INTERNALTRAINING PROGRAM:
INRODUCTION TO STATIC EQUIPMENT
TABLE OF CONTENT
• Introduction of wellhead, Xmas
tree and pipeline valves.
• Product knowledge/sharing
i.
ii.
iii.
iv.
v.
Casing program
Tubing Hanger
Casing Hanger
Surface wellhead system
Pipeline valve / Header
• Conventional Wellhead Equipment
• Equipment and Products
• Preventive Maintenance
i.
ii.
iii.
iv.
v.
Definition
Scope of work
Procedures
Problematic factor
Diagnostic &
troubleshooting
vi. Basic cares
• Corrective maintenance
i.
ii.
Definition
Troubleshooting
• To expose all Essem technical team to
static equipment.
• To fit business needs exactly, adapting
some elements and omitting any
considered unnecessary for the job.
• To enable the employee to learn how to
do the job, its purpose and how it fits
into the corporate strategies.
• Relationship between department as
well as ESSEM Group.
PRODUCT KNOWLEDGE
& SHARING
WELLHEAD AREA / ZONE
Hatch Cover
Main/Wireline deck
Wellhead deck
Production deck
Casing Completion
Christmas Tree &
Wellhead equipment
WELLHEAD AREA / ZONE
SURFACE WELLHEAD SYSTEM
DEFINITION
• Wellhead refers to all permanent equipment
between the uppermost portion of the surface
casing and the tubing head adapter
connection. Wellhead valves includes (but not
limited to) the casing head valves for surface
isolation of the annulus casing which are
commonly manually operated.
• – WRM. Section 2. Rev 02
CONT…
Function :
“Surface wellhead system
is an assemblies of tubing
spool And multiple sizes of
casing spool on top of well
formation”
• Anchor & connection for each
individual casing.
• Pressure isolation of individual
casing.
• Connection for completion
string.
• Isolation of production annulus.
• Access to annulus for pressure
monitoring.
• Type of wellhead design:
i. Conventional Wellhead
(modular)
ii. Compact Wellhead (sub-sea)
CHRISTMAS TREE SECTION
D - Section
Christmas Tree
Tubing Head Adapter (optional)
Christmas Tree Adapter
Seal Flange
Adapter Flange
C - Section
Tubing Spool
Tubing Head
B - Section
Intermediate Head
Casing Spool
A - Section
Lowermost Casing Head
Casing Head Housing
Starting Head
WELLHEAD & CHRISTMAS TREE
SECTION
• SECTION A
refers to the Casing Head which is located at the bottom of the wellhead completion and a shallower
version of surface casing. This section is where Conductor Casing Pressure (CCP) is obtained.
• SECTION B
refers to the on top of the Casing Head which is also called as Casing Spool where Surface Casing
Pressure (SCP) is obtained.
• SECTION C
refers to the Tubing Head or Tubing Spool which is located at the bottom of Christmas tree or on top of
the Casing Spool. This section is where Production Casing Pressure (PCP) value is collected.
• SECTION D
is the Christmas Tree comprising of Masters, Wing and Crown Valves.
CONVENTIONAL WELLHEAD LAYOUT
WITH CHRISTMAS TREE
WELLHEAD & CHRISTMAS TREE
SECTION
Definitions
of
CASING
Steel Lining run into the wellbore and
cemented in place to give permanent
protection from contaminating fluids,
pressure tightness and PREVENTIVE
WELLBORE COLLAPSE
Various casing strings are run &
cemented in a well
• Conductor
• Surface casing
• Intermediate casing
• Production casing
• Liner
Overall Function of Casing
• Protect against borehole collapse
• Prevent unwanted leakage into or from
formations
• Provide wellhead foundation
CASING PROGRAM
“Each type of casing
string is suspended
in CHH & assembled
on module stack
that forms
wellhead”
CASING DESIGN
CASING FUNCTION
•
Protect
collapse.
•
Prevent unwanted leakage into
or from formations.
•
Provide concentric bore for
future operations.
•
Provide wellhead foundation.
against
borehole
CASING FUNCTION:
CONDUCTION/PIPE
• Prevents
unconsolidated
formations being eroded.
• Provides flow path for drilling
fluids.
• Cemented in pre-drilled hole or
pile driven.
• Sizes ranging from 16” –30” OD.
• Depth varies from surface to 40’
–400’.
CASING FUNCTION:
SURFACE
• Protection in case of blowout & Acts
as wellhead foundation.
• Isolates shallow consolidated & fresh
water formations.
• Cemented along its whole length.
• Sizes ranging from 13 ⅜” –20” OD.
• Setting depth up to 1 500’ below
surface.
CASING FUNCTION:
INTERMEDIATE
• Seals off problem zones, loss circulation zones,
high pressure gas pockets & soft formations
encountered.
• Protects production casing from corrosive
fluids.
• Cemented up to surface casing shoe.
• Sizes ranging from 7” –13 ⅜” OD.
• Depth depends on total well depth &
conditions encountered, shallow wells not
necessary to set this.
CASING FUNCTION:
PRODUCTION
• Isolates reservoir from other fluid bearing
formations.
• Set above or through producing formations.
• Cemented from intermediate casing shoe to its
bottom.
• Sizes ranging from 5” –9⅝” OD.
PRODUCTION TUBING
Function :
• Medium to convey well fluids from wellbore to surface or vise
versa & prevent well effluents expose to casing.
Thread Connections
• API :
Tapered thread & rely on thread compound to effect seal
• Premium :
Metal-to-Metal seal
PRODUCTION TUBING
Tubing Selection Governed By:
i. Well peak production rate
ii. Well depth
iii. Use of WL tools
iv. Pressure & temperature
v. Annulus differential pressure etc
CASING HEAD
CASING HEAD SYSTEM:
GENERAL STACK UP
CASING HEAD:
HOUSING
CASING (STARTER) HEAD
Description
• Casing head is the lowest part of the wellhead assembly and is connected
to the surface casing string. Supports the remaining parts of the wellhead
and completion equipment.
Functions
• Provides a means for attachment to surface casing string
• Provides for suspending and packing off next casing string, usually the first
immediate string
• Supports Blowout Preventers (BOP) while hole is drilled for the first
immediate
• Provides outlets for fluid returns coming up the annulus
• Provides a mean to a test Blowout Preventers (BOP) while drilling
CASING HEAD
IDENTIFICATION (CASING HEAD)
•
•
•
•
•
•
•
•
•
Information :
Type (casing bowl)
Bottom connection & press rating:
Top Connection & press rating:
Bottom prep:
Outlet size & press rating:
Outlet type:
Temp class:
PSL:
Material Class:
Example :
C-29-ET
13 5/8 – 5,000 psi API Flange
13 5/8-5,000 psi API flange
Slip-on weld (SOW)
2-3,000 psi
Line Pipe (LP)
S to U
2
EE
Description:
• CASING HEAD BODY, C-29-ET, 13 3/8 SOW X 13 5/8-5K FLG TOP, W/ TWO 2 LPO W/ TEST PORT,
EE, S-U, PSL 2
CASING SPOOL
Description
Like a casing head, casing spool has a bowl which holds the casing hanger that
suspends a string of casing.
Functions
 Provides a load shoulder in the top bowl to support a casing hanger
 Provides a controlled bore in the top bowl of the casing hanger seal
 Provides a seal in the bottom bowl to pack off the previous casing string and
isolate flange or hub seals and casing hanger seals from internal casing
pressure
 Provides outlets for fluid returns coming up the annulus
 Provides a port for pressure-testing casing seals and flange connection
 Provides a mean to a test Blowout Preventers (BOP) while drilling
CASING SPOOL
IDENTIFICATION (CASING SPOOL)
Information :
Example :
• Type (casing bowl)
TCM-ET
• Bottom connection & press rating
13 5/8”-5,000 psi API flange
• Top Connection & press rating
11”-5,000 psi API flange
• Bottom prep
Double FS Seal
• Outlet size & press rating
2 1/16”-5,000 psi
• Outlet type
Studded
• Temp class
S to U
• PSL
2
• Material Class
EE
Description:
• TUBING HEAD BODY, TCM-ET, 13 5/8-5K FLG BTM X 11-5K FLG TOP, W/ TWO 2 1/16-5K STDD
• OUTS W/ FS SEALS & CAVITY TEST PORT, EE, S-U, PSL 2
CASING HANGER
1) Suspends Intermediate Casing
String
2) Seals Off Casing Annulus
Casing Hanger Types
Manual Slip-type Casing Hangers
Automatic Slip-type Casing Hangers
Manual Mandrel Hangers
Automatic Mandrel Hangers
Description
• Casing hangers – to hold or “hang” casing strings, hence allow the
weight of a casing string to be transferred to a casing head/spool.
• Two major types – Slip-type (installed around the casing) or mandrel
type (made up into the string)
Functions
• Suspend the casing load from a casing head/spool
• Center the casing string in the head/spool
• Provides a pressure-tight seal against the inside of the casing
head/spool bowl to contain pressure in the annulus between casing
string and the previous string
TUBING HEAD/SPOOL
Description
• Tubing Head is the top spool on a surface
wellhead assembly. It is installed after the
last casing string (production) to hold the
Tubing Hanger.
Functions
•
Provides a load shoulder in the top bowl to support tubing
hanger and pack off
•
Provides a controlled bore in the top bowl of the tubing hanger
seal
•
Provides a seal in the bottom bowl to pack off the previous casing
string and isolate flange or hub seals and casing hanger seals
from internal casing pressure
•
Provides outlets for fluid returns coming up the annulus
•
Provides a port for pressure-testing casing seals and flange
connection
•
Provides a mean to a test Blowout Preventers (BOP) while drilling
Tubing Spool Features:
• Connections
Size & pressure rating must be compatible of joining
connections.
• Upper Bowl
Provides seal area for tubing hanger
• Lower Bowl
Provide isolation seal
• Tie Down Bolt
Secure & prevent upward movement due to pressure surges.
Energizes body seal on tubing hanger.
• Outlets
Access to ‘A’ annulus (pressure monitoring or gas lift).
• Test Port
Permit pressure testing to hanger seal, lock-down screw
packing connection
between flanges & secondary (isolation) seal.
ANATOMY OF THE TUBING HEAD
Top connection
Ring gasket groove

API Flanged

BX RG


RX RG
FMC Speedloc SEG
CLP
Bowl

CIW CLP HUB

TCM-ET


TC-WD
Flamp (Flange +
CLP)
Lockdown Screws
Load Shoulder
(LDS)
Outlet connection
Bottom connection

API Flanged

FMC Speedloc SEG CLP

CIW CLP HUB

Flamp (Flange + CLP)
Bottom prep

FS seal

FX-RCMS

Studded

Line Pipe
Thread

Flanged
Test Port/s
IDENTIFICATION (TUBING HEAD)
Information :
Example :
Type (casing bowl)
Bottom connection & press rating
Top Connection & press rating
Bottom prep
Outlet size & press rating
Outlet type
Temp class
PSL
Material Class
TCM-ET
13 5/8”-5,000 psi API flange
11”-5,000 psi API flange
Double FS Seal
2 1/16”-5,000 psi
Studded
S to U
2
EE
Description:
TUBING HEAD BODY, TCM-ET, 13 5/8-5K FLG BTM X 11-5K FLG TOP, W/ TWO 2 1/16-5K STDD
OUTS W/ FS SEALS & CAVITY TEST PORT, EE, S-U, PSL 2
TUBING HANGER
Features :
1. Landing Threads
Uppermost threads on the hanger & support the
entire tubing string weight during landing
operations.
2. Bottom Thread
Support entire tubing string weight & seal producing
conduit from the tubing/casing annulus.
3. Sealing Area
Provide compression type sealing between hanger
seal OD & tubing spool ID. Sealing is accomplished
by energizing elastomer seals or metal-to-metal
seals by tubing weight action on various load
bearing surfaces,
SURFACE CONTROLLED
SUBSURFACE SAFETY VALVE (SCSSV)
DEFINITION
• The Subsurface Safety valve (SSSV) is a safety device
installed in the tubing string of the well.
• It is designed to prohibit flow from the wellbore in the
event of emergency. Specifically, its purpose is to prevent
an uncontrolled flow of hydrocarbons to the surface (i.e.
“blow-out”) in the event that, due to a catastrophic
event, the wellhead is rendered inoperable.
• In a very true sense, the SSSV is the first line of defence
against a “blow-out” of a producing well.
• – WRM. Section 3. Rev 02
2 Main type of SCSSV
1. WRSCSSV
• WR-SCSSVs are run separately from the tubing string
• WRSCSSV installed in a Safety Valve Landing Nipple (SVLN) using conventional
wireline techniques.
• The advantage of the WR-SCSSV is that, should it fail, it can be pulled out of hole for
change-out or for repairs, using a relatively inexpensive wireline unit.
• The disadvantage of the WR-SCSSV is that it creates a restriction to flow.
2. TRSCSSV
• The TR-SCSSVs are installed as an integral part of the tubing string.
• Installed as part of the original completion with the hydraulic control line being
attached directly to the TR-SCSSV as it is run in the hole
• TRSCSSV only can be pulled out of the well when the tubing string is pulled.
• The advantage of the TR-SCSSV is that it is “full-bore”, meaning that when opened it
has the same internal diameter as the tubing string ID.
• TRSCSSV can be permanently lock open and replaced by the insert valve which is to
be installed using wireline.
3 Types of closure mechanism
1.
Poppet
Poppet type, a spring holds the valve open
during normal flow. When the flow
reaches a specified rate, the tension in a
retention spring is overcome and the
valve closes.
2.
Ball
Ball type, this closure mechanism uses a
spring and piston to keep the valve
normally open. When pressure differential
exist across the ball, the piston moves up,
causing the ball to rotate about
mechanical linkage to the closed position.
3.
Flapper
Flapper type, the closing mechanism of
the flapper operates similarly to the ball
and poppet. The valve closes when piston
is forced upward due to loss of force on
the spring tension.
CHRISTMAS TREE ASSEMBLES
DEFINITION
• Christmas tree refers to ASSEMBLY of EQUIPMENT, including
tubing head adapter, valves, tees, crosses and top
connectors attached to the uppermost connection of the
tubing head, used to control the well stream for production
or injection. Christmas tree valves includes (but not limited
to) lower master valve, upper master valve (SSV), crown
valve and wing valve. Operation modes of these valves are
as follows:
• - WRM. Section 2. Rev 02
CHRISTMAS TREE EQUIPMENT
Lower Master Valve (LMV)
: Manually operated.
Surface Safety Valve (SSV)
: Automated, either pneumatic or Upper Master
(w/o) actuator hydraulic control.
Crown/Swab Valve (CV)
: Manually operated.
Wing Valve (WV)
: Manually or automated, either pneumatic or
hydraulic control.
Secondary Surface Safety valve
(between WV and Choke valve)
control system.
: Automated, either pneumatic or hydraulic
CHRISTMAS TREE EQUIPMENT
CHRISTMAS TREE EQUIPMENT:
VALVE FUNCTION
CHRISTMAS TREE EQUIPMENT:
VALVE FUNCTION
CHRISTMAS TREE EQUIPMENT:
VALVE OPERATION & BASIC CARE
Surface valves manifold to control flow of well fluids & access for well intervention activities.
Below are individual valve operational and general basic care :
Lower Master Valve (LMV)
Manual, must be left in open
position in ideal condition – Only
close this valve if really needed e.g.
use as a barrier for valve repairing
purpose
Upper Master / Surface Safety
Valve (SSV)
Manual or automated, must be left
in open position in ideal condition.
Only
close
during
valve
maintenance intervention
Flow Wing Valve (FWV)
Permit passage of well fluids to
choke valve – use to shut in valve the
system
Crown Valve (CV)
Permit entry of well interventions –
always in close position
CHRISTMAS TREE EQUIPMENT:
STANDARD TYPE
The valve used in X’mas tree are invariably of the GATE type providing
full bore access to the well. These valves must be operated in the fully
open or fully close position.
Christmas Tree Types :
I. Solid Block
II. Composite Block
III. Horizontal Xmas tree (subsea)
CHRISTMAS TREE EQUIPMENT:
STANDARD TYPE
CHRISTMAS TREE EQUIPMENT:
EXAMPLE OF GATE VALVE MODEL
2 types of operating valve (Service Scope):
• Manual valve
• Actuated valve
Type of gate valves :
• Expandable
• Slab / Floating
ACTUATED VALVE
WHAT IS ACTUATOR
A gate valve actuator is
the combination of a
piston and a set of
springs that are used to
hydraulically/pneumatic
ally/electrically
open
and close a gate valve
WHAT IS ACTUATOR
WHAT IS ACTUATOR
HOW THE ACTUATOR FUNCTION??
MANUAL VALVE
GATE VALVE MODEL:
EXPANDABLE
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
X.
XI.
XII.
XIII.
2 1/16” to 4 1/16”
2000 to 5000 psi
Expanding gate design
Mechanical seal
Stem packing can be re-energized
Body cavity isolated from flow
Uni-directional
Cast body
2 body grease ports
Packing injection fitting
No backseat capability
Butterfly handwheel
2-1/16” to 4-1/16”
One piece bonnet means ‘ Tighten
Hand-Wheel’ after gate stops
GATE VALVE MODEL:
EXPANDABLE
• Expanding Gate has two halves
• Bottom out gate & tighten hand wheel 1/4 to
1/2 turn
• Gate wedges and expands to achieve
mechanical seal in open and closed positions
GATE VALVE MODEL:
EXPANDABLE
GATE VALVE MODEL:
SLAB/FLOATING
•
•
•
•
•
•
2 1/16” to 7 1/16”
2000 to 15,000 psi
Slab gate design
Back-seating
No body ports
Typically used in higher
pressure applications (10,000 &
15,000 PSI)
GATE VALVE MODEL:
SLAB/FLOATING
•
•
Packing can be injected through
packing fitting in bonnet (2) to
energize stem seal
Inject grease in body fittings (1) and
bearing housing in bonnet (3) at least
seasonally
 Many service problems with gate valves occur from operation.
 NEVER throttle a Gate Valve in the PARTIALLY OPEN position or extensive damage will
occur
 Lubricate the stem bearings and valve body a minimum of twice per year or every 15 to
20 cycles, and prior to ‘Shutting-in a Well’ – recommended by valve manufacturer
 To Operate:
i.
Turn Handwheel counter-clockwise to open
ii. Turn Handwheel clockwise to close
iii. Tighten up the Handwheel for Expandable valve model
iv. Back-off the Handwheel for Floating/Slab valve model
BASIC OPERATING INSTRUCTION
BALL VALVE
Ball Valve - Trunnion
• A ball valve is a form of quarter-turn valve which uses a hollow,
perforated and pivoting ball to control flow through it.
• There are five general body styles of ball valves: single body, three-piece
body, split body, top entry, and welded.
• A trunnion ball valve has additional mechanical anchoring of the ball at
the top and the bottom, suitable for larger and higher pressure valves
(above 4 inch and 40 bars ).
Ball Valve - Floating
• A floating ball valve is one where the ball is not held in place by a
trunnion.
• In normal operation, this will cause the ball to float downstream slightly.
• This causes the seating mechanism to compress under the ball pressing
against it.
• Furthermore, in some types, in the event of some force causing the seat
mechanism to dissipate (such as extreme heat from fire outside the
valve), the ball will float all the way to metal body which is designed to
seal against the ball providing a somewhat failsafe design.
PLUG VALVE
Plug Valve
• Plug valves are valves with cylindrical or conically tapered "plugs" which
can be rotated inside the valve body to control flow through the valve.
• The plugs in plug valves have one or more hollow passageways going
sideways through the plug, so that fluid can flow through the plug when
the valve is open.
• Plug valves are simple and often economical.
Globe Valve
Globe Valve
• A globe valve, different from ball valve, is a
type of valve used for regulating flow in
a pipeline, consisting of a movable disk-type
element and a stationary ring seat in a
generally spherical body.
• Globe valves are named for their spherical
body shape with the two halves of
the body being separated by an
internal baffle.
Butterfly Valve
Butterfly Valve
• A butterfly valve is a valve which can be used
for isolating or regulating flow.
• The closing mechanism takes the form of
a disk. Operation is similar to that of a ball
valve, which allows for quick shut off.
• Butterfly valves are generally favoured
because they are lower in cost to other valve
designs as well as lighter.
Choke Valve / Control Valve
Control Valve / Choke Valve
• Control valves are valves used to control conditions such
as flow, pressure, temperature, and liquid level by fully or partially
opening or closing in response to signals received from controllers that
compare a "set point" to a "process variable" whose value is provided
by sensors that monitor changes in such conditions.
• Control Valve is also termed as the Final Control Element.
• The opening or closing of control valves is usually done automatically
by electrical, hydraulic or pneumatic actuators. Positioners are used to
control the opening or closing of the actuator based on electric, or
pneumatic signals.
• A choke valve is a type of valve designed to create choked flow in a
fluid. Over a wide range of valve settings the flow through the valve can
be understood by ignoring the viscosity of the fluid passing through
the valve; the rate of flow is determined only by the ambient pressure on
the upstream side of the valve.
• For choke valve, usually controlled manually.
Check Valve
CHECK VALVE
• A check valve is a type of valve that allows fluids
to flow in one direction but closes automatically
to prevent flow in the opposite direction
(backflow).
• An important concept in check valves is the
cracking pressure which is the minimum upstream
pressure at which the valve will operate.
• 3 types of check valve:
1.
2.
3.
Swing Type
Dual Plate
Lift Type
GATE VALVE BRAND
GATE VALVE BRAND:
FMC 120
GATE VALVE BRAND:
FMC 120
• API 6A PR2 qualified + FMC 300 cycle endurance tested
• Slab gate creates a positive mechanical seal across the seats,
with or without line pressure
• Full-bore, through-conduit gate-to-seat seal maximizes valve
life by virtually eliminating turbulence and pressure drop
• Gate skirts reduce loss of body lubricants
• Low running stress enhances life of the gate-to-seat interface
• Upper/lower roller thrust bearings are isolated from well fluid,
minimizing torque
• Stem packing can be re-energized with valve under pressure
• Non-rising stem permits valve installation in closer quarters
• Seats, gates, stem, and other working parts are field
replaceable
GATE VALVE BRAND:
FMC 120
• Complete valve family tested and qualified 2 1/16” to 6 5/8” 6,650 psi
• -75OF to +250OF
• API monogrammed for 5K service with FMC certification for use
at 6,650 psi working pressure.
• Same features as FMC M120 series gate valve, with upgrades
to…
i. Seat and gate hardfacing
ii. Lift nut material
• Offers lower cost option for working pressures in the 4,500 psi
to 6,600 psi range.
M120 Gate Valve :
Forged body
Patented UV stem
Full metal sealing (gate/seat, seat/body,
selective stem backseat)
Metal gasket bonnet seal
API 6A Appendix F PR2 qualified
FMC 500 cycle endurance test
Full size range (1 13/16” to 9”)
Full API pressure range (2K-15K)
Full API material class (AA-HH)
Full API temperature range
Premium valve
M120 GATE VALVE
GATE VALVE BRAND:
CAMERON
There are three (3) types of
Cameron Valve used in SKO
Platform:
Cameron Type
FLS
Cameron Type F
Cameron Type
FL
 Full bore, forged valve available in low and high pressure rating from 2000 to 20,000 psi
and bore sizes from 1-13/16” to 9”.
 Application for critical requirement including clad and subsea.
 Bi-directional design provides flow direction versatility and increased service life.
 Positive metal to metal sealing (gate to seat and seat to body).
 Simple, reliable gate and seat design
 Two spring loaded, pressure energized, non-elastomeric lip seal between each seat &
body.

Grease injection fitting located downstream of stem backseat for safety.
 Bearing cap grease fitting allow positive bearing lubrication.
CAMERON TYPE FLS
 Full bore, forged valve available in pressure rating from
2000, 3000 & 5000 psi bore sizes from 2-1/16” to 41/16”.
 Design can be fitted with a wide range of Cameron
actuators.
 Bidirectional design provides flow direction versatility
and increased service life.
 Positive metal to metal sealing (gate to seat and seat to
body).
 Simple gate and seat design
 Spring loaded, pressure energized, non-elastomeric lip
seal between each seat & body.
 Grease injection fitting located downstream of stem
backseat for safety.
 Bearing cap grease fitting allow positive bearing
lubrication.
 Easy closing and sealing without excessive force.
CAMERON TYPE FL
 Full bore, forged valve available in low and high pressure
rating from 2000 to 20,000 psi and bore sizes from 113/16” to 4-1/16”.
 Application for critical requirement including clad and
subsea.
 Bidirectional design provides flow direction versatility
and increased service life.
 Positive metal to metal sealing (gate to seat and seat to
body).
 Simple, reliable gate and seat design
 Two spring loaded, pressure energized, non-elastomeric
lip seal between each seat & body.
 Grease injection fitting located downstream of stem
backseat for safety.
 Bearing cap grease fitting allow positive bearing
lubrication.
CAMERON TYPE F
GATE VALVE BRAND:
WKM
GATE VALVE BRAND:
MC EVOY ‘C’
DOWNSTREAM
UPSTREAM
P2
P1
Open
Position
P3
P1 = P2 =
P3
P2
Closed
Position
P1
P3
P1 = P2 = P3
GATE VALVE CONCEPT: OPEN AND CLOSE POSITION
DOWNSTREAM
Closed Position Pressure Applied
P1
P2
P3
P1> P3 > P2
UPSTREAM
UNI-DIRECTIONAL
SEALING ALLOWS
PRESSURE TO
EQUALIZE
Gate Floats In Downstream
Direction
GATE VALVE CONCEPT: CLOSE POSITION SEQUENCE 1
DOWNSTREAM
Closed Position Pressure
Equalized
P1= P3 > P2
P2
P1
P3
GATE VALVE CONCEPT: CLOSE POSITION SEQUENCE 2
UPSTREAM
DOWNSTREAM
P2
Pressure
Relieves
P1
Upstream
Closed Position Pressure Relief
UPSTREAM
Temperature
Increase
P3 = P1 > P2
P3
GATE VALVE CONCEPT: CLOSE POSITION SEQUENCE 3
GATE VALVE BRAND:
FMC 120
Basic sequence of XT Tree valve during Opening and Shut-In well when bringing
production:
Shut – In / Closing Well
System
Opening Well System
• WV
• SCSSV
• SSV
• LMV
• LMV
• SSV
• SCSSV
• WV
If tubing head pressure (THP) is to be read from the pressure gauge installed on the tree
cap, the CV should be cracked open only, and then re-close. If a well has been shut in using
the SSV or LMV, the WV should be closed prior to re-opening the SSV or LMV.
INTRODUCTION OF
EQUIPMENT
Olivals 751
GREASE/SEALANT PUMP
OLIVALS 751 – Valve
Master High Pressure
Pump
- Air operated
- Operating Air Pressure
Range: 30 – 200 psi
- Maximum delivery
pressure of 15,000 psi
- Max output @ 75cpm:4500
cc per min/1lb per 16
strokes
- For delivery of lubricants
and sealant into valve
seats
Olivals FM II
Flushing/Hydraulic PUMP
OLIVALS FM II – Valve Master High
Pressure Pump
- Air operated
- 20 – 200 psi input pressure.
- Maximum delivery pressure of 10,000
psi
- Tank capacity 6.5 L
- For delivery of flush into valve seats
- Single well control panel (SWCP) for
SCSSV and SSV.
- Also used for pressure testing.
Olivals FM III
Flushing/Hydraulic PUMP
OLIVALS FM III – Valve Master High
Pressure Pump
- Air operated
- 20 – 200 psi input pressure.
- Maximum delivery pressure of 10,000
psi
- Tank capacity 6.5 L
- For delivery of flush into valve seats
- Single well control panel (SWCP) for
SCSSV and SSV.
- Also used for pressure testing.
VR Lubricator
Valve Removal Lubricator
• used to replace, not repair, a side
outlet valve, annular valve, or wing
valve under pressure.
• It is mounted on the gate valve
outlet flange and installs and
removes the VR plug through the
open valve bore.
BPV Lubricator
Back Pressure Valve Lubricator
• Used to set and retrieve back
pressure valve (BPV).
• It is mounted on top of Xmas
tree/tree cap using crossover.
• Manual operated using Parmelee
Wrench.
INTRODUCTION OF GREASE /
SEALANT
- PRODUCT
OLIVALS® - VF (Valve Liquid
Flushing)
A liquid penetrate that effectively cleans and
removes rust and hydrocarbon deposits. Harmless to
any valve mater components
(Eg. Seats and seals)
Operating temperature : -18°c to 80°c
Base oil : Hydrocarbon
Flash Point : 65°c (ASTM D-56)
Auto Ignition : 450°c
OLIVALS® - GVS (Gate Valve Sealant)
A molybdenum disulphide composite having excellent
gate valve lubricant and emergency sealant even up
to high temperature applications and low passing
rate.
Operating temperature : up to 230°c
Base Oil : Vegetable
Dropping Point : >260°c (ASTM D-2265)
NLGI Grade : 2 - 3
OLIVALS® - VL (Valve Lubricant)
Lubricated valves by providing a lasting lubricating film to
prevent metal-to metal contact in moving parts as well as
corrosion protection.
Operating temperature : -1°c to 210°c
Base Oil : Synthetic
Dropping Point : >260°c (ASTM D-942)
Oxidation Stability: 1.35 PSI loss
(ASTM D-942)
Corrosive Preventive : Pass
(ASTM D-1743)
OLIVALS® - GVS 2 (Gate Valve Sealant 2)
A Liquilon and silica amorphous mixtures as excellent gate
valve lubricant and emergency sealant even up to high
temperature applications and high passing rate.
Operating temperature : up to 230°c
Base oil : Synthetic
Dropping point : >260°c (ASTM D-2265)
NLGI Grade : 3
OLIVALS® - VS2 (Valve Sealant 2)
Seals leak, provides extremely low friction
coefficient, contains rust and corrosion inhibitor.
Operating temperature : 12°c to 204°c
Base Oil : Synthetic
Dropping point : >260°c (ASTM D-2265)
NLGI Grade : 1 to 2
OLIVALS® - SZLS (Sub-zero Lubricant and Sealant)
Manufacture to perform under artic and artic-like
conditions. Immiscible with water and will not
freeze-up in valves.
Operating temperature : -5°c to 204°c
Base Oil : Synthetic
Dropping point : >260°c (ASTM D-2265)
NLGI Grade : 2 - 3
OLIVALS® - VRS (Valve Repair Sealant)
Recommended for use on damaged valves. Formulated
using synthetic resins, graphite and liquillon.
Operating temperature : 5°c to 240°c
Base Oil : Vegetable
Dropping point : >260°c (ASTM D -942)
NLGI Grade : 2
PREVENTIVE
MAINTENANCE SCOPE &
DETAILS
INTRODUCTION
Wellhead valve lubrication and sealing are
processes that lubricate and seal the respective
valve of the system. This is a process that utilise
specific equipment to inject selective grease,
sealant and flushing/degreaser into wellhead
valve via grease (nipple) fitting point.
PREVENTIVE MAINTENANCE (PM)
Fundamentally covers
LUBRICATING, GREASING and
FLUSHING processes on
variety type of static
equipment - valves (e.g.;
wellhead gate valve & pipeline
valve).
Some required a SEALING activity on
the equipment during certain activity.
This is a process that uses
specific/suitable equipment to inject
selective/suitable sealant via existing
injecting point/port. Sealing activity is
consider a temporary solution during
performing PM while waiting for
repairing job.
No need to
dismantle valves
from line
Eliminates
downtime and
minimize inventory
Preserve
internal
components
from corrosion
To support other
important
intervention
activity
Fast and Effective
OBJECTIVE
The objectives of On-line
Flushing, Lubricating &
Sealing:
Reduce overall
maintenance &
repair cost
To provide
temporary
solution
To maintain the
integrity of the
equipment without
effecting volume
WHY ARE THEY PASSING?
New Valves Can Also Be Damaged
• Minor seat damage may occur after the valve is shipped from the factory due to improper
handling or because
• Or sand/dirt gets into the valve while sitting at the pipeline right-of-way waiting for
installation.
• The valve is usually cycled during installation of actuators and during hydrostatic testing at
site. Dry contaminants can create tiny scratches on the metal seating surfaces and soft
insert material, causing minor leak paths.
• As testing has proven, a valve with even minor scratches will leak after high pressure gas is
introduced. These scratches may continue to erode into larger leak paths if a preventative
maintenance program is not in place.
Solutions that can lead to bigger problems
•
Traditionally, valves are removed from the line and sent to have it “shopped”
•
Sometimes, these valves jammed so badly that a hydraulic press is used to remove the
plug from the valve body - $$$$
•
Sometimes, on-site, even chain blocks are used to force jammed valves to loosen.
•
These drastic measures can twist the stem off the valve, necessitating a shutdown of the
entire system or even worse, cause injuries to workmen
The importance of flushing
 Proper lubrication is not possible until the cleaning process has been done
because the valve is full of dry materials and there is no room for lubricants
 Even a program of regular lubrication is not satisfactory because the old
grease remains in the valve and under those circumstances, the injection of
lubricants or sealants is a hit-or-miss proposition
 Flushing softens old hardened grease and when followed by an application
of proper lubricants, makes the seized or hard to operate valves easier to
handle
•
Normally PM job done 6 monthly/12 monthly operation, based on general
guideline from individual end user
•
To preserve and secure all static equipment (XT gate valves) from major integrity
damage.
•
PM activities is divided into 3 main activities:
1. Critical Device Function Test (CDFT).
2. Valve Flushing (optional), Lubricant and Sealant.
3. Down-Hole Safety Valve test (Optional)
PREVENTIVE MAINTENANCE ACTIVITIES
CONT…
• Valve Lubrication & Sealing are processes where the static
equipment (valves on the pipeline/wellhead/Christmas tree) been
lubricated and sealed without taking them out to be serviced in a
workshop. It can be perform during shutdown or also production
online.
• The process/activity advantages are:
i. Fast & effective.
ii. Eliminate unplanned costly downtime.
iii. Optimize valve performance & prolong valve life.
iv. Preserve internal valve component from corrosion.
When dealing with high pressure environments, SAFETY is our main
priority in order to safeguard our clients’ assets, but most
importantly, human life.
 Proper pressure relief tools used in depressurizing the valve
 Special monitoring gauges fitted on equipment
 Constant monitoring of pressure readings by trained technicians
 Set procedures for stop-work in cases of varied or abnormal readings
 Air driven equipment powered by line air – non hot-work environment
All products used are non flammable and compatible with hydrocarbon
SCOPE OF WORK – Preventive
Maintenance
1. To carry out Wellhead Preventive Maintenance (WHPM) which basically inclusive of Section A, B,
C and D.
2. WHPM includes bonnet cap lubrication (bearing), injection of flush and grease/sealant (body
filler), pressure/function testing of valves and actuators, cleaning, preservation, painting of
associated equipment.
3. To carry out periodic maintenance:• On all Wellhead & XT valves by performing Critical Device Function Test (CDFT) that consist of leak test and
function test according to standard guideline (WRM).
• On Down-Hole Safety Valve (SCSSV) by conducting a cycling test, leak test and slam test according to standard
guideline (WRM) and irrespective of type of safety valve.
• On production, surface and conductor casing section by performing Annular Pressure Bleed-off Test according
to client standard procedure/guideline.
• On all actuators consist of hydraulic or pneumatic by performing a function test according to respective OEM
specification, i.e. stroking and trip check.
CRITICAL DEVICE FUNCTION
TEST (CDFT)
• Critical devise function test is a compilation of
few activities which involve valves leak test and
function test on every each of wellhead and XT
valves.
PETRONAS CARIGALI SDN BHD
PROCEDURE TO LEAK TEST WELLHEAD VALVES
Wellhead type / Tag no. :
KNJT-C
FMC / KN-C-02 @ WH-180
1. Well Status
: Shut-in / Flowing / Injecting / Idle
2. Well Type
: Natural Flowing
Long String
: Injection Water / Injection Gas
Short String
Platform
:
Tester
:
Date
:
SHAHIR /ROXAS
28.09.2013
SECTION D
Sheet 1 of 2
Tubing String :
X
Single
3. Pressures prior to starting test (psi) :
FTHP
PCP
SCP
* FTHP - Flowing Tubing Head Pressure
* PCP - Production Casing Pressure
CCP
PROD. HEADER
* SCP - Surface Casing Pressure
* CCP - Conductor Casing Pressure
4. Shut in the well by closing the wing valve (if flowing). Record SITHP (psi) =
shut-in time (hrs) =
5.Tick the appropriate valve(s) to be tested :
• To identify wellhead gate valves are in good
condition or not.
• Standard parameter or allowable rate used
were determined in Wellbore Risk Management
(WRM).
To test the Crown Valve (CV) :
Size / Class :
Brand :
Close the crown valve. Open SSV and LMV
Bleed down the pressure downstream of the CV to zero or as low as possible (at least half of the SITHP)
Monitor pressure at the following time intervals :
BEFORE
Time (min)
0
1
AFTER
5
10
Pressure(psi)
Time (min)
0
1
5
10
Pressure(psi)
Remark:
Remark:
Valve Flush
Valve Sealant
Actuator model:
Valve Lubricant
Sealant type:
Fully Open & Close :
turns
To test the Surface Safety Valve (SSV) :
Size / Class :
Brand :
Close the SSV, Open the CV and LMV
Bleed down the pressure downstream of the SSV to zero or as low as possible (at least half of the SITHP)
Monitor pressure at the following time intervals :
BEFORE
Time (min)
0
1
AFTER
5
10
Time (min)
Pressure(psi)
pressure(psi)
Remark:
Remark:
0
1
Valve Flush
Valve Sealant
Actutor model :
Valve Lubricant
Sealant type:
Fully Open & Close :
5
10
turns
To test the Lower Master Valve (LMV)
Size / Class :
Brand :
Close the LMV, Open the CV and SSV
Bleed down the pressure downstream of the LMV to zero or as low as possible (at least half of the SITHP)
Monitor pressure of the following time intervals :
BEFORE
Time (min)
• Allowable rate for wellhead follow the WRM is
pressure build-up off 100 psi (700 kPa) in one
minutes.
0
1
AFTER
5
10
Time (min)
Pressure(psi)
Pressure(psi)
Remark:
Remark:
0
1
Valve Flush
Valve Sealant
Actuator model:
Valve Lubricant
Sealant type:
Fully Open & Close :
5
10
turns
Page 1 of 2
CRITICAL DEVICE FUNCTION
TEST (CDFT)
• Critical devise function test is also been carried
out to SCSSV.
• To identify downhole safety valve are in good
condition or not.
• Standard parameter or allowable rate used
were determined in Wellbore Risk Management
(WRM).
• Allowable rate for SCSSV as per table below :
SCSSV CYCLING TEST
• SCSSV should be exercised by regular cycling, or
stroking of the valve on 6 monthly basis.
• To keeps wellbore debris from forming in the
sealing area.
• To keep this critical area “scraped” clean, and help
to keep the valve functioning properly.
• keep the valve from “seizing” due to non-use
• to keep the elastomers in the valve from becoming
permanently deformed by remaining in the same
position for a long period of time.
WRSCSSV SLAM TEST
• Additionally, for Wireline Retrievable SCSSSV the
tendency for the valve to be off seated from its
locking position after installation and during
production after certain period is high.
• Slam Test need to be carried out to ensure the
valve properly seated in locking nipple profile.
• The test shall be conducted immediately after
installation and subsequently once every 6
monthly.
PREVENTIVE MAINTENANCE
PROCEDURE
All tests listed below are perform base on standard guideline (WRM and API 6A)
• Standard Operating Procedure for PM
•
Critical Device Function Test (Leak test)
1. Wellhead and Christmas Tree Valve – describe per model
2. Surface control Subsurface Safety Valve (SCSSV)
•
Respective Surface control Sub surface safety Valve Test
1. Cycling test
2. Slam Test
•
Actuator Function Test and Record (Open & Close Timing)
•
Annulus Bleed Off
CORRECTIVE
MAINTENANCE SCOPE &
DETAILS
INTRODUCTION
• CORRECTIVE MAINTENANCE is troubleshooting
and rectification process to sustain the
integrity of valve.
• Its cover actuator rectification and valve
rectification.
CM CRITICAL JOB COMPLETION
•
Rig Up Lubricator to set Back Pressure Valve (BPV) for
natural flow well which is SITHP is 2000psi and above.
CM CRITICAL JOB COMPLETION
• Rig up VR lubricator to retrieve VR Plug from casing.
CM CRITICAL JOB COMPLETION
• Rectify WV passing while FLV and Header Valve passing during Coil Tubing
Drilling in progress.
CM CRITICAL JOB COMPLETION
• Adjustment alignment pin due to leak from production tubing
CM CRITICAL JOB COMPLETION
• Leak between casing and Xmas tree.
CM CRITICAL JOB COMPLETION
• Onshore refurbished actuator ( OTIS, CAMERON WILLIS,
STREAM FLO, SOLAR ALERT AND ETC.)
PREVENTIVE MAINTENANCE
BASIC CARE
PREVENTIVE MAINTENANCE
BASIC CARE
 USE Pressure Release Tool (PRT) prior any activities
in order to bleed off any trap pressure in a cavity
area:
TOPPING UP.
Routine maintenance consists of topping-up of the
lubricants/sealants into the valve cavity & reservoirs
VALVE CLEANING
Valves that hang up are hard to operate and do not seal
properly. Inject sufficient quantities of valve cleaner to
displace all the lubricant/sealant in the valve system.
EMERGENCY SEALING.
Introduction of heavy lubricants/sealants are only
recommended to achieve a temporary seal even if a seal
damage has occurred. Valves that require an extra
heavy sealant may require adjustment, repair or
replacement
INJECTION TECHNIQUES.
Best results are achieved by injecting while valve is in
the full open or full closed position.
American Petroleum
Institute
• “To afford a means of cooperation with the U.S. government in matters of
national concern
• To foster foreign and domestic trade in American petroleum products
• To promote in general the interests of the petroleum industry in all its
branches
• To promote the mutual improvement of its members and the study of the
arts and sciences connected with the oil and natural gas industry”
EQUIPMENT TAGGING & DETAILS
Product Specification Levels (PSL)
Definition of Levels of Effort or Technical
Requirements That May Be Assigned to a
Product
Generally Represent Industry Practice for
Various Service Conditions
API 6A, Annex A Provides the Purchaser With
Guidelines to Assist in Selecting
the
Appropriate PSL
API Pressure Ratings
(psi)
API Pressure Rating
(Mpa)
2,000
13.8
3,000
20.7
5,000
34.5
10,000
69.0
15,000
103.4
20,000
138.0
API Pressure Rating
API Temperature Ratings
Temperature Rating
*
Operating Range
°F
°C
K
-75 to 180
-60 to 82
L
-50 to 180
-46 to 82
N
-50 to 140
-46 to 60
P
-20 to 180
-29 to 82
R
Room Temperature
Room Temperature
S
0 to 140
-18 to 60
T
0 to 180
-18 to 82
U
0 to 250
-18 to 121
V
35 to 250
2 to 121
* Annex G Defines Temperature Rating X and Y
API Material Classes
API Material Class
Body, Bonnet, End &
Outlet Connections
Pressure Controlling Parts,
Stems & Mandrel Hangers
AA – General Service
Carbon or Low Alloy Steel
Carbon or Low Alloy Steel
BB – General Service
Carbon or Low Alloy Steel
Stainless Steel
CC – General Service
Stainless Steel
Stainless Steel
DD – Sour Service a
Carbon or Low Alloy Steel
Carbon or Low Alloy Steel
EE – Sour Service a
Carbon or Low Alloy Steel
Stainless Steel
FF – Sour Service a
Stainless Steel
Stainless Steel
HH – Sour Service a
Corrosion Resistant Alloy b
Corrosion Resistant Alloy b
Notes:
Material Classes DD thru HH are required to include a designator of maximum
partial pressure H2S for which the item is suitable based on limitations imposed
by NACE MR0175/ISO 15156.
Material Class ZZ may be designated by end user in order to utilize materials
outside of the limitations imposed by NACE MR0175/ISO 15156.
Annex F Performance Requirements
– Valves (PR)
PR Level
PR 1
PR 2
Open/Close Dynamic
Pressure Test @ Room
Temperature
3 Cycles
160 Cycles
Low Pressure Seat Test @
Room Temperature
Objective Evidence
1 Hour at 5-10% WP
Open/Close Dynamic
Pressure Test @ Max/Min
Temperature
Objective Evidence
20 Cycles at Each Extreme
Low Pressure Seat Test @
Min Temperature
Objective Evidence
1 Hour at 5-10% WP
Fluid Compatibility
Objective Evidence
Yes
Operating Force
Per Manufacturer’s Spec
Yes
Pressure/Temperature
Cycling
Objective Evidence
Yes
API 6A Performance Requirements
 Performance Requirements (PR 1, PR 2)
 Specific and Unique to Product
 [Not the Same as Annex F PR Levels (PR 1, PR 2)]
 Section 4 – Design and Performance
 Service Conditions
 Design Methods
 Design Information
 Design Documentation
 Section 10 – Equipment-Specific Requirements
Equipment-Specific Performance
Requirements
Equipment
PR Level
PR 1
PR 2
Valves
Operating Cycles
3 Cycles
200 Cycles
Load Capacity
1 Cycle @ Min
Rated Load to Max
Rated Load
3 Cycles @ Min
Rated Load to Max
Rated Load
Load Capacity
1 Cycle @ Min
Rated Load to Max
Rated Load
3 Cycles @ Min
Rated Load to Max
Rated Load
Operating Cycles
3 Cycles
200 Cycles
Seat/Body Sealing
1 Cycle
3 Cycles
Crossover
Connectors
Pressure Integrity
1 Cycle
3 Cycles
Actuator
Operating Cycles
3 Cycles
200 Cycles
Lockscrews
Pressure Integrity
1 Cycles
3 Cycles
Slip Hangers
Mandrel Hangers
Chokes
Shall Seal Maximum Rated Pressure Internally
PREVENTIVE MAINTENANCE
PROBLEMATIC FACTOR
Jammed / slow stroking gate valves:
• Old Grease / Sealants that hardened
• Rust formation in seat area (lack of lubrication)
• Sand / debris blockage internally
• Mechanical failure/damage
Passing gate valves:
• Scratches on ball/gate/plug due to:
- Forced stroke with hardened grease
- Forced stroke with sand / debris stuck to grease
/sealants
• Misalignment of ball/gate/plug due to hardened
grease
Cont..
• Stress due to cycle of the valve
i.
Normally closed valve:
• Even when a valve is not regularly cycled, if it is normally closed,
internal components will have mechanical forces applied. Both the seat
and gate will have constant pressure and, therefore, will be stressed
continually. Here, watch seats for failure because constant pressure
robs them of resiliency, and gaps or cracks can develop.
ii. Normally open valve:
• Although a normally open valve will stress internal components very
little, it is still an operational valve.
iii. Twenty-four-hour service:
• Obviously if a valve is cycling continually over 24 hours, wear rates and
stress increase accordingly. Therefore, such valves usually will cycle
more times than other valves operating over less time.
For Your Attention
..End..