UNREST UNR ESTR RICTED Octtober 19 Oc 1998 98
Docu Doc ume ment nt ID: ID: PR PR-IOSI Filling key: Fi key:
Inspection Inspecti on and Certi Certifi fica cati tion on of Equipme Equi pment nt Pro Procedu cedure re
Keyword Keywo rds: s: inspe pec ction tion,, ce cerrtificat ificatiion on,, equipment, equipment, well pulli ulling ng bo boiist, mobile f low owlline, press pressure ure vessel vess el,, wellbe wellbea ad, pi pip ping ng,, aud audit, it, contr contractor, actor, mo mobili bilis sation ation..
This docum document ent is the pr proper operty ty of Petrol Petroleum Deve Develop lopm ment Oma Oman n, LLC LLC.. Nei Neitthe herr th thee whole whole nor any partt of th par thiis doc ocum umen entt ma may y be discl disclos osed ed to oth ot her erss or repr reproduc oduced ed,, sto torred in a ret retrie rieval val sys systtem, or transmit tran smitted ted in any any form by by an any y mea means ns (e (ellect ectrronic onic,, mechanical mechanical,, reprograp reprograph hic rec record ordin ing g or other otherw wise) with wi tho out prior written con consent oft fthe he owner ner..
NAEEM NAEE M ASHRA ASHRAF F INSPECTOR
L EVEL-II
I nspe nspe ction c tion an d d C e ertific r tific a a t ti i o on n
i p pm m en e n t t of Equ i
Signed:
P r ro o c c edu edu r re e
. Robb ert de Weijer, Robbe Weijer, OT OTW W Head He ad of Well Serv Ser vice cess
The foll follow owing ing is a brie brief f summar summary y of the fo four ur most re reccent revisi isio ons to thi thiss documen documentt. rev eviision ionss prior to to these are held on fil file by the iss ssuin uing g depa eparrtme tment nt..
Rev Re v. No No.. 0
Date Date 14/ 10/ 10/ 1998 1998
Author TM Service icess - OTW / 1
Scon Sc onee / Remarks Initial Iss ssu ue
Dettail De ilss of all
1
2
Introduction
1
1.1 I .2 1.3 1.4
1 1 1 1
Back ground Purpose Distribution/ Target Audience Structure of This Document
3
Proced u re
2.1 Scope 2.2 Procedure Descri ption 2.2.1 General 2.2.2 General Requirements for Well Services Equipment 2.2.2.1 Inspection and Certification 2.2.2.2 Pressure Contai ning Equ ipment. 2.2.2.3 Lifti ng Equipment 2.2.2.4 Documentary Evidence 2.2.3 Pressure Test Bay 2.2.4 Well Test Equ ipment 2.2.4.1 Pressure Vessels (Separators, Surge Tank s) 2.2.4.2 Wellhead Equipment (Choke Manifolds, Data Headers, SSV's, etc) 2.2.4.3 Piping (Chicksans, Flowlines, etc.) 2.2.4.4 Lifti ng Equipment \ 2.2.5 Well Pulling Hoist Equipment... 2.2.5.1 General 2.2.5.2 Inspection Requirements 2.2.6 Wireiine Equipment. 2.2.6.1 General 2.2.6.2 Inspection and Certification Requirements 2.2.6.3 Pressure Control Equipment 2.2.6.4 Wireline Management System 2.2.6.5 Wirel ine Tools 2.2.7 Mobile Flowline and Accessory Equipment. 2.2.7.1 General 2.2.7.2 Material Specification 2.2.7.3 Equipment Identif ication 2.2.7.4 Inspection Requirements 2.2.7.5 Documentation 2.2.7.6 Inspection Detai Is 2.2.8 Audit of Contractor's Equipment 2.2.8.1 Initial Mobilisation Audit 2.2.8.2 Certificates and Other Documentation 2.2.8.3 Callout Mobil isation 2.3 Identi f ied Hazards/ Threats 2.4 Roles and Responsibilities 2.4.1 Equipment User 2.4.2 Contractor 2.4.3 PDO Well Services Representative 2.5 Related Forms and Reports 2.5.1 Inspection, Testing and Certification Documentation 2.5.2 Two-Monthly Hoist Inspection Report 2.6 Related Business Control Documents 2.7 Review and Improvement 2.8 Step-out and Approval A
ppendices
A
Glossary of Terms, Abbreviations
3 3 3 3 3 4 4 4 4 5 5 6 6 7 7 7 7 8 8 9 10 10 10 10 10 II II 12 13 13 15 15 15 16 17 18 18 18 18 19 19 19 19 19 20 21
& Def initions
21
Equipment used in Well Services operations is mostly either pressure containing and/ or load bearing. As such, it is essential that this equipment be maintained in a fit-for-purpose condition in order to prevent failure and accident that could result in danger/ injury to personnel, threat to well integrity or damage to Company assets. It is a requirement by local regulations and safe Company practices that the equipment is subject to regular inspection and certif ication to verify that it is safe to use. Most of this is covered by relevant International Codes and Recommended Practices (see Related Business Control Documents in section 2.6 below). Whilst limited in their guidance on specific mobile f l ow line equipment, the various components related to good oil field practices have been extracted and incorporated in this procedure.
This procedure sets out to establish the standards and certification required for initial acceptance of Well Services equipment, and the periodic inspections and re-certifications required to ensure that the equipment continues to perf orm saf ely and within specification during Well Services operations conducted on PD~ operated wells.
It provides the basic framework for a Safety Management and Inspection (SMI) System that contractors who perform Well Services operations on behalf of PD~ shall apply to ensure that the equipment supplied and used by them is maintained in a satisfactory and safe condition.
This Well Services Procedure document wil1 be distributed to all PD~ Section Heads who have interf a ces with the Well Services Operations, all Well Services Supervisors and Contractor Supervisors.
The document is structured in line with the latest template available for standard documents within PDO's Document Management System. This section 1 gives general inf ormation about the type of document and section 2 contains the details relating to the specific subject matter.
Section 2.2 gives a description of the process of Inspection and Certif ication for equipment used during Well Services operations on a PD~ operated well. Section 2.3 identif ies the hazards that are prevalent in the process covered by this procedure and indicates the respective Hazard Register reference sheet, which illuminates the controls to be applied.
Section 2.6 lists related standards and guideline documents that should be used in conjunction with this procedure.
Section 2.8 describes the steps to be taken to seek and obtain step-out approval in the event that circumstances prevent compliance with this procedure.
Appendix B is a User Feedback Form that can be used to submit comments or recommendations to correct errors, inaccuracies or ambiguities f ound by users o f the document.
This Procedure is applicable to all equipment, owned and/ or used by PDO or Contractor, used during Well Services operations conducted on any production well operated by PDO.
Proper initial and subsequent routine inspection of Well Services equipment is essential to prevent equipment failure resulting in possibly injury to personnel, equipment damage, loss of well control etc. It is a requirement by local legislation and PDO safety regulations that this equipment has upto-date certificates and inspection records to prove that it is safe to use. The majority of equipment used during Well Services operations is owned by the Contractor conducting the operations on behalf of PDO under the terms of a service contract. The requirements expected of the Contractor shall normally be written into the scope of services terms of the service contract
All equipment used in Well Services Operations, either contractor owned or supplied by PDO shall be subject to regular visual inspection. All load bearing and pressure containing equipment shall be inspected and certified/ recertified, on an annual basis as a minimum, by a Company approved inspection agency in accordance with: m
PDO ERD-07-01 "Code of Practice for the Inspection of Static Equipment".
All equipment that has been exposed to hostile environments (extreme temperatures, chemicals, corrosive environment, etc.) shall be re-inspected and re-certif ied before re-use The Contractor shall k eep inspection records of all equipment on the basis of a unique code, which shall be clearly marked on the Equipment by means of a plate, stainless steel strap or other wise (see section 2.2.7.3 below). All Inspection and Certification documentation, including manufacturer's certification, design and material Specif ication Certification, shall be made available t o the Company at Initial Mobilisation. Subsequent re-certif ication documentation and inspection reports shall, be made available within one month after re-inspection. Under no circumstances shall Equipment be provided, or be used in the performance of Services for the manufacturer's certif ication, of which design and material Specification and certification are absent or expired. Reference shall also be made to: m
WSSC PDO "Well Services Saf ety Case"
In addition to inspection and certification, requirements given in section 2.2.2.1 above, all pressure containing components and pressure control equipment (e.g. lubricators, BOP's, stuf f ing boxes, pump discharge lines, pressure vessels, pressure relief valves, circulating head valves, crossovers, pumping tees, etc.) shall be tested in accordance with: m
PDO ERD-07-01 "Code of Practice f or the Inspection of Static Equipment"; and
m
PDO ERD-07-02: "Methods for Non-Destructive Examination".
Tests shall include hydraulic pressure testing and ultrasonic wall thickness examination similar to that given in section 2.2.6 below for mobile f low lines and accessory equipment. All pressure testing of equipment shall be conducted in a dedicated test bay, or alternatively and underground dedicated pressure test cellar to ensure the safety of personnel.
Lifting equipment shall also be tested in accordance with: m
PDO ERD-80-0I "Lifting Equipment Specification".
For WPH hoist draw works and mast additional inspection requirements shall apply as detailed in section 2.2.5.2 below, which relates to: ill DRS 130-05 PDO "Drilling Equipment Inspection Manual".
The Contractor shall also submit to the Company f or approval a Hoist Drill Line Replacement Programme. This shall be either a periodical complete line replacement programme or a 'slip and cut' programme. Either programme shall be based on routine visual inspections and/ or 'ton-mile' concept and shall include a statement on maximum service life of the drill line.
The Contractor shall maintain documentary evidence and/ o r computer records In an SMI system or similar, of all such tests. Documentary evidence together with the regulations, procedures and standards of the tests shall be subject to audits by the Company.
All hydrostatic pressure testing of equipment shall be conducted in a dedicated pressure test bay that meets the following specif ications: •
It must have four external walls independent of the main workshop (or other similar building) structure.
•
All walls shall be o f suff icient height to contain f lying debris in order to protect personnel, outside the test facility, f rom injury.
•
Doors and observation windows shall be capable of withstanding a direct impact from within the facility.
•
Pressure lines form the test pumps shall be secured to the walls of the test bay - loose lines shall be kept as short as possible.
•
Test bay f loors shall be adequately drained to allow work to continue in a relatively dry and clean environment.
•
High-pressure test pumps shall be enclosed within the test facility (if possible) with only the control panel externally positioned.
The pressure test bay shall also be equipped with a fail-safe warning system with flashing lights to alert personnel that equipment is under pressure test. The system shall automatically dump the pressure on the equipment as soon as the test bay door is opened. Energising the system shall be dependent upon the locking of the door, without which pressurisation shall be unable to commence. An acceptable alternative t o a w alled room test bay will be an underground pressure test cellar, provided that the above criteria, as appropriate, are complied with.
Acceptance of any pressure vessel shall be contingent upon delivery of a valid certificate from a competent certifying body (e.g. ABS, DNV, Bureau Veritas, L1oyds) verifying that it has been designed and manufactured in accordance with the requirement of :
m ASME "Boiler and Pressure Vessel Code of Practice", Section VIII, Division I. Certificates shall also verify that all materials used in the manufacture conform to the requirement of the following. Full traceability of materials is required. m
PDO ERD-80-02 "Materials Selection - Sour Service"; and
m
NACE MR0175-90 "Standard Sulphide Stress Crack i ng Resistant Metallic Materials For Oilfield Equipment".
All pressure vessels shall be fully certif ied that they have undergone all non-destructive testing as required under ASTM code and in accordance with:
m PDO ERD-07-02: "Methods for Non-Destructive Examination". Specif ically, all welds shall undergo 100% radiography and the radiographs shall be independently certif ied as conforming to the requirements. Magnetic particle inspection shall be performed on all welds and independently certified. An ultrasonic wall thickness map shall be supplied showing that the wall thick ness is in accordance with the approved design including additional thickness to allow for corrosion as specif ied in the ASME code Appendix E. This additional thickness shall be 1/ 8" for the pressure vessel and 1/ 10" for all associated piping. All pressure relieving devices shall be supplied with certif icates of conformance, including relevant set pressures and relief capacity, to the requirements of: m
SlEP DEP 80.45.10.10 "Pressure Relief , Emergency Depressurising & Flare Systems"
Pressure vessels shall be pressure tested using water or water/ glycol mixture as follows: 1.
11.
Raise pressure to maximum working pressure (MWP) and hold f or minimum 15 minutes. Bleed down to atmospheric pressure.
iii. Raise pressure again to MWP and hold for a f urther 15 minutes.
All pressure vessels shall undergo annual inspection and re-certif ication by a competent independent authority (e.g. ABS, DNV, Bureau Veritas, Lloyds or similar organisation authorised and approved by PDO). Testing and certif ication required is as follows: •
Ultrasonic wall thickness test;
•
Pressure test to MWP;
•
Relief valve set pressure test certif icate.
If for whatever reason, a pressure vessel should undergo any repair involving welding, this shall be done in conformance to the requirements of the ASME code. All welds shall undergo inspection and the pressure vessel shall undergo a pressure test similar to that detailed above, except that the test pressure shall be 1.5 times MWP.
Acceptance of chok e manifolds, data headers, surf ace safety valves and wellhead connections shall be contingent upon delivery of a valid certificate of conformance to: m
API Spec 6A "Wellhead and Xmas Tree Equipment",
and that all materials utilised conf o rm to: m
NACE MR0175-90 "Standard Sulphide Stress Cracking Resistant Metallic Materials For Oilfield Equipment".
All Non-destructive and pressure testing shall be perf ormed in conformance with the above specification and: m
PD~ ERD-07-02: "Methods for Non-Destructive Examination".
All wellhead equipment shall undergo annual inspection and re-certif ication conforming to API Spec 6A, including radiographic inspection and ultrasonic examination as applicable for wellhead equipment. Pressure testing shall be to MWP unless the equipment has been subject to modification involving welding, or other physical change, when the subsequent f irst pressure test shall be to 1.5 times MWP.
All piping and accessories shall conf orm to the requirements of section 2.2.6 below, regarding the acquisition, certification, annual and bi-annual inspections and re-certification: A certificate of conf ormance shall be required regarding: •
material traceability;
•
conformance to ANSI B 31.1 and NACE MROI75-90;
•
non-destructive testing in accordance with PD~ ERD-07-02;
•
pressure test to MWP.
Any lifting equipment assigned to Well Test Units shall be inspected in accordance with: W
PDO ERD-80-01 "Lifting Equipment Specification"
WPH equipment belonging to a contractor will normally be inspected by a c ertified and approved third party inspection company, but may it be inspected by a designated PDO Inspector, on an occasional urgent basis. For each item of WPH equipment in use, a properly completed, authorised inspection certificate shall be available on the WPH site for verification purposes. If no valid up-to-date certificate can be presented, the equipment shall not be used. All modifications, repairs or alterations to load or pressure bearing equipment shall be inspected by appropriate methods and verified and certified accordingly. Consultation with the manuf a cturer for approval of materials and methods shall be required prior to proceeding with such planned work . For identification purposes each item shall have a unique serial number stamped on it. Inspection reports/ certif icates shall refer to this number.
The inspection requirements in this procedure are largely based on the following and modified where necessary to suit the equipment in use on WPH's: W
DRS 130-05 PDO "Drilling Equipment Inspection Manual".
The inspection requirements and proper procedures for testing o f WPH equipment are indicated in the following tables, which in tum refer to Testing Technique Data Sheets in the Drilling Standard Instructions. Test frequencies for critical area NOT inspections are also indicated together with the required frequency for f ully disassembled. The Testing Technique Data Sheets, together with the relevant NOT procedures, are also contained in the Hoist Equipment Inspection Requirement Manual, held in the Well Services Section Head office in Marmul. An additional copy of this manual will be made available to WPH Contractor Supervisory Staff on request.
ITEM
Kelly Valve Overshot (Bowen) Spears (Bowen) Tapered Tap Inside BOP
DATA
CRITICAL AREA
SHEET
NDT INSPECTION
INSPECTION
NUMBER
FREQUENCY
FREQUENCY
A.l.l A.1.2 A.I.3 A.1.4 A.1.5
N/ A Each Each Each Each
Use Use Use Use
FuLLY DISASSEMBLED
6 Monthly Annually Annually N/ A 6 Monthly
ITEM
Hoist Mast Crown Block Travelling Block Clevis Hook Link s Elevators Spiders Tongs Brak e Bands/ Brake Equaliser Beam Tubing Board SIR Basket Deadline Anchor Plate Lifting Subs/ Slings/ Shackles
ITEM
Riser Spools BOP Equipment Shooting Nipple Chick san Line / Swivels Circulation Head, Swivels Air Receivers Brake Water Splash Tank Relief Valve Inspection Manifolds Gate Valves
DATA
CRITICAL AREA
SHEET
NDT INSPECTION
INSPECTION
NUMBER
FREQUENCY
FREQUENCY
B.1.1 R1.2 R1.3 RIA B.1.5 B.1.6 R1.7 RI.8 B.1.9 R1.10 R1.11 R1.12 B.1.I3
Annually Annually Annually 6 Monthly 6 Monthly 6 Monthly N/ A N/ A When Blocks Changed 6 Monthly 6 Monthly 6 Monthly N/ A
FULLY DISASSEMBLED
3-5 Years 3 Yearly 3 Yearly 2 Yearly N/ A Annually 6 Monthly 6 Monthly Annually af t er Last Inspection Annually Annually 2 Yearly 6 Monthly
DATA
CRITICAL AREA
SHEET
NOT INSPECTION
FuLLY DISASSEMBLED INSPECTION
NUMBER
FREQUENCY
FREQUENCY
N/ A Annually* Annually
N/ A
Annually N/ A N/ A N/ A
C.1.5
6 Monthly
Annually
C.1.6 C.1.7
N/ A N/ A
Annually Annually
C.1.8 C.1.9
N/ A Annually *
Annually N/ A
C.1.10
Annually*
N/ A
C.I.l C.l.2 C.1.3
Annually *
Pressure test to MWP after re-assembly, except after weld repairs when test to 1.5 times MWP. Refer to section 2.2.6 below for testing procedure.
Equipment used for PDO wireline operations either belongs to PDO or to the wireline contractor, depending upon size. The Wireline Contractor is responsible for ensuring that this inspection and re-certification is conducted accordingly. Most of the equipment used is pressure containing, e.g. BOP's (wireline valves), crossovers, lubricators, stuf f ing boxes, circulating head valves, pumping tees, well head connectors, BPV's, etc.
This equipment shall be subject to inspection and certification/ re-certif i cation before f irst use and shall also be re-inspected and re-certified at periodic intervals. Equipment that has been subjected to over-pressure or exposed to hostile environments (extreme temperatures, chemicals, corrosive environment, etc.) shall be re-inspected and re-certif i ed immediately, bef ore re-use Ref er also to:
m PR-l 034 "Wi reline Operations"
A third party inspector shall inspect and certify new equipment. Full documentation shall include, but not be limited to material physical/ chemical properties, hardness and full material traceability.
•
magnetic particle inspection of all welded/ forged sections;
•
hydrotests to 1.5 times WP;
•
material traceability
•
material certification to NACE MR0175-90 as in section 2.2.7.2 below.
The following actions shall be carried out with a certified inspection system or certified third party: 1.
Visual inspection of external surfaces for wear, cracks and damage.
2.
Visual inspection of internal surfaces for erosion.
3.
Magnetic particle inspection of welds.
4.
Pressure test to rated working pressure. Note: The test pressure/working pressure ratio may be varied as per manuf acturer's recommendations.
Equipment that has been subject to modification (especially involving welding) shall be pressure tested immediately afterwards to the same pressures as the Initial Acceptance Test, according to recognised industry standards. All pressure tests shall be conducted using water or water/ glycol mixture, as f ollows: 1.
Raise pressure to test pressure and hold for minimum 15 minutes.
ii. Bleed down to atmospheric pressure. iii. Raise pressure again to test pressure and hold for a f urther 15 minutes.
All pressure control equipment (lubricators, control heads, BOP's, etc.) shall be tested as above to ensure it performs its designated task within specification. In addition to this all lubricator sections shall be drifted to check f ull bore. A semi-permanent record of this testing, in the f orm of a metal band with test date, test and working pressure of the item shall be attached to each item of equipment. The band shall also indicate if the item is rated for HzS use. All pressure control equipment shall be identified with a unique serial number to ensure control and record k eeping. Marking shall be done in a manner that does not reduce the maximum rated work ing pressure of the item. All relevant certification relating to material selection, traceability and re-certification by Company or third parties shall be available f o r inspection at any time.
Pressure testing of items containing sealing elements (BOP rams, stuffing boxes grease injection control heads) shall be perf ormed in two stages: 1.
Test of body integrity This shall be performed to the test pressures given above with suitable blank ing plugs to contain the pressure, and not utilising the seals
2.
Test of sealing capability The test of sealing capability of elastomer sealing elements (BOP rams, stuffing box numbers) shall be perf ormed to Working Pressure only using a polished rod of diameter equal to the cable for which the seals are designed. It shall never be performed with a stranded line, as the seals may be damaged when closed on the cable and pressure is applied. The polished rod shall have suitable end pieces to ensure it is held correctly in position.
In order to prove the integrity of the wireline, the contractor will implement a wireline management system as detailed in:
m PR-1034 "Wireline Operations", section 2.2.7
All wireline tools shall be maintained and inspected as per the manufacturer's best practices, design and maintenance instructions (BDMI). This will include regular visual inspection, critical dimension checks and tool maintenance.
Mobile flowline and accessory equipment has wide usage within the oilfield where highpressure non-permanent flow paths for well fluids, kill fluids, stimulation fluids, and work over f luids are required. Areas of use include well testing, well stimulation, well control and workover operations.
The mobile flowline and accessory equipment ref erred to in this procedure includes: •
mobile flowline joints;
•
chiksans - loops and swivels;
•
manifolds and crossovers;
All mobile flowline equipment shall be rated for 70,000 k Pa (10,000 psi) maximum allowable working pressure (MA WP) and sour service except for the f lowlines used for interconnecting well testing equipment downstream of the chok e manif old that need only be rated f o r 35,000 kPa (5,000 psi). All hammer unions fitted to mobile flowline equipment shall be of figure 1502 design and be butt-welded or integral forged. The Exploration Well Test Units have mobile vent and flare lines that are made from used 3Y z inch and 4Y z inch EUE tubing with 3 inch and 4 inch figure 602 hammer unions with MAWP of 14,000 k Pa (2,000 psi). All pumping equipment f rom the check valve to the Xmas tree shall be rated for 70,000 kPa (10,000 psi) MAWP and sour service. Equipment from the pumps to the check valve need not meet the HzS requirement. The WPH kill pump has a maximum pressure rating of 21,000 k Pa (3,000 psi) and is protected by a relief valve. Theref ore, the MA WP rating for WPH kill lines and any wellhead that the WPH will rig up on is 21,000 kPa. All equipment shall be fitted with safety snubbing lines through clamps. These lines shall be of sufficient strength to withstand impact load if failure o f equipment occurs and shall be inspected as lif ting equipment.
New equipment shall be purchased against design and fabrication codes such as ANSI B31.1 or similar recognised specifications. All equipment shall be suitable for sour service in accordance with:
m NACE MR0175-90 "Standard Sulphide Stress Cracking Resistant Metallic Materials For Oilfield Equipment".
All equipment shall be identif i ed by means of a stainless steel band, attached to individual items, containing the following information: •
identification number;
•
working pressure;
•
sour service (if applicable);
•
date of last full inspection.
The steel band shall be at least 20 mm wide, f ree moving and of such construction that it cannot be removed from the item without cutting.
All equipment shall have its base colour denoting the equipment pressure rating. •
for 70,000 kPa (10,000 psi) rating this shall be BLACK with a 1 metre WHITE the centre of each joint;
band in
•
for the 10,500 k Pa (1,500 psi) with the exception of Well Test vent and f lare lines, the base colour shall be BLACK.
All equipment having a service rating for HzS shall be painted with a 10 cm circumferential ORANGE band; f or f lowlines at their mid length, and at the pin end for all accessories.
A third party inspector shall inspect and certify new equipment. Full documentation shall include, but not be limited to material physical/ c hemical properties, hardness and f ull material traceability.
•
visual inspection;
•
ultrasonic wall thickness measurements;
•
magnetic particle inspection of all welded/ f orged sections;
•
hydrotests;
•
material certification to NACE MR0175-90 as in section 2.2.7.2 above.
For PDQ owned equipment, f u ll inspection for all equipment re-certification shall be carried out annually by PDQ, or a recognised third party, and comply with API Recommended Practices or simi lar codes of practice. For Contractor owned equipment, f u ll inspection carried out by the contractor with a certif ied inspection system or certified third party.
•
ultrasonic wall thickness measurement at k ey points;
•
magnetic particle inspection of all welded/ forged sections;
•
hydrostatic test to rated working pressure.
Chiksans, manifolds, check valves, plug valves, etc., shall be disassembled during f ull inspection to visually check all parts and to replace elastomers. Valves shall be function and leak tested at rated working pressure.
A six-monthly inspection of all equipment, limited to visual and wall thick ness checks, shall be carried out by PDO or a recognised third party. This inspection may be carried out at work site. Additional monthly visual recorded inspections o f all equipment shall be performed by the user as part of routine planned maintenance. Note: Any equipment unable to meet the inspection requirements shall be immediately removed f rom service.
The user shall also k eep service and inspection records of each PDO owned item in EPMARS and copies of re-certification and interim inspection documents on file, available f or immediate inspection. Service companies shall maintain similar records to the above, available for immediate inspection by PDO whenever required.
The following actions shall be undertak en: 6.
Swivels shall be f ully disassembled and rebuilt.
7.
Visual inspection of external surfaces for wear, cracks and damage.
8.
Visual inspection of internal surfaces for erosion.
9.
Visual inspection of unions for damage and crack s
10. Check rotation of swivel for roughness. 11.
Ultrasonic wall thickness inspection - maximum erosion allowable is 20% of nominal wall thickness.
12. Magnetic particle inspection of welds. 13. Pressure test to rated working pressure.
Items 2. to 6. above shall be carried out on all equipment, this inspection may be carried out on the work site.
Items 2. to 5. above shall be carried out on all equipment, this inspection may be performed on site.
All pipe shall be inspected f or erosion, crack s and damaged threads. The pipe shall then be checked with the ultrasonic wall thickness tester at each end and the middle, to ensure that the wall thickness is within the limits given in ANSI B.31.3, e.g. f or 4130 low alloy steel sour service pipe rated for 70,000 k Pa WP and 300 F: 0
PIPE SIZE
MINIMUM W ALL THICKNESS
2"
0.220"
3"
0.330"
On parts where wear limits are not known, the limit for allowable wall thick ness shall be taken as 20% of the new wall thickness.
All valves shall be visually inspected for erosion, crack s and damaged threads. The valves shall then be operated and sealing surface check for pitting and repaired as necessary. The male sub end shall be checked with an ultrasonic thickness tester and the unit pressure tested to working pressure.
Check valves shall be visually inspected for erosion, cracks and damaged threads. Check valves must be stripped down and the sealing mechanism check ed and repaired as necessary. The valve body and the check mechanism must be pressure tested alternately to working pressure. The male sub end shall be check ed with an ultrasonic thickness tester.
The discharge arms shall be removed Manifolds, the unions disconnected and they shall be checked internally, using a light, for excessive erosion. The complete manifold shall be checked externally for any signs of crack s or wear on union ends. The manifold shall then be checked with an ultrasonic thickness tester and pressure tested to the MWP.
Loops and swivels shall be visually inspected f or erosion, cracks and damaged threads. The swivels shall be disassembled and the parts check e d with the ultrasonic thickness tester to limits shown below: W ALL THICKNESS CIf ICKSAN SIZE
As NEW
MlNlMUM
2"
0.450"
0.330"
3"
0.530"
0.420"
Tees, Y's, laterals and crossovers shall be visually inspected for erosion, cracks and damaged threads. They shall then be check ed at the male sub end with an ultrasonic thickness tester to limits shown below: W A LL
THICKNESS
SIZE
AsNEW
MINIMUM
2"
0.480"
0.360"
3"
0.540"
0.400"
The wear limits f or segmented male subs shall be used to check Tee's Y's laterals and machine crossovers.
The Company shall, as and when notif ied by the Contractor that the Initial Mobilisation is complete, conduct an audit of equipment and personnel at the field base or any other mutually agreed location.
•
quantity, type and operational status of equipment;
•
availability of equipment and personnel to meet the required Well Services resources;
•
availability and operational status of site facilities;
•
number and approval of personnel;
•
implementation of the computerised database management system;
•
implementation of HSE procedures and availability ofHSE equipment.
The Contractor shall, to f acilitate such an audit, ensure that approvals, documentation and certif icates as given in section 2.2.8.2 below, are obtained and the equipment and personnel are mobilised well in advance of the Commencement Date.
The Contractor shall obtain the approval of the Company f or the following certificates and documentation. Approvals shall be a necessary condition for satisfactory mobilisation. • • •
Certification of all pressure containing or load bearing equipment and manufacturer's certificates on all equipment. Personnel and job descriptions. Safety plan and documentation, including certificates showing that all personnel have been instructed in and have satisfactorily passed all safety procedures and drills.
NAEEM ASHRAF I NS PE CT OR
L EVEL-II
Where equipment and personnel required f or a Callout have not been audited as per section 2.2.8.1 above, in particular call off equipment and associated personnel and replacement equipment and personnel, all such equipment and personnel shall be separately audited by the Company prior to mobilisation to the well site.
•
quantity, type and operational status of equipment;
•
approval of personnel;
•
implementation ofHSE procedures; and
•
availability of safety equipment.
For each Callout, the Contractor shall be responsible to provide principal equipment and personnel detailed in the Callout Order and to ascertain and to provide all additional equipment and personnel deemed necessary to satisf actorily execute the required service at the well site.
The following hazards or threats have been identified as being prevalent during the process covered by this procedure. These are assessed and the controls to be applied are given in the Hazards Register, which forms section 5.2 of the "Well Services Saf ety Case, Rev 1", October 1994 and the "Additional Sheets f or Well Services Safety Case for Hoist", March 1996. Hazardff breat
I. 2. 3. 4. 5. 6. 7. 8. 9. 10. II. 12. 13. 14. 15. 16. 17. 18. 19. 20.
High Pressure Chicksan Lines High Pressures during Pressure Testing High Pressure Pumping High Pressure Equipment Elevated Loads, Crane Operations Elevated Tubulars on Piperack or Catwalk Rotating Equipment Gas Cylinders Wireline Cable Heavy Moving Equipment/ Tubulars Pneumatic Tools Drawworks Hoisting Equipment Wireline/ Sandline Cable Tongs, Slips and Elevators Blockline during Slipping/ Cutting Operations Air Winches Electrical Equipment Loaded Rig Structure Tubular Loading Breakdown of Well Integrity in the Long Term
Hazard Register Ref .
H-03.001 H-03.002 H-03.003 H-03.005a H-04.001 H-04.001a H-10.003 H-10.004 H-1O.006 H-I1.006a H-II.007a H-l1.008a H-II.009a H-II.OlOa H-1I.OI4a H-l1.018a H-14.001 H-19.001a H-19.002a H-20.015a
Hazard Register Refs. followed by 'a' (e.g. H-03.005a) refer to the "Additional Sheets for Well Services Safety Case for Hoist", March 1996.
The equipment user, be it PD~ or Contractor, is responsible for ensuring that all equipment used is fit-for-purpose and properly certified. The user is responsible to of f er the equipment for fu ll inspection at an earlier time than normally scheduled when it has been used under severe conditions i.e. high gas flow rates, sand production, high H2S and CO2 concentrations etc. The user shall co-ordinate inspection, testing and maintenance of e quipment with other relevant parties and maintain full documentation.
The Contractor is responsible f or providing equipment as required by the service contract that satisfies the standards detailed in this procedure with regard to: •
identification tagging;
•
material specifications;
•
inspection and testing;
•
certification.
Under no circumstances shall Equipment be provided, or be used in the performance of Well Services operations for which design and material Specification and certification are absent or expired. The Contractor shall keep certification and inspection/ testing records of all equipment, including manufacturer's certif ication, design and material specification certification, which shall be made available to the Company as required. The Contractor shall maintain documentary evidence and/ or computer records in an SMI system or similar.
The PD~ Well Services Representative shall conduct audits of equipment and respective documentation at the field base or any other mutually agreed location, as required.
The Contractor shall keep all certification and inspection/ testing records of all equipment on the basis of a unique equipment code (see section 2.2.7.3 above). All such documentation, including manufacturer's certif ication, design and material Specification Certif ication, shall be made available to the Company at Initial Mobilisation and at other times on demand. Subsequent re-certif ication documentation and inspection reports shall, be made available within one month af ter re-inspection.
The Contractor shall submit a Well Pulling Hoist Inspection Report, in a format approved by PDO, every two months giving details of the routine inspection carried out on the hoist.
I. 2. 3. 4. 5. 6. 7. 8. 9. 10. II. 12.
Document
Co.
No.
Wellhead and Xmas Tree Equipment, Boiler and Pressure Vessel Code of Practice, Section VIII, Division Quality Systems, PaJi I Standard Sulphide Stress Crack ing Resistant Metallic Materials f or Oilfield Equipment, 1995 Drilling Equipment Inspection Manual Code of Practice f or the Inspection of Static Equipment Methods for Non-DestlUctive Testing Lifting Equipment Specif ication Material Selection - Sour Service Wireline Operations Well Services Safety Case (October 1994), includes Hazard Register Pressure Relief , Emergency Depressurising and Flare Systems
API ASME
Spec 6A
BS NACE
BS 5750 MR0175-90
PD~ PD~ PD~ PD~ PD~ PD~ PD~
DRS 130-05 ERD-07-01 ERD-07-02 ERD-80-01 ERD-80-02 PR-1034 WSSC
SIEP
DEP 80.45.10.10
For a complete listing of all business control documents, related to Well Services Activities, refer to the following document, which should be used in conjunction with this procedure: m
PR-1042 "General Operational Safety", Section 2.6.
As this document is a live work ing document, it will be reviewed on a continuous basis and updated to incorporate any major amendments as necessary resulting from changes in current activity and/ or changes in responsibility effected by reorganisation within PD~ as soon as practicable. It will be formally reviewed on an annual basis and any improvements and/ or minor amendments will be incorporated at this stage. Any person discovering discrepancies or inadequacies in this document should report them to the CDFP, Well Services, f or inclusion in the next update, using the 'User Feedback Form' included in this document as Appendix B.
Well Services Operations are conducted f ollowing close liaison between the PDO Well Services and the Contractor, who is bound by service contract Well Services work , by its very nature, is open to several hazards and it is therefore necessary to exert stringent controls on the quality of equipment used in order to minimise the risk and consequences of failure. However, it is recognised that deviations from standard procedures are required under special circumstances and in order to rectity unplanned occurrences. Any deviation requires authorisation by the CFDH or authorised delegate, who will discuss the circumstances and consequences with the Contractor concerned, prior to giving his approval.
ASME
American Society for Mechanical Engineers
ASTM
American Society f or Testing Materials
CDFP
Corporate Discipline Focal Point (currently Corporate Well Services Functional Engineer)
CFDH
Corporate Functional Discipline Head
EDMS
Electronic Document Management System
EPMARS
Exploration
EV E
Externally Upset Ends (tubing)
ID
Identif ication
MAWP
Maximum Allowable Working Pressure
MPI
Magnetic Particle Inspection
NACE
National Association of Corrosion Engineers
NDE
Non-Destructive Examination
NDT
Non-Destructive Testing
SMI
Safety Management and Inspection (system)
SSC
Sulphide Stress Cracking
UWT
Ultrasonic Wall Thickness
WP
Working Pressure
WPH
Well Pulling Hoist
& Production
Administration
& Reporting
System
Any user who identifies an error, inaccuracy or ambiguity in these Operations Procedures documents is requested to advise the COFP, Well Services (UOWI1), by returning this page (or a copy) with their comments.
Inspection and Certification of Well Services Equipment Procedure
Title:
SECTION
FURTHER
NUMBER
COMMENTSIERRORS/SUGG
RECOMMENDATIONS:
New Procedure Required
Yes/ No
ESTIONS
