Revision 0.2. Petroleum Company Sendirian Berhad. Document No. TMS1175. Approved by: Document Owner:

Transcription

1 Petroleum Company Sendirian Berhad W E L L S E R V I C E S P R O C E D U R E S W E L L H E A D I N S T A L L A T I O N & M A I N T E N A N C E Document No. Revision 0.2 Approved by: Document Owner: Production Superintendent (OPD) Head of Well Services (OPD/4)

2 Document Control TYPE OWNER SECURITY CLASS Activity Description OPD/4 Unclassified REFERENCE AUTHOR APPROVED BY OPD/4 OPD KEY WORDS Well, wellhead, completion, workover, hoist, maintenance Send improvement suggestions to the document owner through a request for improvement form according to the following manual. Documentation Control Procedure (TMS0436). Revision Record REV REVISION DESCRIPTION DATE st draft for client approval Oct st issue Jan. 98 This document is valid for a maximum of 3 years after the last revision date. Beyond this date, it must be re-validated according to the following manual. Documentation Control Procedure (TMS0436). Distribution Control The document owner is responsible for distribution control. The target readership is shown below. Managers, Department Heads and Division Heads, directly involved. Contractor Management, directly involved. Process owners. Other staff as requested by the line. Archive - FOS/3. OPD/5251 Contact the document owner for additional copies. Notice and Warning Copyright 1998, Petroleum Company Sendirian Berhad. This document is the property of Petroleum Company Sendirian Berhad (), Seria 7082, Negara Darussalam. Circulation is restricted to and, where a business requirement exists, to its designated associates, contractors and consultants. It must not be copied or used for any other purpose other than for that which it is supplied, without the expressed written authority of. Except where provided for purposes of contractual requirements, disclaims any responsibility or liability for any use or misuse of the document by any person and makes no warranty as to the accuracy or suitability of the information to any third party. Any misuse of the document is re-dressed by. 2 WS-PWI&M EV 0.2

3 T A B L E O F C O N T E N T S 1. INTRODUCTION TO THE MANUAL Description Purpose Scope Terminology WELLHEAD SERVICING Introduction Wellhead Servicing Procedure Offshore Well Service Skids CAMERON/MCEVOY WELLHEADS & XMAS TREES Introduction Location of Injection Fittings - McEvoy Valves Injecting Sealing Compound - McEvoy Valves Pressure Testing - McEvoy Valves Injecting Body Filler Grease - McEvoy Valves Greasing Stem Bearing - McEvoy Valves Testing Xmas Tree Valves Against Well Pressure - Oil Wells Testing Xmas Tree Valves Against Well Pressure - Gas Wells Testing Bottom Flanged Connection - McEvoy Xmas Tree - Single Oil & Gas Testing Bottom Flanged Connection - Xmas Tree (Dual Oil & Gas) Testing Studded Connection Between Double Studded Adapter & Tubing Hanger Necks Testing Seals on Extended Neck & Outside Diameter - Cameron BRX Casing Hangers Stem Packing Replacement - McEvoy Valves Bonnet Gasket, Gate & Seat Replacement - McEvoy Valves Field Gauging Body & Bonnet Nut Threads - Cameron H2 Chokes FMC WELLHEADS & VALVES Introduction Injecting Grease - FMC Valve Bodies Greasing Stem Bearing - FMC Valves Replacing Stem Packing - FMC Valves Testing Bottom Flanged Connection - FMC Xmas Tree Installation - TC-M-ET Tubing Head Installation - TC-M-ET Tubing Installation - TC-M-ET Tubing Head Installation - Single Tubing Hangers Installation - FMC Single Block Beam Pump Xmas Tree Servicing - Dual-Pac Stuffing Box Installation - 7" Slip Lock Connector CAMERON TYPE FC GATE VALVES Introduction Injecting Body Filler Grease - Cameron FC Valve... WSP-WI&M REV 0.2 3

4 5.3 Stem Bearing Lubrication - Cameron FC Valve Testing - Cameron FC Valves WKM MODEL M POW-R-SEAL GATE VALVES Introduction Greasing - WKM Model M POW-R-Seal Gate Valves Stem Bearing Lubrication - WKM Model M POW-R-Seal Valves Pressure Testing - WKM Model M POW-R-Seal Gate Valves Stem Packing - WKM Model M POW-R-Seal Valve Replacing Gates & Seats - WKM Model M POW-R-Seal Gate Valves Testing Bottom Flanged Connection - WKM Xmas Tree CIW S-10 LUBRICATOR Introduction Installation of Back Pressure Valve Using S-10 Lubricator Removal of Back Pressure Valve Using S-10 Lubricator Servicing the S-10 Lubricator CIW TYPE A VALVE REMOVAL TOOL Introduction Installation/Removal - Valve Removal Plug (Using CIW Type A Removal Tool) SERVICING AVA OOH LINEAR HYDRAULIC SLIM LINE ACTUATOR Introduction Disassembly/Assembly TYPE OF WELLHEAD ARRANGEMENT Standard Wellhead Arrangements Single Oil Wellhead Assemblies Dual Oil Wellhead Assemblies Single Gas Wellhead Assemblies Dual Gas Wellhead Assemblies OTIS ACTUATORS Servicing Otis Actuators Otis XS Actuators Otis U Actuators Otis N Actuator Pilot BAKER ACTUATORS...55 C H A P T E R 1.1 Description 12.1 Introduction Baker WC Actuator Baker Bonnet Assembly I N T R O D U C T I O N T O T H E M A N U A L This document describes the wellhead installation and maintenance procedures undertaken by the Well Services Division in support of the Production Operations Department of Petroleum. 4 WS-PWI&M EV 0.2

5 This manual has been compiled to document the procedures necessary to properly maintain wellhead assemblies including the Christmas Trees and Annulus Valves. Basically, maintenance consists of greasing the moving parts on the wellhead and Xmas tree valves, and pressure testing all seals in the valves and Wellhead Assembly. Replacing seals or injecting plastic packing where necessary. The purpose of the maintenance programme is to ensure that the Wellhead Assembly and Xmas tree contain well fluids without leakage. 1.2 Purpose The wellhead installation and maintenance procedures have been documented in order to comply with the following manuals. Ensure compliance with Health, Safety and Environment (HSE) standards. Ensure compliance with Well Services standards. Promote efficiency and effectiveness. For details of the HSE standards refer to the manual shown below. HSE Standards (TMS0434). 1.3 Scope This document describes the activities of the Well Services Division. Relationships with other departments and other Companies are covered but their activities are not described unless it contributes to a better understanding of the Well Services Division s role or activities. 1.4 Terminology Key terminology in this document is either defined on its first occurrence or takes the common definitions provided in the following manual. Management System Glossary (TMS0522). The following table contains terms specific to this document. BOP BPV LIB PRT PSAT LP THP AOS CITHP Term Blow out preventer Back pressure valve Lead impression block Pressure release tool Power spring assembly tool Low pressure Tubing head pressure Area operations supervisor Closed in tubing head pressure Description C H A P T E R 2.1 Introduction Table Specific Terminology 2. W E L L H E A D S E R V I C I N G To ensure that the wellheads can be properly maintained, special servicing units have been constructed and equipped for this purpose. For the offshore wellheads the servicing equipment is carried on a pair of skidded units. For the onshore wellheads it is mounted on a trailer. WSP-WI&M REV 0.2 5

6 2.2 Wellhead Servicing Procedure General These procedures are to be followed when servicing wellhead equipment under the maintenance programme. They are divided into offshore and onshore operations Offshore Wells 1. Report to the Area Operations Supervisor (AOS) at the main platform. 2. Complete appropriate work permit application form(s). Ensure these are approved before moving to work site. WARNING: Hot work permit is required for the operation of the diesel engine on the service skid and also for a camera if photographs are to be taken. 3. Identify wellhead to be serviced. Request OPD/11/12/13 or OPD/21 as appropriate to close flowline valve, SC-SSSV and bleed off pressure from the well. The wellhead is now ready for servicing. 4. Close all valves on Xmas tree and wellhead. 5. Identify type of wellhead arrangement and select appropriate test report forms. 6. Service all valves on Xmas tree and wellhead annuli. Pressure test all packoffs on casing, casing hangers and tubing hanger Onshore Wells Five different types of completions are to be found on onshore wells and they may be either producing or closed in. The five types are natural flow, beam pumper, gas lift, plunger lift and water injection. 1. Report to OPD/31 who will issue the necessary work permits with a list of safety requirements attached. Before issuing a work permit it is the supervisors responsibility to have checked the cellar for the presence of fluid. If fluid is present it must be pumped out. The wellhead is to be washed down with high pressure water prior to servicing. 2. If the cellar is more than 1.5 m deep it must tested for gas, oxygen and H 2 S. 3. Take the work permit(s) to the OPD/31, Engineering Support Group for an approval signature. 4. Ensure the work permit(s) are approved before moving to the work site. 5. Prior to starting work, ensure that all safety requirements have been fully met. 6. Close in each type of well in accordance with the procedure shown in Table Type Natural Flow Beam Pumper Gas Lift Plunger Lift Water Injection Procedure Close SC-SSSV and flowline valve. Open all valves on Xmas tree and bleed off well pressure through the flowline and into the test separator. Switch off pump in the up stroke position. Pull handbrake on pump unit and secure it. Bleed off any pressure through the flowline and into the test separator. Close gas lift gas supply. Close the SC-SSSV. Open all valves on Xmas tree and bleed off any pressure through the flowline and into the test separator. Supervisor to make arrangements for the asset manager to close off the gas supply. Close the SC-SSSV. Open all valves on Xmas tree and bleed off any pressure through the flowline and into the test separator. Supervisor to make arrangements for the asset manager to close in and isolate the water supply. Open all valves on Xmas tree and bleed off any pressure through the flowline and into the production facility. Table Well Close In Procedure It is important that OPD/31 be notified at the time of well closing and opening. These times are required for inclusion in the daily surface production report. 6 WS-PWI&M EV 0.2

7 7. Service all valves on Xmas tree and wellhead annuli. Pressure test all packoffs on casing, casing hangers and tubing hangers. To service assemblies installed prior to 1960, consult OPD/421 who will advise on the maintenance to be undertaken. 2.3 Offshore Well Service Skids General The equipment for servicing offshore wells is mounted on a pair of skid units. One skid carries the air compressor which is powered by a zone 2 diesel engine, fitted with exhaust spark arrestor and rig saver device and with the hoses to deliver compressed air to run the grease/sealant injection pump and a portable test pump. The compressed air tank must be fitted with a pressure relief valve. The other skid has grease and sealing compound injection equipment supplies, together with two hose reels to deliver these to the wellhead deck. At one end is a large tool compartment that contains tools and equipment. Each skid has four lifting eyes provided at the top. The top and sides are covered with removable weather proof sheeting. A hydraulic jacking trolley is included with the pump skid to assist with placement on the deck. The two skids are designed to be used as a pair connected together by a length of hose Operating Instructions 1. Untie weatherproof sheeting from sides of each skid. Roll up and secure. 2. Ensure all valves on both skids are in the closed position. 3. Attach earth grounding clamp to a steel beam on the platform structure. 4. Connect compressor output to pump skid air inlet with length of hose housed on the compressor skid. 5. Open drain valve at bottom of air receiver and drain out water. 6. Close drain valve. 7. Pump hydraulic pressure on starter panel to 14,000 kpa. 8. Engage hydraulic starter. 9. Pull emergency stop lever forward to ensure it is in the OUT position. 10. Open throttle a small amount to give correct starting speed. 11. Open ball valve on hydraulic starter panel. Engine should start. If it fails repeat the procedure. 12. Push in hydraulic starter and set throttle to give desired operating speed. 13. Open drain valve at bottom of air receiver and blow out water. 14. Close drain valve. 15. Open air supply valve adjacent to air receiver. 16. Open air supply valve to pump skid. 17. Open air supply valves to test, grease or seal in any desired combination as required. WSP-WI&M REV 0.2 7

8 C H A P T E R 3.1 Introduction 3. C A M E R O N / M C E V O Y W E L L H E A D S & X M A S T R E E S In order to keep wellheads in an optimum safe working condition it is necessary that regular maintenance be undertaken. All McEvoy Xmas tree and annulus valves have sealing compound injected into the two Alemite Type Ball Check Fittings provided. After which they are pressure tested to the cold working pressure. The body cavity is then filled with grease and the stem bearing lubricated. The Cameron casing heads, casing spools and tubing heads have the hanger and packoff seals pressure tested. A test port is provided in each connection for this purpose. All needle valves and pressure gauges on the wellhead assembly are inspected and replaced if necessary. USE A SPANNER OR WRENCH TO REMOVE AND INSTALL A GAUGE. NEVER HAND TIGHTEN AS THIS WILL DAMAGE THE GAUGE. 3.2 Location of Injection Fittings - McEvoy Valves General Each McEvoy Model C Valve is equipped with three 3/4"-16 UNF Alemite Type ball check grease injection fittings. The single central fitting in line with the valve stem is always the body grease filler port. The cap of which is threaded 7/8"-14 UNF. The other two fittings located on each side of the grease port are for the injection of sealing compound. These caps are threaded 1"-14 UNF. The two types of fittings are threaded differently to avoid the wrong type of material being inadvertently injected. In addition to the check valve in the Alemite fitting all injection ports have a buried check valve. WARNING: CARE MUST BE TAKEN WHEN REMOVING INJECTION FITTINGS AS PRESSURE MAY BE TRAPPED UNDERNEATH. 3.3 Injecting Sealing Compound - McEvoy Valves General Each McEvoy valve seat contains a sealant reservoir that is filled through the external Alemite type fittings. Hand wheel operated and standard acting actuated valves such as Otis Type XS are to be filled with the valve in the closed position. Reverse acting valves such as Otis Type U are to be filled in the open position Procedure 1. Remove the caps from the two sealing compound fittings of the valve to be serviced. 2. Attach injection hose from the sealing compound supply to one of the fittings. 3. Inject the required amount of sealing compound as shown in Table below. Counting the injection time in seconds if the service skid is used or the number of strokes if a hand gun is used. Nominal valve size Weight Time Hand pump strokes Maximum Injection pressure 2" 43 gm 13s 18 3" 94 gm 28s 35 4" 128 gm 38s 50 Table Sealing Compound Per Fitting To Fill One Seat Reservoir 4. Remove hose and replace cap fitting. 8 WS-PWI&M EV 0.2

9 4. Repeat the procedure for the second fitting. 5. Fully open and close valve Trouble Shooting Leakage Possible corrective action Refer to Stem packing Fit new set of packing Bonnet gasket Fit new bonnet gasket Seat/body Replace seat and gate if necessary Seat gate Replace seat, gate or both as necessary Bonnet bleeder Replace ball and bleeder screw Sealing compound or body filler fittings Replace buried check valve and also fitting if necessary. Table McEvoy Valve Trouble Shooting Guide Pressure Testing - McEvoy Valves General This procedure describes the method for testing a McEvoy gate valve through the body filler port. Testing will include the pressure integrity of a seat and body pair, pair of gates and seats, body and bonnet gasket, bonnet bleeder, stem packing, and sealing compound fittings. Solid block trees require a separate test on each master valve, wing valve and swab valve Procedure 1. Ensure valve is fully closed and filled with sealing compound. For details refer to procedure Remove cap of body filler grease injection fitting. 3. Attach test manifold fitted with adapter 7/8" - 14 UNF female x 1/4" NPT male and connected to test pump and chart recorder. 4. Fill the valve body cavity with hydraulic oil from test pump. 5. Pressure test to working pressure of Xmas tree. Hold pressure for period of 15 minutes. 6. Check chart recorder for drop in pressure. Check bonnet gasket, bonnet bleeder, sealing compound fittings and stem packing for visible signs of leakage. No leakage is permitted. 7. Reduce body test pressure to 0 kpa. 8. Repeat Steps 5, 6, and 7 for a second test. 9. If two successful tests have been obtained remove test manifold and replace body filler fitting cap. Proceed to fill valve with grease. For details refer to procedure or 3.5.3, as appropriate. 10. Record results on appropriate test sheet. 11. If valve has failed to test report results to OPD/421. Await instruction for necessary corrective action. WSP-WI&M REV 0.2 9

10 3.5 Injecting Body Filler Grease - McEvoy Valves General A single Alemite Type ball check grease fitting is provided in the centre of each McEvoy valve body for the injecting of grease. THIS PROCEDURE REFERS TO HAND WHEEL OPERATED VALVES ONLY. ACTUATED VALVES MUST NOT HAVE BODY FILLER GREASE INJECTED UNDER ANY CIRCUMSTANCES. PROBLEMS HAVE BEEN EXPERIENCED WITH THE FUNCTIONING OF SOME ACTUATORS WHEN THIS HAS BEEN DONE. THE BODY FILLER PORT SHOULD BE FITTED WITH A BLANK PLUG INSTEAD OF AN ALEMITE FITTING TO PREVENT INADVERTENT FILLING WITH GREASE Procedure - Valve Closed Use this procedure if the valve can be closed. If it cannot be closed use procedure for when the valve is open or partially open. 1. Ensure valve is in closed position. 2. Open the bonnet bleeder. 3. Remove cap from body filler fitting. 4. Attach grease supply hose to the valve body filler fitting ensuring that adapter 7/8"- 14 UNF female x 1"-14 UNF male is attached to the grease hose. 5. Pump grease into body cavity until it discharges from the bonnet bleeder. GREASE INJECTION PRESSURE MUST NOT EXCEED THE WORKING PRESSURE OF THE VALVE. 6. Remove supply hose and replace cap fittings Procedure - Valve Open or Partially Open Use this procedure if the valve is open or partially open. Use procedure if the valve can be closed. 1. Remove cap from body filler fitting. 2. Attach grease supply hose to the valve body filler fitting ensuring that adapter 7/8"- 14 UNF female x 1"-14 UNF male is attached to the grease hose. 3. Pump grease into the body cavity. Measure the grease injection in accordance with Table below. GREASE INJECTION PRESSURE MUST NOT EXCEED THE WORKING PRESSURE OF THE VALVE. Nominal valve size Weight Strokes 2" 0.9 kg 3" 1.4 kg 4" 2.3 kg Table Grease To Fill One Valve 4. Remove supply hose and replace cap fittings. 3.6 Greasing Stem Bearing - McEvoy Valves General A single hydraulic type grease nipple is provided in the bonnet cap to enable the stem bearings to be lubricated using an ordinary hand held grease gun. 10 WS-PWI&M EV 0.2

11 3.6.2 Procedure 1. Install hydraulic-type hand grease gun on to the nipple provided in the bonnet cap. 2. Pump grease into the bearing until it comes out of the vent hole situated approximately 30 mm below the grease nipple. 3. Remove grease gun. 4. Rotate hand wheel back and forth to distribute grease around bearings. 5. Repeat steps 1-4 as required. 3.7 Testing Xmas Tree Valves Against Well Pressure - Oil Wells General The downstream gate and seat of each Xmas tree Valve may be tested with the closed in tubing head pressure (CITHP) from below and atmospheric pressure from above. A blind bean is to be fitted into the bean box. A block and bleed valve into the Xmas tree top cap and bean box cap are also to be fitted Procedure 1. Ensure that all the valves are closed and the well is shut in. 2. Open the bleeder on the bean box cap to vent any trapped pressure. 3. Remove the bean box cap by knocking off the hammer nut. 4. Remove the bean and fit the blind bean. 5. Refit the bean box cap and the hammer nut. 6. Install a block and bleed valve with a suitable pressure gauge for the well pressure into the bean box cap. 7. Open the gauge valve on the Xmas tree top cap to vent any trapped pressure. 8. Remove gauge valve. Install block and bleed valve with a pressure gauge suitable for the well pressure into Xmas tree top cap. 9. Open all valves on Xmas tree. Ensure valve on flowline remains closed. 10. Request OPD/11/12/13 or OPD/21 as appropriate to open SC-SSSV. 11. Record pressure shown on both gauges and report on appropriate form. 12. Close master valve. 13. Bleed off pressure through block and bleed valve in top tree cap. 14. Close block and bleed valve. Monitor pressure at Xmas tree cap for period of 15 minutes. Record results. 15. Open master valve and close swab valve. 16. Repeat Steps 13 and Open swab valve and close wing valve. 18. Bleed off pressure through block and bleed valve in bean box. 19. Close block and bleed valve. Monitor pressure at bean box cap for period of 15 minutes. Record and report results. 20. If Xmas tree is dual type repeat the procedure for the second string. 21. Close all valves on Xmas tree. 22. Open block and bleed valves to release any trapped pressure. 23. Remove block and bleed valves from the Xmas tree top cap and bean box cap. 24. Re-fit the original fittings. 25. Knock off bean box cap nut, remove blind bean and refit original bean. WSP-WI&M REV

12 26. Carefully check there is no leakage in the joints of the components that have been restored to the wellhead assembly. 27. Hand over well to OPD/11/12/13 or OPD/21 to restore production. 3.8 Testing Xmas Tree Valves Against Well Pressure - Gas Wells General The downstream gate and seat of each Xmas tree valve may be tested with the closed in tubing head pressure (CITHP) from below and atmospheric pressure from above. Request OPD/12/21/421 to isolate downstream of the flow wing and kill valves. Install a block and bleed valve with pressure gauge in both these sections, and also onto the Xmas tree top cap Procedure 1. Ensure that all the valves are closed and the well is shut in. 2. Open the gauge valve on the Xmas tree top cap to vent any trapped pressure. 3. Remove the gauge valve from the Xmas tree top cap and install block and bleed valve fitted with a pressure gauge suitable for the well pressure. 4. Remove the gauge valve from downstream of the flow and kill wing valves. field crew to advise position. Install block and bleed valve fitted with a pressure gauge suitable for the well pressure. 5. Open all valves on Xmas tree, but ensure valves on flow and kill wings remain closed. 6. Request OPD/12 or OPD/21 as appropriate to open SC-SSSV and ensure valves downstream of both flow and kill wings are closed. 7. Record pressure shown on all three pressure gauges and report on appropriate form. 8. Close bottom master valve. 9. Bleed off pressure through block and bleed valve in Xmas tree cap. 10. Close block and bleed valve. Monitor pressure for period of 15 minutes. Record and report results. 11. Open bottom master valve and close top master valve. 12. Repeat Steps 10 and Open top master and close swab valve. 14. Repeat Steps 10 and Open swab valve. Close flow wing valve. 16. Bleed off pressure through block and bleed valve downstream of flow wing. 17. Close bleed off valve and monitor for 15 minutes. Record and report results. 18. For dual completions only repeat Steps 1 to 17 for the second string. 19. For single completions test kill wing valve by following Steps 20 and Bleed off pressure through block and bleed valve downstream of kill wing valve. 21. Close bleed off valve and monitor for 15 minutes. Record and report results. 22. Remove all three block and bleed valves with pressure gauges and refit original fittings. 23. Return all valves to normal operating position and hand over well to OPD12/21/421 to restore production. 12 WS-PWI&M EV 0.2

13 3.9 Testing Bottom Flanged Connection - McEvoy Xmas Tree - Single Oil & Gas General The Xmas tree bottom flanged connection on single oil and gas wells, sizes 7.1/16" API psi, 7.1/16" API psi, 7.1/16" API - 10,000 psi and 11" API psi are to have the seals in the packoff pressure tested to the working pressure of the flange. Xmas trees with a 3" API psi flange do not require testing because they do not have a packoff. Two types of packoff can be found. The double P seals which packs off on a 5.1/2" or 6" diameter plain neck and a seal sub pocket that packs off on a 6.1/4" diameter seal sub with S seals on the outside diameter. The two types of packoff can be easily identified by the fittings in the flange outside diameter. The double P has two plastic packing ports and two test ports. The seal sub has one packing port and one test port Test Procedure - P Seals 1. Open bleeder screw in P seal test port and remove plug assembly. 2. Attach test manifold from portable test pump to test port. 3. Open bleeder in lower flange test port and remove plug assembly. 4. Screw unseating tool into flange test port and unseat ball in buried check valve. 5. Apply test pressure equal to working pressure of flange for a period of 15 minutes. Observe for any leakage from flange test port and record results. If leakage occurs the P seals may be re-energised. For details refer to procedure Reduce pressure to 0 kpa. 7. Repeat Steps 5 and 6 for a second test. 8. Remove test manifold and unseating tool. 9. Replace plug in P seal test port only and close bleeder Test Procedure - Between Lower P Seal, Ring Gasket, & Hanger Seals 1. Attach test manifold from portable test pump to the flange test port. 2. Screw unseating tool into the P seal test port and unseat ball check. 3. Apply test pressure equal to flange working pressure for a period of 15 minutes. Observe for leakage from P seal test port. Record results. 4. Reduce pressure to 0 kpa. 5. Repeat Steps 3 and 4 for a second test. 6. Remove test manifold and unseating tool. 7. Replace plug assembly in flange test port and close bleeder Energising Procedure - P Seals 1. Loosen bleeder screw in upper P seal packing port and remove plug assembly. 2. Install plastic packing injection gun. 3. Inject plastic packing. 4. Remove plastic packing injection gun and re-fit the plug assembly. 5. Repeat the procedure for the lower seal. WSP-WI&M REV

14 3.9.5 Testing Procedure - Seal-Subs With 6.1/4" Diam. S Seals on OD 1. Open bleeder in 1/2" NPT test plug and remove plug assembly. 2. Screw in unseating tool ensuring that tool stem is fully retracted before installation. 3. Unseat ball in check valve to bleed-off pressure. 4. Attach test manifold from portable test pump to outlet of the unseating tool. 5. Apply test pressure equal to working pressure of flange for a period of 15 minutes and record results. In the event of leakage, plastic packing may be injected through the plastic packing injection port following the same procedure as for PP Seals. For details refer to procedure Reduce the pressure to 0 kpa. 7. Repeat Steps 5 and 6 for a second test. 8. Remove the test manifold and re-seat the ball check by turning the handle of the unseating tool in a counter-clockwise direction. 9. Remove the unseating tool, refit the bleeder plug and close the bleeder Testing Bottom Flanged Connection - Xmas Tree (Dual Oil & Gas) General The Xmas tree bottom flanged connection on dual oil and gas wells have the packoff pressure tested to the working pressure of the flange. Flange size is either 11" API psi or 11" API 5000 psi and they both packoff on two 4.5/8" OD seal-subs with S seals on the OD. There are three ports in the flange, a 1/2" NPT test port, 1" NPT plastic packing port and a 3/4"-10 UNC packing relief valve port Testing Procedure - Between Seals Subs, Ring Gasket & Tubing Hanger 1. Open the test port bleeder and remove the plug assembly. 2. Screw in unseating tool, ensuring that tool stem is fully retracted before installation. 3. Unseat the ball in check valve to bleed-off the pressure. 4. Attach the test manifold from the portable test pump to outlet of the unseating tool. 5. Apply test pressure equal to flange working pressure for a period of 15 minutes and record the results. If leakage occurs, plastic packing may be injected in the plastic packing injection port following the same procedure as for P Seals. For details refer to Procedure Reduce pressure to 0 kpa. 7. Repeat Steps 5 and 6 for a second test. 8. Remove the test manifold and re-seat the ball check by turning the handle of the unseating tool in a counter-clockwise direction. 9. Remove the unseating tool, refit the bleeder plug and close the bleeder. 14 WS-PWI&M EV 0.2

15 3.11 Testing Studded Connection Between Double Studded Adapter & Tubing Hanger Necks General The seals in the bottom of the double studded adapter flanges are exactly the same as found in the bottom flange of the Xmas trees. To test these seals identify type of completion and type of packoff. Follow same procedure as Xmas tree. For details refer to procedure 3.9 or 3.10, as appropriate Testing Seals on Extended Neck & Outside Diameter - Cameron BRX Casing Hangers General The Cameron BRX casing hanger has an extended neck with seals on the OD. These seals packoff in the bottom of the tubing head or casing head above. It also has a seal or seals on its OD that seal in the casing head bowl in which it sits. The annular space between the outside of the hanger and the ring joint must be pressure tested as per the table in procedure A test port and plastic packing port are provided in the hub above the clamp for this purpose Procedure THE TEST PRESSURE FOR THE 9.5/8" AND 13.3/8" CASING HANGERS ARE LESS THAN THE WORKING PRESSURE OF THE CLAMP CONNECTION. THIS IS TO ELIMINATE THE DANGER OF COLLAPSING THE CASING IN THE EVENT OF A SLIP TYPE CASING HANGER HAVING BEEN USED IN THE ORIGINAL COMPLETION. 1. Open bleeder in 1/2" NPT test plug and remove plug assembly. 2. Screw in check valve unseating tool ensuring tool stem is fully retracted before installation. 3. Bleed off pressure. 4. If pressure does not bleed-off ensure ball re-seats and inject plastic packing. For details refer to procedure Attach test manifold to outlet of unseating tool. 6. Apply the appropriate test pressure in accordance with Table below for a period of 15 minutes and record results. Clamp connection size Casing size Test pressure 20.3/4" psi No. 17 RX /8" 7000 kpa 13.5/8" psi No. 11 RX57 9.5/8" 14,000 kpa 13.5/8" psi No. 13 BX /8" 14,000 kpa 11" psi No. 9 RX53 7" 21,000 kpa 11" psi No. 10 RX54 7" 35,000 kpa 7. Reduce pressure to 0 kpa. 8. Repeat Steps 6 and 7 for second test. Table Cameron BRX Seal Testing 9. Remove unseating tool and test manifold. 10. Refit plug assembly in test port and close bleeder. WSP-WI&M REV

16 3.13 Stem Packing Replacement - McEvoy Valves General This procedure describes how to remove and install a set of stem packing in a McEvoy Model C hand wheel operated valve. During this operation the stem is back seated which means that if required the packing may be safely renewed with pressure in the valve Procedure 1. Fully close valve. 2. Unscrew bonnet cap two turns. 3. Backseat stem by further closing valve. 4. Check stem back seated by further unscrewing bonnet cap and attempting to further close valve. When no movement of the hand wheel occurs the stem is back seated. 5. Loosen the bonnet bleeder screw to release any pressure trapped between the stem backseat and the packing. IF PACKING IS BEING REMOVED WITH PRESSURE INSIDE THE VALVE. A POSITIVE BACKSEAT MUST BE OBTAINED AND ALL PRESSURE RELEASED AS DESCRIBED IN STEP 5 BEFORE REMOVAL OF THE BONNET CAP. A MODERATE AMOUNT OF FORCE MAY BE REQUIRED ON THE HANDWHEEL TO OBTAIN AN ABSOLUTE SEAL ON THE BACKSEAT. DO NOT USE CHEATERS OR WRENCHES. 6. Remove hand wheel and bonnet cap. 7. Remove top bearing, split bearing keeper, bottom bearing and packing retainer. 8. Remove bonnet bleeder and ball. 9. Remove stem packing. This may be done by either pumping grease into this bonnet bleeder hole or by digging it out with a small prong or packing hook. 10. Carefully clean out packing bore. 11. Install new set of packing one ring at a time, lightly coating each ring with Alvania grease before installation. Ensure lips of rings are not turned up or damaged. 12. Reinstall packing retainers, bottom bearing, bearing keeper, top bearing and bonnet cap. 13. Install hand wheel and turn in the direction to open valve at the same time tighten the bonnet cap to take up the slack caused by the stem moving into the valve. When no more slack is created by moving the hand wheel in the opening direction securely tighten the bonnet cap. 14. Reinstall the bonnet bleeder and ball Bonnet Gasket, Gate & Seat Replacement - McEvoy Valves General The McEvoy Model C Gate Valves in service with have press-fit seats. It is necessary that each replacement seat has its hub machined to an exact size to give an interference fit with the seat counter bore in the body. The bonnet gaskets are made from soft steel. A new one should always fitted when the bonnet is removed Procedure to Replace Bonnet Gasket & Gates 1. Fully close valve. 2. Loosen the bonnet bleeder and ensure all pressure is bled from the valve cavity. Alternatively if the valve is fitted with an actuator without a bonnet bleeder. Bleed off through body grease filler fitting by removing fitting and installing check valve stinger. 3. Loosen and remove the bonnet nuts. 16 WS-PWI&M EV 0.2

17 4. Lift the bonnet assembly from the body a sufficient distance to allow gates to be clamped together with a C-clamp. 5. Clamp the gates together and pull the whole assembly from the body. 6. Remove C-clamp. 7. If necessary replace the seats. For details refer to procedure Remove the old bonnet gasket. 9. Clean the body and bonnet gasket face. Install a new bonnet gasket lightly smeared with McEvoy sealing compound. 10. Fit the new springs and trash ring into the pair of gates. 11. Install on lifting nut attached to stem/bonnet assembly. 12. Clamp together with a C-clamp. 13. Push the gates into the body until the clamp can be safely removed. 14. Push bonnet assembly until bonnet seats on the body. 15. Install bonnet nuts and tighten in sequence Preparation of Replacement Seats Before removing the seats replacements must be on hand. These must have their hubs exactly machined to give an interference fit with the body seat counter bore. The actual diameter of the counter bore is stamped on the valve body. Single valves on the outside diameter of the body bonnet flange, directly above the seat. Block trees on the back face above the sealing compound fitting for each individual counter bore. If the counter bore size has been obliterated, it must be measured with an inside micrometer to find the exact size. The seat hubs must be machined slightly larger than the body counter bore as follows: 2" size within a range of mm to mm. 3" size within a range of mm to mm. 4" size within a range of mm to mm. To ensure the correct replacement seats are fitted it is essential that in addition to the counter bore size, seat part number or the following information from the valve or block tree assembly be given. Serial Number. Figure Number. Nominal Size. Assembly Number. Type - Single valve or block tree and cast or forged bodies. The 3" and 4" size seats used on cast valves have short hubs whilst those used on forged valves have long hubs. The 2" size has only one type of seat used on both cast and forged valves. Xmas tree block bodies made from castings can be recognised by their curved shape and the forged type by its square shape Procedure to Replace Seats 1. Remove the bonnet and gates. For details refer to procedure Insert and correctly position the hydraulic seat extraction tool into the valve bore. 3. Connect the hydraulic pump to seat extraction tool, pump out and remove the seat. 4. Clean and inspect the seat counter bore in the valve body. 5. Check that the replacement seat matches the seat taken out. The hub is turned to give the correct interference fit. For details refer to procedure Coat the outside diameter and the replacement seat hub with McEvoy sealing compound. 7. Install the hydraulic seat press into the bore. WSP-WI&M REV

18 8. Insert and level the seat in its counter bore. 9. Align centreline of the seat sealant reservoir with that of the bonnet gasket. 10. Push the grease piston to bottom of the sealant reservoir. 11. Insert the alignment plate between the fixed seat and seat press. 12. Connect the hydraulic pump to seat press and pump seat into the body, ensuring the seat remains square with the body centreline during this operation. 13. Repeat the same procedure for the second seat Field Gauging Body & Bonnet Nut Threads - Cameron H2 Chokes General The bonnet nuts of Cameron chokes are frequently removed for access to the choke bean. The repeated threading and unthreading of this nut results in metal loss due to wear. Further metal loss also occurs due to corrosion. Over a long period of time this metal loss can reduce the threads to a point of failure resulting in a potentially dangerous situation. Therefore, it is important that each time a bonnet nut is removed that the male stub acme thread of the body be carefully inspected for metal loss due to corrosion or wear. If the thread is found to be unacceptable the choke must be replaced. The bonnet nut must always be replaced and the old one returned to OPD/421 as appropriate for inspection. The stub acme threads on the body and bonnet should have a flat on the crest. Parts with a rounded form are to be scrapped. The following gauges are required. Gauge Purpose No-go ring gauge To check the major diameter of the external body threads. No-go plug gauge To check the internal bonnet nut threads. Thread profile gauge To check for metal loss on the thread flanks of the external body thread. 150 mm calliper To measure the major diameter of the external body thread and the minor diameter of the bonnet nut thread. Table Ring and Plug Gauge Cameron H2 Chokes Prior to use, all gauges must be checked to make sure they are not past due for calibration. The due date is identified on the sticker affixed to the gauge. Past due gauges should be returned CIW/Willis for calibration. When not in use the gauges should be protected and stored in a secure area. A 75 mm and 100 mm micrometer ground standard should be used daily to verify accuracy of the 150 mm calliper Procedure for Gauging External Body Threads 1. Thoroughly clean threads with a wire brush and solvent. 2. Visually inspect profile of the thread and remove any burrs that may prevent accurate gauging. 3. Attempt sliding appropriate ring gauge over the body threads. Bodies that accept the ring are to be scrapped. 4. Measure the outside diameter of the thread with the calliper across two points at 45º to the left and right of the vertical axis. Any bodies with a thread measurement at any point equal to or less than 88.4 mm on the 2" nominal size chokes or mm on the 3" chokes are to be scrapped. 5. Check thread profile with appropriate profile gauge in the following three places. Lowermost portion of thread. 120º to right. 120º to left. 18 WS-PWI&M EV 0.2

19 6. Scrap any choke that does not meet the acceptance criteria Procedure for Gauging Internal Thread of Bonnet Nuts 1. Disassemble blanking plug from bonnet nut and thoroughly clean threads of nut with wire brush and solvent. 2. Visually inspect profile of thread and remove any burrs that may prevent accurate gauging. 3. Screw in appropriate plug gauge. 4. The plug gauge must be threaded in and out by hand. NEVER USE A WRENCH ON A PLUG GAUGE. NEVER FORCE THE PLUG GAUGE INTO THE THREADS. 5. The threads are acceptable if the following apply. The gauge does not enter. The gauge can be entered provided that a definite resistance due to friction from contact and a complete stop occurs on or before the second complete turn of entry. The gauge should not be forced after the resistance is definite. Bonnet nuts accepting this gauge two turns with shake are unacceptable. Bonnet nuts accepting this gauge more than two turns are unacceptable. 6. Check the inside diameter of the thread. 7. This must measure on or between / mm for 2" chokes and / mm for 3". Nuts outside this range must be scrapped Assembly 1. Coat threads of both body and bonnet with a thread lubricant having corrosion and wear inhibiting qualities. A high viscosity dry film impregnated grease is recommended. 2. Assemble blanking plug to nut and screw on to body using a pipe wrench. A torque of 136 J for the 2" choke and 340 J for the 3" choke is recommended. C H A P T E R 4.1 Introduction 4. F M C W E L L H E A D S & V A L V E S On the onshore field the FMC Xmas trees are used on beam pump oil wells only. The extended neck tubing hanger packoff in the bottom of the Xmas tree is tested through a single bleeder plug located in the flange outside diameter. The routine maintenance for the FMC Model 120 gate valve is lubrication of the stem bearing and filling the body cavity with grease. The valve stem can be back seated allowing the packing to be changed whilst the valve is in service. The valve has a single gate with a pair of ring seats which means it cannot easily be field tested. Therefore, it is not recommended to change the gate and seats in the field. If this is found to be necessary the valve or tree should be changed out and sent back to the workshop for repair. 4.2 Injecting Grease - FMC Valve Bodies General Grease is injected into the FMC gate valve body cavity through the bonnet bleeder plug, located on the outside diameter of the bonnet flange. WSP-WI&M REV

20 4.2.2 Procedure 1. Ensure that the valve is in closed position. 2. Remove the cap from the bonnet bleeder plug. Use a back-up wrench on the bleeder plug to ensure that it does not unscrew from the bonnet. 3. Attach grease supply hose from service unit. 4. Pump grease into the valve body until pressure builds up. GREASE INJECTION PRESSURE MUST NEVER EXCEED THE WORKING PRESSURE OF THE VALVE. 5. Open the valve slightly to relieve the pressure. 6. Continue pumping until the body cavity is filled with grease. 7. Disconnect the grease supply from the bonnet bleeder plug and replace the cap. 8. Fully close the valve. 4.3 Greasing Stem Bearing - FMC Valves General A single hydraulic type grease fitting is provided in the bonnet cap to enable the stem bearings to be lubricated using an ordinary hand held grease gun Procedure 1. Install hydraulic type hand grease gun on to the grease fitting provided in the bonnet cap. 2. Pump grease into the bearing. 3. Remove the grease gun. 4. Rotate the hand wheel back and forth to distribute grease around bearings. 4.4 Replacing Stem Packing - FMC Valves General The FMC Model 120 gate valve can be back seated allowing the stem packing to be replaced with the pressure inside the valve. Whilst the packing set is being renewed the stem bearings, packing nut seal and bonnet cap weather seal should be carefully examined. Replace if necessary Procedure 1. Fully close the valve. 2. Roll the bonnet cap weather seal up out of the way. 3. Unscrew the bonnet cap three or four turns until it touches the hand wheel. 4. Turn the hand wheel to close the valve until the stem backseats in the bonnet. 5. Apply a reasonable amount of force on the hand wheel to ensure the stem backseats. 6. Remove the cap from the bonnet bleeder plug. Use a back-up wrench on the bleeder plug to ensure that it does not unscrew from the bonnet. 7. Attach the WKM pressure releasing tool to the bonnet bleeder plug. 8. Turn the handle of the PRT (pressure release tool) in a clockwise direction to unseat the ball check, release the ball check and release any trapped pressure. 20 WS-PWI&M EV 0.2

21 IF THE PACKING IS BEING REPLACED WITH THE PRESSURE INSIDE THE VALVE AND THE PRESSURE DOES NOT BLEED-OFF, BUT CONTINUES TO ESCAPE FROM THE PRT. RESEAT THE BALL IN THE BONNET BLEEDER PLUG BY TURNING THE HANDLE OF THE PRT IN AN COUNTER CLOCKWISE DIRECTION. TURN THE VALVE HAND WHEEL A COUPLE OF TURNS IN THE OPENING DIRECTION AND REPEAT STEPS 4 AND 5. IF A SUCCESSFUL BACKSEAT STILL CANNOT BE OBTAINED THEN THE VALVE MUST BE ISOLATED AND THE PRESSURE BLED TO 0 KPA BEFORE PROCEEDING. 9. Pull the quick release pin from the hand wheel and remove it. 10. Remove the stem shear pin using a hammer and punch. 11. Remove the bonnet cap. 12. Remove the outer bearing, split retainer and the inner bearing. 13. Unscrew the packing nut by turning it anti-clockwise with an adjustable wrench. 14. Remove the PRT from the bonnet bleeder plug. 15. Connect the grease supply hose to the bonnet bleeder plug and pump out the stem packing. If all the packing rings do not come out of the bonnet use a packing hook to remove the remaining rings. Take care not to scratch the stem or bonnet packing areas. 16. Disconnect grease supply hose and replace the cap on the bonnet bleeder fitting. 17. Thoroughly clean the stem inside of bonnet, packing nut, split ring and bonnet cap using a suitable solvent. 18. Inspect the bearings and replace if necessary. 19. Inspect the stem and bonnet packing areas for burrs. Remove any burrs with emery cloth. 20. Lightly grease the packing bore of the bonnet and the exposed part of the stem. 21. Correctly assemble a new set of stem packing. Carefully install over the stem and into the bonnet packing chamber one ring at a time. Take care not to damage any of the packing ring lips. 22. Inspect the seal inside the packing nut. Replace if necessary. 23. Lightly grease the threads and bore of the packing nut and install over the stem, using it to press the packing set into the bonnet. 24. Screw in the packing nut using an adjustable wrench. Tighten using approximately 95 J torque. 25. Pack the bearings with grease. 26. Install the inner bearing with the cage to the packing nut. 27. Install the split retainer and the outer bearing with the cage facing outwards towards the end of the stem. 28. Inspect the wiper seal inside the bonnet cap. Replace if necessary. 29. Lightly grease the bonnet cap threads and install it on the bonnet, but do not tighten. 30. Install the shear pin into the stem. The pin should project equally from both sides of the stem. If necessary lightly tap the pin with a hammer until it is correctly positioned. 31. Install the hand wheel and push in the quick release pin. 32. Rotate the hand wheel a few turns in the opening direction to lift the gate off the bottom of the body. 33. Torque up the bonnet cap using approximately 135 J force. 34. Roll the bonnet cap weather seal into place between the bonnet cap and the bonnet. WSP-WI&M REV

22 35. Connect a hydraulic type hand grease gun to the bearing grease fitting and inject grease into the bearing chamber. 36. Open and close the valve fully at least twice to ensure the valve operates smoothly. 37. Return the valve to normal operating position. 4.5 Testing Bottom Flanged Connection - FMC Xmas Tree General The bottom flanged connection of the FMC Xmas tree packs off on the extended neck of the tubing hanger. A single test port is provided in the bottom flange of the tree to enable the annular space between the seals on the tubing hanger and the ring gasket to be pressure tested Procedure 1. Remove the cap from the blanking plug in the test port using a back-up wrench on the plug to ensure that it does not unscrew from the flange. 2. Screw on pressure releasing tool ensuring that the stem is fully retracted before installation. 3. Bleed off any pressure by turning the handle in a clockwise direction to unseat the ball check in the blanking plug. 4. Attach the test manifold from the portable test pump to outlet of the pressure releasing tool. 5. Apply test pressure equal to the working pressure of the Xmas tree bottom flange for a period of 15 minutes and record the results. 6. Reduce the pressure to 0 kpa. 7. Repeat Steps 5 and 6 for a second test. 8. Remove the test manifold from the pressure releasing tool. 9. Ensure that all the pressure has been bleed off from the tree flange. Remove the pressure releasing tool from the blanking plug and re-fit the cap. 4.6 Installation - TC-M-ET Tubing Head This procedure applies to the 13.5/8" 5,000 psi x 11" 3,000 psi and the 11 5,000psi x 3,000psi tubing heads Installation of Tubing Head Spool 1. Check the inside diameter of the top bowl to be certain that the tubing spool is compatible with the hanger. 2. Inspect the CIW bottom X-bushing profile for proper ID and depth to accept the CIW extended neck hanger. 3. See that all tubing head ET lockdown screws operate freely and are fully retracted. 4. Check all attached valves for smooth operation. 5. Examine the tubing spool and previous casing spool ring-gasket grooves and mating surfaces for foreign material, burrs or other damage. 6. Make sure the correct number, size and types of ring-gaskets, clamp hubs, and bolts and nuts are on hand. 7. Lightly grease the CIW casing hanger extended neck. 8. Fill cavity area of the CIW casing spool with light oil. 9. Clean the ring grooves and install the BX-160 ring-gasket for 13.5/8" psi WP clamp hub, or RX-54 ring gasket for the 11 5,000psi WP clamp hub. 22 WS-PWI&M EV 0.2