this system is capable of producing high pressure (10.000 psi). Check pressure rating and compatibility of all connections. Select suitable equipment. Make sure valves and regulators are correctly positioned. Never try to tighten or loosen connections under pressure. 4.0 EQUIPMENT REQUIREMENT AND JOB PREPARATION
The required equipment is the Elmar panel itself with all its components. Additionally a suitable connection port is required at the Wellhead Control Panel to attach the Elmar panel hoses. Do not weld, file or use metal stamps on pressure rated equipment – this can initiate cracks. Do not over-tighten any valves. Do not attach anything to this equipment unless you are sure it has a suitable pressure rating. Watch for trapped pressure. Always bleed off pressure before breaking unions.
Disconnect the air supply before carrying out any maintenance.
5.0 PROCEDURE FOR USE OF THE ELMAR PANEL
Elmar panels offer an appropriate solution for isolation and remote control of the SSV during Well intervention by switching their hydraulic control from the Wellhead Control Panel to the Elmar panel pumps (hand or air operated). The panel should be remotely located from the Well. This procedure instructs all personnel on how to operate the pumps within the panel for a remote shut down in case of emergency. It is important that personnel only need to be trained to operate ONE pump configuration, keeping the Elmar panels consistent: the two pumps have been installed in a compact hydraulic package. A companion package contains the two hose reels, each with 150 feet hoses to connect the Elmar panel with the Wellhead Control Panel (WHCP), switching Well control to the Elmar panel. Elmar panel checks.
5.1 Check that the Elmar Unit has been serviced within the last three months. If not, ensure that it is serviced prior to commencing the job. 5.2 Ensure the unit is function tested and topped up with the correct hydraulic fluid, prior to going to site. The air and hydraulic low-pressure warning system air tank should be kept fully charged. Inspect all hoses and fittings for damage. 5.3 Locate the Elmar package remotely from the Wellhead in such a position that it may be operated quickly and easily in an emergency, without compromising any escape routes. 5.4 Ensure that the Elmar panel and compressor units are correctly grounded. 5.5 Position the remote emergency shut down (ESD) box or boxes in a safe place, at an easily reached and safe distance from the Wellhead area. The boxes should be securely fastened with the strap provided for that purpose. Ensure all remote station ESD buttons are reset, I.E. fully out. 5.6 Reset the ESD system on the panel by lifting the cover on the panel and holding the button out until the pilot pressure gauge shows greater than 30 psi. 5.7 Before connecting the panel hoses to the Wellhead control panel: • •
Inspect all hoses and fittings for any damage incurred during transport. Check that the hydraulic fluid tank is filled above the minimum level indicated on the sight glass.
6.0 INSTALLATION ON WHCP
6.1 Run out SSV hose to the Wellhead control panel. 6.2 Connect the SSV hose to the control panel as follows: •
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Ensure that the Wellhead Control Panel (WHCP) control line, and the secondary input line are isolated. Attach the SSV hose. Pressure test the connection against the closed isolation valve; set SSV regulator to a safe pressure, sufficient to keep the SSV open and then stroke the Elmar unit until the same pressure is reached. Ensure that the pressure is maintained steady for ten minutes without the pump stroking.
6.3 Perform the following function tests on the unit: •
•
Check that the ESD system is bleeding pressure from the SSV line. This is performed by lifting the cover marked ESD and pushing the enclosed button if applicable. If there is no button on the panel, use the remote button/s. If more than one remote button is installed, each should be tested, separately. Gauge pressure should drop to drop to zero. Reset the panel or button.
Check that the alarm air tank is sufficiently charged (>1,000 psig) and function test the alarm system on each of It's three separate operating criteria, I.E. loss of air supply, SSV minimum opening pressure.
Before assuming control of the SSV with the Elmar panel, ensure that the hydraulic hoses have been connected to the correct safety valve port. As the line is pressurised and tightens up, ensure that it does not foul itself on instrument pipework. Note:
7.0 ASSUME CONTROL OF THE SSV WITH THE ELMAR PANEL •
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If the SSV is open and controlled by the WHCP, set the SSV regulator to a safe pressure sufficient to keep the SSV open (normally 2500 psi). Stroke the Elmar unit until the same pressure is reached. Open the secondary isolation valve and isolate the WHCP. If the SSV is closed. Ensure that the WHCP is isolated and open the secondary isolation valve. To open the SSV, set the regulator to 2500 psi (The position of the SSV can be checked by inspecting the position of the valve actuator).
7.1 Once the above procedures have been carried out the Well will be under the control of the Elmar unit. 7.2 Ensure the low pressure warning system is in use. Whilst the Well is under the control of the Elmar unit, this must not be switched off. 7.3 The SSV is now controlled from the Elmar unit and the Well intervention may commence. Valves may be closed by isolating the Elmar unit pump and bleeding off the pressure via the dump valve. 7.4 Correct functioning of the Elmar unit should be checked on a regular basis during the operation (at least every two hours). Check gauge pressures and monitor for pump stroking, which can indicate a hydraulic leak. 7.5 Should the air supply fail, the pressure can be maintained manually via the hand pump (#7 in the drawing attached). Note: When flushing control lines and/or when pumps are stroking continuously, check the level of oil in the reservoir frequently. Do not allow the level to fall below half full.
7.6 During a Well intervention the SSV pump should be left in the ON position, with the pressure regulated to keep the valve open. Regularly monitor for loss of pressure/pump stroking. 8.0 Returning the Well to Wellhead Panel control.
If the SSV is to be left open, ensure that the primary supply signal to the valves is present. If the SSV is to remain closed, ensure there is no primary supply signal. This may be confirmed by a visual inspection of the relevant pressure gauge on the WHCP. 8.1 Open the needle valve controlling the primary input from the WHCP. 8.2 Close the needle valves controlling the remote supply from the Elmar unit to the SSV. Bleed hose pressure. 8.3 Remove the hose from the control panel. 8.4 Inform the Control Room that Well control has been returned to the WHCP. 9.0 EMERGENCY SHUT DOWN PROCEDURES.
In an emergency the SSV can be closed in either of two ways dependent upon the nature of the emergency. •
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To close the valve, isolate the respective air supply and bleed off pressure through the dump valve.
To close the valve simultaneously with above, or independently, press the ESD button - either on the Elmar panel if fitted or at the remote ESD station. To reset the valve simply pull the ESD button out until the pilot pressure gauge indicates a pressure greater than 30 psi.
10.0 MAINTENANCE
Service the Elmar hydraulic control package every three months.
The air motor must be kept clean and the air filter properly maintained. Ensure that the fluid being pumped is clean and free of water. The pump inlet filters should be removed and cleaned every year. The pumps must be disassembled and checked for corrosion and wear annually. Reviewed by:
Designated Technical Reviewer
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Well Management Team Leader
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PE Supervisor
____/_____/____
Approved by:
WEO Superintendent
____/_____/____
Operational and Technical Authority
____/_____/____
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