SIEP - ABC Guide To Temporary Pipework Ver 02

Drilling and Well Services
ABC Guide to
Temporary Pipework
Practices to implement EP 2006-5393
Shell Global Standard for Temporary Pipework
ABC Guide to Temporary Pipework
Basics for Common Understanding

Pipework connected by Hammer Unions is used in chemical
process plants, the mining industry, on dredging vessels and
in the oil industry. It is an old design (early 1950s) created
by the Well Equipment COmpany (WECO) which was
aquired by FMC.
Female / Male Unions
The identification of the Female and Male parts of a

Hammer type union is shown in the picture below.
Female Union
Male Union
Wing Nut
The union parts are called out using a Nominal pipe size, a
FIG designation and a code e.g.1502.
For example: 2 FIG 1502
The 2 is close to the inside diameter. The meaning of FIG
has been lost in the depths of time but is probably an abbreviation of figure - meaning drawing, and 1502 is a code for
the working pressure rating - 15 referring to 15,000 psi.
But over time the addition of larger diameter pipework and
H2S pipework has led to the designation becoming corrupted
- so beware.
Ver. 2.0
The meaning of "Temporary"
"Temporary," in the context of pipework and flowline equipment, applies to any pipework and flowline equipment which
can be installed or changed-out without recourse to structural and process engineering.
["Permanent" pipework and flowline equipment (e.g. spoolpieces connected between the production wing valve and the
production manifold) are designed, constructed and installed
subject to requirements of structural and process engineering codes and reviews. Without these formal checks being
required for temporary pipework, the ABC Guide indicates
the minimum precautions to be taken when working with
temporary pipework used in Drilling and Well Services operations.]
Temporary Pipework is commonly referred to as Chicksan
or Flowline Equipment.
Ver. 2.0
Contents
Introduction
What is Temporary Pipework

Equipment Involved
Background Information
Pressure
Stored Energy
Dynamic Loading
Vibration
Bending Forces
Shock Loading
Hazardous Fluids
14
Loss of Containment
Leaks - Erosion
H2S
Catastrophic Failure
Historic Incidents
Pipework Connections and Interfaces
the Same-Size
Pipe Pressure Ratings
Wing Nuts
Components
Non-Detachable and Detachable
14
14
15
16
17
20
20
20
22
23
23
23
26
Hazard Identification and Mitigation

Mitigation Methods
Check lists
No-Go areas
Restraints
Ver. 2.0
9
9
11
11
11
12
13
13
Operational Hazards
Mismatches
Mismatching
Mismatching
Mismatching
Mismatching
Mismatching
Components
Flexible Pipes
5
7
28
28
28
30
30
Avoiding Injury
38
Hammering Unions
Gauges
38
39
Completing the Connection Interface Diagram

Walking the Lines
40
43
Example walkthrough
Awareness of Safety Initiatives
FMC Technologies Ltd
43
45
45
Ver. 2.0
Introduction
This ABC Guide to Temporary Pipework is designed as a practical
guide to create an awareness of the issues faced when using temporary pipework in the field.
This guide covers:

Flowline equipment.
Pressures and types of fluids involved.
Operational hazards.
Pipework connections and interfaces.
Hazard identification and mitigation.
Operational guidelines.
This guide should be read and understood by all involved in temporary pipework operations. The guide should also be re-read prior to
the commencement of each temporary pipework operation and also
referred to during each step of that operation.
If the correct procedure is unclear at any stage of the operation:
Stop and Ask.
What is Temporary Pipework

Temporary pipework consists of the conduits and equipment for
directing fluids (liquids or gasses):

From a pump to a wellhead.

A high pressure point to a lower pressure point.
Fluids directed to outlets ending with plugs on which sensors
are mounted.
Usually one source

will be the well (the
Wellhead or Xmas
Tree). Occasionally,
temporary pipework
may be required for
transfer of fluids
between vessels.
Figure 1 - Temporary
Pipework / Permanent
Pipework.
Ver. 2.0
Temporary
Pipework
To temporary
pipework system
Permanent
Pipework
Pipework part of
original design
(e.g. production
facilities)
Temporary pipework is piping and flowline equipment that is

mobilised and assembled for the purpose of carrying out the following operations:
General Pumping Operations (transfer of fluids, mud/brine

mixing operations, (reverse) circulating well fluids, etc.
Pressure Testing of Surface Lines and Equipment (including
wellhead, BOP, X-mas tree, flow lines, etc).
Pressure Testing of Downhole Equipment (casing, packers,
tubing, plugs, valves, accessories).
Cementing.
Well Killing.
Well Stimulation.
Nitrogen Pumping.
Well Clean-up.
Well Testing.
Under Balanced Drilling operations.
Managed Pressure Drilling Operations.
Temporary pipework can be both hard and flexible pipe.
Figure 2 - Typical Temporary Pipework Set-ups

Ver. 2.0
Equipment Involved

Pipework runs (straights), pup joints, elbows.

Strainers, pots, plug valves, check valves.
T-pieces.
Laterals (Y-pieces).
Swivel joints.
Treating Loops.
Crossovers.
High Pressure Hoses.
Flanges & Blinds.
Treating loop
Pipework
Chiksan (Swivel) Joint

Tee
Typical Coflexip Line
Figure 3 - Some typical equipment involved
Ver. 2.0
The pipework connections referred to in the guide are known as:

Hammer-type connections.
Hub-type connections.
Flange connections.
Pipe body to pipe body (welded).
Hammer-type Union
Graylok Hub-type Connection
Flange Connection
Welded Connection
Figure 4 - Temporary Pipework Connections
In summary, Temporary Pipework (chicksan, flowline equipment)

comprises such fittings as straights or pup joints, T-pieces,
elbows, crosses, crossovers, blinds, plugs, swivel joints and plug,
loops and check valves. A combination of such equipment is often
referred to as steel hose.
Ver. 2.0
Background Information
As previously described, Temporary Pipework Operations involves
the transport of fluids under pressure from one point to another.
Due to the typical pressures and flow rates involved, Temporary
Pipework Systems contain a lot of stored energy which can cause
vibration, bending forces and shock loading on the system. The fluids being flowed can be hazardous or corrosive and can therefore
also attack the integrity or strength of the system. It is therefore
vitally important that all equipment used in a Temporary Pipework
Operation set up is:
Mechanically sound and has been properly inspected prior to

use.
Of suitable material, particularly where seals are concerned;
this applies both to working pressure rating and to the fluid
type being flowed (e.g Sour Service).
Made up correctly at all connections and unions as per the
recommendations of the operational design.
Secured with the proper restraints attached to the proper
anchor points in the system.
In order to better understand these requirements we will now look
at some of the physical factors that Temporary Pipework set-ups
have to cope with.
Pressure
Pressure is the term for measuring the force per unit area, the
units typically used for measuring pressure are pounds per
square inch, which is abbreviated
p.s.i.
A familiar example is the air
pressure in a tyre, which is typically around 30 p.s.i. for a car.
What this means is that a force
of 30 pounds is exerted on each
and every square inch of the
inside of the tyre, There are a lot
of square inches on the inside
Ver. 2.0
Units of Pressure
Pounds per square inch (or
pounds-force per square inch)
is still the most widely used
oilfield unit for pressure.
Other common units are the
SI (or metric) unit which is the
Pascal (Pa), the Atmosphere
(atm), and the Bar (bar).
The Pascal is a very small
unit, 1 Pa being only about
1/7000th p.s.i. 1 Atm and 1 Bar
are approximately 15 p.s.i.
10
surface of a tyre, and because of this, the force exerted on that tyre
is very large. Every square inch is pushed on with a force of 30
pounds.
In Temporary Pipework Operations, low pressure is often used for
values of around 300 p.s.i. (that is TEN times that of a car tyre)
and the operational pressure may be above 10,000 p.s.i. That is
10,000 lbs exerted on every square inch of the inside of piping,
unions, swivel joints, crossovers etc in the system.
Figure 5 - Relative Pressure Comparison
Thinking about the forces involved, it should be clear why it is vital

to ensure there are no weak points in the system. Any improper
use of equipment such as mismatching pressure ratings or using
poorly conditioned equipment can have devastating consequences.
Ver. 2.0
Stored Energy
Yield strength
Stored energy is the capacity

of a volume of pressured
fluid to do work if allowed to
expand. An example of this
work would be a volume of
pressurised gas expanding
and pushing a piston. The
greater the stored energy of
the fluid, the greater the
force with which the piston
would be pushed and the
greater the amount of work
that piston could perform.
The danger associated with
Stored Energy in Temporary
Pipework is that the Stored
Energy is typically very
large and any weak point in
the system will allow this
energy to expand with potentially catastrophic results
Dynamic Loading
11
Yield Strength is the stress a

material can withstand without
permanent deformation. Typical
minimum yield strengths for
pipework range from 75,000 to
115,000 psi
It is interesting to compare
Temporary pipework with the
guidelines for artillery safety
regarding the use of cannons in
historical re-enactments. The
guidelines state that: The bore
should be lined with steel tubing
with a minimum wall thickness of
3/8 and yield strength of 85,000
psi or greater.
A liner equivalent to pipework is
what a cannon requires to safely
contain and direct the stored energy which propelled 8lb cannon
balls in the American Civil War!
When pipe bursts the strain on any restraint when it snaps tight to
restrain the pipe is called the dynamic loading by process engineers. The rule-of-thumb used to work out this dynamic loading is
twice that due to the static force on the pipe arising from internal
pressure.
Vibration
Vibration can be a significant risk to pipework integrity, leading to
mechanical failure, fluid release, and potentially serious safety
implications. Common areas of vibration in Temporary Pipework
are

Long pipe runs .

Piping appenditures such as gauges.
Equipment such as valves, chokes, etc.
Pumps.
Ver. 2.0
12
Figure 6 - Vibration in Temporary Pipework
Common causes of Vibration

Excessive Pulsation (from pumps for example).

Mechanical Natural Frequencies.
Inadequate Supports and/or Support Structure.
Common effects of Vibration

Loosening of Bolts.
Compromising of Mechanical Joints (backing-off of Wing
Nuts).
Movement or slackening of Tie Downs and Restraints.
Bending Forces
Temporary Pipework is commonly subjected to bending forces due
to fluid velocity and internal pressure of the pipe. Bending force
occurs at junctions or bends in the pipework where it effectively
tries to straighten out the bend.
Bending force attempts to straighten out the
corner bend and forces the pipe outwards
straining the connections
Figure 7 - Bend is being straightened due to bending forces
Ver. 2.0
13
Such bending forces are then transferred along the pipework and
result in additional strain on connections. Improperly made-up connections (e.g. worn or mismatched components, wrong pressure rating etc) not able to cope with this increased load can fail catastrophically.
Shock Loading
A significant change in the flowrate, or pressure, during an operation (such as the emergency closure of a valve) causes a sudden
extra load or jolt on the system. This is temporary increase of load
on the system usually imposes increased pressure, vibration, and
bending forces on the system. During this period of Shock Loading,
any sub-standard part of the system (inferior pipe, worn connections, mismatched connections, wrong pressure rated equipment)
can fail with potentially disastrous consequences. It is important to
consider that failure due to Shock Loading may occur when there is
already an emergency event of some kind already taking place (e.g.
an emergency shut-in).
Hazardous Fluids
While there are many physical factors (such as pressure, temperature and flowrates) that must be considered when dealing with
temporary pipework, chemical factors such as hazardous fluids
must also be taken into account. Many fluids involved in operations (such as brines or acids) are corrosive to temporary pipework
and will weaken pipework over a period of time. It is important
that all pipework and connections used have been properly maintained, inspected and certified before use. Standard Service components must not be used on Sour Service wells (wells where
Hydrogen Sulphide, H2S, is present) as this will cause stress corrosion cracking, and pitting in the metal as well as destroying any
elastomer seals in Unions etc. Both of these factors will lead to premature failure under pressure of components in the system.
Ver. 2.0
14
Operational Hazards
Loss of Containment
Leaks - Erosion
Erosion takes place in flow systems where turbulence occurs, typically in pipe bends (e.g. elbows), tube constrictions (e.g. chokes or
valves), and other structures that alter flow direction such as laterals or tees. Specific erosion points within these components can
vary depending on the fluid velocity and size of any suspended particles. With typically sized sand grains, the erosion point in a bend
is usually past the mid-point of the bend and it is for this reason
that wall thickness is measured at the 80-90 degree point.
80o
Erosion point
Figure 8 - Erosion point in a short radius bend
Erosion can lead to leakage a rapid failure and it is therefore

important that the layout is designed, where possible, to minimise
bends and constrictions and that such areas are inspected regularly.
Intrusion into the flow path can cause vortices to be created and
shed. The local fluid speed within the vortex can be much greater
than the average fluid speed in the pipe. Local pipe erosion, in an
area as small as 1/2 inch square, can arise where the vortex makes
contact with the equipment or pipe wall.
Since the pipe thickness can be otherwise within operational limits,
workshop personnel should be vigilant when making visual inspections.
Ver. 2.0
Flow
15
Flow
Maximum
erosion
Maximum
erosion
Plugged
tee
Standard elbow
(r/D=1.5)
Flow
Maximum
erosion
Long-raduis elbow
(r/D=5.0)
Predicted erosion rates

for standard elbow,
plugged tee and longradius elbow.
Areas shown in red and
yellow have maximum
erosion
Figure 9 - Erosion of common equipment
H 2S
When H2S is present, the system is known as Sour and Sour Service
equipment must be used. For working pressure above 6000 psi, Sour
Service equipment has a significantly lower rated cold working pressure than than the equivalent Standard Service equipment and it is
therefore important to avoid mixing Standard and Sour Service
equipment in the same operation.
Ver. 2.0
16
Catastrophic Failure
When flow lines fail; whether it is due to excess pressure, faulty
connections, worn components, damage to the piping connection, or
other reasons; the results can be devastating and catastrophic to
both equipment and personnel. The metal components that were
previously being subjected to up to 15,000 p.s.i. of internal pressure
are suddenly and instantly forced to relieve their stored energy. In
such a failure there could be hundreds or even thousands of pounds
of iron pipe flailing around. In that scenario, there is a high likelihood of severe personal injury or death. As we will cover later,
restraint systems can help reduce this risk of damage or injury but
they cannot eliminate it fully. Preventing the failure from occurring in the first place is the only truly safe method.
Energy Release
The following sequence of pictures were taken from a Schlumberger
demonstration video showing the failure of a 15,000 p.s.i. unrestrained line. In this catastrophic failure the energy release occurs
in a very short period of time - a fraction of a second in fact, and
the damage and risk to personnel would have been severe.
Line ruptures
Test manikins
15,000
psi line
Pup joint flies off and

lands 200 yards away
Test manikins
destroyed
Piece of loop
flies outward
Figure 10 - Demonstration of energy involved in Catastrophic Failure
Ver. 2.0
17
Historic Incidents
Equipment
Operation
Event
Cause
Chicksan
Pressure
Testing
Chiksan elbow parted

at swivel at 4800 psi
Snap Rings and

Ball Plugs were
missing
Hammer
Union
Pressure
Testing
WECO union pressure

sensor connection on rig
floor ripped off.
Mismatch
between standard
2 1502 WECO
Union and rigs
2 1002 WECO
union
Hammer
Union /
Chiksan
connection
Making
up pipe
A 2 inch WECO union

with a swivel connection made up hammer
tight, became
unscrewed while tubing
(onto which the union
was connected) was
being made up. The
swivel assembly fell 10
metres on to a floorman resulting in severe
injury leading to death.
Hammer tight
right hand connection is not
reliable when
rotated in this
manner. Such
connections must
always be
snubbed and
attached to a
safety sling.
Hammer
Union Plug
End
Well Test
Female hammer union

plug end dislodged from
a side outlet of a sand
filter, with a pressure of
3,500 psi, while the
injured party was operating a valve. This
resulted in multiple
injuries leading to
death.
Mismatch in connection between

602 female and
1502 hammer
wingnut.
Ver. 2.0
18
Equipment
Operation
Event
Cause
Hammer
Union Seal
Well Cleanup
Operation
Vapour release from

connection
During operation, flowing temperature went

below minus 20 deg C (4 deg F) of the rating of
the seal. (This is the
same failure that caused
the Challenger disaster!)
Hammer
Union
Clean-up of
Wellhead
and BOP
prior to
pressure
testing.
While circulating
through a standpipe
manifold, a section
of chiksan line was
blown from its connection on the drain
line manifold. Mud
escaped onto rig
floor and over
drilling equipment.
Mismatch in connection
between 2 1502 hammer lock fitting on the
chicksan and a 2 1002
male fitting on the
standpipe. The pressure
at the time of failure
was approximately 2900
psi
Hammer
Unions
and Swivel
Joints
General
Multiple failure of
Hammer unions due
to poor make-up.
Hammer lugs tend to

deform and thereby
reduce the efficiency of
hammer blows
Flexible
Hose
In Service
2 flexible hose terminated in a 1502

chicksan
male/female connections failed in service.
There was evidence of

corrosion, splitting and
cracking, (manufacturing defect - slight over
swaging), no routine
inspections, hose assembly over 2 years old.
Hammer
Union
Equipment
Testing
Incident
occurred
during water
flow test
through a
Mud Line
Cellar Bit.
Shortly after pumping started, a 2 602

hammer union on the
pump stand pipe separated. An Assistant
Driller was struck
and fatally injured by
the male half while
reading a gauge.
Mismatch of 2 602
female and 1502 male.
Higher than expected
pressures due to misalignment of the rig floor
manifold. Assistant
driller was in line of
fire.
Ver. 2.0
Equipment
Flexible Hose
NPT Tape
Threaded
Fittings
Ver. 2.0
19
Operation
Event
Cause
Pressure
Venting
During pressure
venting after transfer
of bulk chemicals, a
4 flexible hose was
lowered over side of
vessel into the sea to
prevent dust clouds
during venting. It
was kept submerged
by using an old valve
and ballast chain on
the outboard end and
had a 4m length of
rope to aid recovery.
A sudden release of
compressed air
occurred when a vent
valve in the engine
room was opened and
caused the vent hose
to whip out of the sea
onto the deck of the
vessel where a crew
man was struck on
the head and fatally
injured.
There was an
uncontrolled
release of pressure due to vents
being opened in
the wrong
sequence.
On inspection a number of NPT fittings

made up to several
hose connections
appeared to not be
fully made up.
Fittings were
found to be galled
and only connected with effectively only two
threads. Further
investigation confirmed that these
fittings were outside acceptable
tolerance standards.
Make-up
Inspection
The hose was not

adequately
secured to preventing whipping
onto the deck and
the method used
was not safe or
recommended
practice.
The crew man
was in a dangerous position and
had apparently
ignored verbal
instructions to
clear the area
before venting.
20
Pipework Connections and Interfaces

In earlier sections it has been shown how important the quality of
pipework connections and interfaces is to the integrity of the system.
Improperly fitted, rated or sized connections repeatedly prove to be
the weak point of the system when exposed to operating conditions.
Mismatches
Mismatches in Hammer Unions are severe mechanical hazards to
the integrity of the Temporary Pipework System. They are weak
points that may fail under pressure and can result in serious personal injury, death and/or property damage.
Such Mismatches occur in 5 main categories:
Mismatching the Same Size.

Mismatching the Pressure Ratings.
Mismatching of Wing Nuts.
Mismatching of Components.
Mismatching of Non-Detachable and Detachable Components.
Avoiding these Mismatches is of prime importance in all aspects of
Temporary Pipework Operations. To further illustrate this each
Mismatch is covered more fully in the sections below.
Mismatching the Same-Size
These mismatches refer to connecting Hammer Union products having the same size, but different figure numbers. Improper matching
of this equipment can lead to two very dangerous situations:
1
Two parts of a hammer union with different pressure ratings,

and
Union threading appearing to be fully made up when in fact

only a portion of the threads are made up.
This will lead to a failure under pressure.

For Example:
The Wing Half of the 602 can mate up with the female 1002
but the common belief that it will hold the lower pressure rating of the two models is incorrect. This is a potentially dangerous mismatch and must be avoided.
Ver. 2.0
21
The Wing Half of the 1002 can mate up with the female 602,
but again, the common belief that it will hold the lower pressure rating of the two models is incorrect. This is a potentially dangerous mismatch and must be avoided.
And most seriously
The Wing Half of the 1502 can accept a female 602 or 1002.
This connection can appear to make-up and maintain a significant pressure (up to 3,500 p.s.i). However, once this pressure is exceeded, either section can become a projectile and
can cause death, serious injury or equipment damage. This
will also release high pressure fluids which are a clear hazard to health and the environment. The integrity of the
Union is compromised by the depth of thread engagement of
the nut thread with the female union, the threads have the
same pitch so the connection can appear to be secure, but it is
not; such connections will fail.
MIS-MATCH!
1502
Male Sub
and Wing Nut
602
Female Sub
Never connect products with hammer

union end connections that are not positively identified as to the manufacturer
and that are not identified to have identical union figure number, size and pressure rating. Mismatched connections
may fail under pressure, which can
result in serious personal injury, death
and/or property damage.
The following Hammer union mismatches are possible and must be

avoided
Size
Union Figure Nos
1 1/2
600, 602, 1002
402, 602, 1002, 1502
400, 1002
THE 2 602 AND 2 1002 UNIONS ARE BANNED IN SHELL .

THEY MUST BE IDENTIFIED BY CONTRACTORS AND INSTALLATIONS
AND SYSTEMATICALLY REMOVED AND REPLACED WITH
2 1502 UNIONS.
Ver. 2.0
22
Use of the Go No-Go Gauge

The Go No-Go Gauge should be used to be sure you have a 1502
Female Sub. The gauge wil be No-Go on a 1502 sub but will be a
Go on a 602 sub.
2 1502 Female - NO-GO
2 602 Female -GO
Mismatching Pipe Pressure Ratings

This Type of mismatch refers to connecting Hammerlug Union
products having different pressure ratings but with end connections
of the same size and Figure number. This occurs when mixing Sour
Gas pipe with Standard Service pipe or when mixing Unions
attached by pipe threads to pipe of service different to that specified by the Union.
Wing union components that cannot be positively identified with
regard to manufacturer, size, figure number, pressure rating and
type of service must never be used. Incorrectly identified components will lead to hazardous assemblies, which can fail under pressure and result in serious personal injury, death and/or property
damage.
15,000psi
WP
2 1502
Standard
Female Sub
10,000psi
WP
2 1502
Sour Service
Male Sub
and Wing Nut
MIS-MATCH!
Wing union components that cannot be
positively identified with regard to manufacturer, size, figure number, pressure rating and type of service must never be
used. Incorrectly identified components
will lead to hazardous assemblies, which
can fail under pressure and result in serious personal injury, death and/or property
damage.
Ver. 2.0
23
Mismatching Wing Nuts

This mismatch occurs when the Wing nut of one Size and Figure
number is mounted on the male sub of another Size and Figure
number. There is only a small amount of engagement of the male
sub in the wing nut and therefore the connection will not safely
hold typical working pressures.
MIS-MATCH!
2 1502
Wing Nut
2 602
Standard
Male Sub
Never assemble any combination of male

sub, wing nut or segments that are not
positively identified to assure that union
figure number, size, pressure rating and
manufacturer are identical. Mismatched
components will result in hazardous connections, which may fail under pressure,
which can result in serious personal
injury, death and/or property damage.
Mismatching Components
Mismatching of Components occur when segments and nut of one
Figure number are made up to a detachable male sub with a different Figure number. This results in a small amount of engagement
of the male sub with the segment engaging the wing nut. This will
not hold pressure safely during typical operations.
MIS-MATCH!
2 1502
Wing Nut
2 602
Detachable
Male Sub
Never assemble any combination of male

sub, wing nut or segments that are not
positively identified to assure that union
figure number, size, pressure rating and
manufacturer are identical. Mismatched
components will result in hazardous connections, which may fail under pressure,
which can result in serious personal
injury, death and/or property damage.
Mismatching Non-Detachable and Detachable Components

This mismatch is caused by the assembly of non-detachable nuts on
detachable male subs. The detachable wing nuts require a longer
thread length to compensate for the segments between the wing
nut and the sub shoulder. Use of a non-detachable wing nut in a
Ver. 2.0
24
detachable Union results in a lack of thread engagement and an

insufficient engagement between of the male sub shoulder with the
wing nut ID.
MIS-MATCH!
2" 1002 non-detachable nut inappropriately

used in a detachable union assembly. Notice
the resulting lack of thread engagement with
the female sub.
The misapplication of standard, non-detachable style wing nuts on 2", 3" and 4" Figure
602 and 1002 detachable nut connections
will result in an unsafe connection leading
to separation when under pressure. Failure
to avoid this condition may result in death,
serious personal injury and severe property
damage.
MIS-MATCH!
4" 1002 non-detachable nut inappropriately

assembled to a detached male sub end. Notice
the excessive play between the ID of the nut
and male sub OD behind the shoulder.
The misapplication of standard, non-detachable style wing nuts on 2", 3" and 4" Figure
602 and 1002 detachable nut connections
will result in an unsafe connection leading
to separation when under pressure. Failure
to avoid this condition may result in death,
serious personal injury and severe property
damage.
Mismatching Swivel Joint Components

The TripleStep (TSi) swivel joint, manufactured by FMC, employs a
stepped ball race design. Differences in the swivel load capacity
over traditional nonstepped race designs mean that potentially serious occurrences that could result from mismatching swivel joint
components of different designs and/or manufacturers.
Like the FMC 3 TSi swivel joint, the recently introduced SPM 3
HD-LR swivel joint employs a stepped ball race feature. FMCs 3
TSi swivel joints employ a one ball step in raceway diameter
between each of the three raceways. SPMs HD-LR swivel has a
Ver. 2.0
25
step between only two of the raceways. In addition to the stepped

race similarities, the axial spacing between the raceways of the two
models is very similar.
Because of these similarities, it is physically possible to erroneously
assemble a male race end of a SPM 3 HD-LR component into the
female race end of an FMC 3 TSi component. This mismatch of
components may falsely give the impression of a proper assembly,
since the swivel assembly may feel tight and hold pressure. While
the resulting assembly may give the false sense of a correct assembly and would likely contain pressure, the assembly would not be
structurally sound. This condition would result in a swivel connection that is unsafe and could potentially lead to catastrophic failure
of the connection.
Gap in 3
ball race
SPM 3 HD-LR
male ball race end
No step between
second and third race
FMC 3 TripleStep
female ball race end
Male race interferes

with female end
FMC 3 TripleStep
male ball race end
Dangerous Mismatch to be Avoided
SPM 3 HD-LR
female ball race end
Mismatch Avoided
Figure 11 - Dangers of mismatching Swivel Joint Components
Ver. 2.0
26
Flexible Pipes
Flexible pipes or hoses are resistant to bending, including frequentcontinuous flexure, however it is impreative that they are handled,
stored and maintained correctly.
In general:

The preferred installation for a flexible line is with the pipe

positioned in a J or U configuration, with the end fittings pointing up in a vertical position.
Do not leave medium to longer lengths of horizontal pipe
unsupported.
Ensure flexible pipe is not bent over or resting on sharp edges any vibration will cause damage at such points.
Do not exceed the minimum bending radius of flexible pipe.
[As a rule of thumb, the minimum bending radius (MBR) is
roughly 12 x the I.D. of the pipe].
MBR
d = (2 x MBR - OD)
d is the minimum
inside distance between
two surfaces
Figure 12 - Minimum bending radius of Flexible Pipe.
Ver. 2.0
Soft strops with

shackles
Cable SWL 5.7t
27
2
3
SF4
PN
15m
Chain block
Steel sling or soft

strop SWL 5t
Cable
Deck beam
One shackle connection SWL 6t as cable

is not long enough
Similar configuration for coflex on both ends
4
3
Figure 13 - Hose Installing Concept for long spans
Ver. 2.0
28
Hazard Identification and Mitigation

Mitigation Methods
Check lists
Pre-Pressure Test Temporary Pipework Walk-the-Lines Check
List
The purpose of the checklist is to ensure that the Temporary
Pipework and equipment:

Is hooked-up in compliance with the approved drawings and

equipment lists.
Can be operated as required by the Programme.
To ensure the adequacy of the ratings of the interfaces and
blanked-off outlets.
Checklists are an orderly and sequential collection of best practices for confirming the configuration of temporary pipework for
safe operations. Checking a temporary layout must often be undertaken amid a host of competing job priorities. Routine supervisory
duties can interfere with walking-the lines resulting in failure to
complete the checklist and confirm the correct configuration of the
temporary pipework. The consequences of disrupted or interrupted
checklists are varied and potentially serious and must be avoided.
The key points are:
1. The Wells Services Supervisor (WSS) and the Contractor
Services Supervisor (CSS) are jointly responsible for ensuring
that the Temporary Pipework is hooked-up as required by the
approved P&ID or Process Flow Diagram.
2. Any deviation in the Temporary Pipework hook-up from the
requirements of the Standard for Temporary Pipework (EP
2006-5393) needs a Dispensation.
3. A confirmation that all temporary pipework has been certified (maintained and tested) according to Contractors procedures (endorsed via contract awarded by Shell). Specifically
that no equipment is derated or below the minimum wall
thickness allowed.
4. The checks may be carried out Line Section by Line Section
determined by specification (pressure) breaks progressing
from high pressure to low pressure.
Ver. 2.0
29
5. Refer to EP 2006-5393 Appendices for specific hammer union

mismatches and restraint dynamic loads. (Note specifically:
both male and female 2 Fig 602 and 2 Fig 1002 unions are
banned in all configurations e.g. vessel outlets, burner boom
piping).
6. Where appropriate, record the number of connections inspected (Count) or equipment identification number (Eq. no.) in
the tick column and if NO is ticked, the Reason.
Location/Well:
Supervisors:
Reference Drawing No.
Job No.
Programme:
Date:
Reference Equipment List(s):
Line Section:
Dispensations Requested for this line section:
Item/ Description of Check Procedure
YES
NO
Count/Eq No.
Reason
1. Check pressure rating of upstream interface connection and subsequent

connections in the line by reference to banding.
2. Check pipework material for suitability for service.
3. Check that the number of swivels has been minimised.
3. Check/confirm that correct bolts and gaskets are installed at all mechanical
joints and bolt engagement. (Bolts shall extend completely through the nut
with at least one thread exposed at each end. Confirm that bolting has been
made up to the correct torque with calibrated torque wrenches.)
4. Check sealant on screwed connections is as per specification.
5. Check/confirm elastomers in hammer unions are compatible with
fluids/service.
6a. Confirm that vessel/equipment outlets, not in the flow path and potentially
subject to being pressured are appropriately blanked. Where the blanking
comprises a male or female hammer union confirm the FIG no. and service is
compatible with the vessel/equipment specification.
6. Check for correct flow through filters and strainers, traps, check valves,
globe valves and control valves.
7. Check that the valve positions are tagged (open/closed) and are correctly
lined up for the pressure testing. Where a valve is required to be locked open
or closed, ensure that the locking system is sufficiently robust, preventing it
from being simply overridden. Note those valves the position of which needs
to be altered for the first operation.
8. Check that all chain wheels and extended spindles required for specified
valves have been installed
9. Check that orifice flanges have required upstream and downstream
clearances.
10. Check that all vents and drains are installed. The drains should be at the
lowest points and vents at the highest points. Check for proper slope (e.g.
flare lines).
11. Check all instrument thermowells installed. Check that welded nipples are
properly installed. Threaded nipples shall be checked for engagement, Check
that they have not been seal-welded.
12. Confirm the setting of pressure pilots, and sizing of pressure reliefs.
13. Confirm the safety of electrical instruments.
14. Check that all pipe supports, anchor point, clamps and restraints are
adequate. (Confirm that expansion allowance has been provided. Confirm that
there is no excessive bending moment resulting from lack of support or
overloading from tugger lines on the pipework.)
15. For items marked No, raise outstanding works list and ensure that it is
completed prior to pressure testing.
Figure 14 - Pre-Pressure Test Temporary Pipework Check List

Ver. 2.0
N/A
30
No-Go areas
During pressure testing keep at least 2 pipe run lengths
away from the line under pressure.
Keep out of line-of-sight of pressured plugged outlets, instrument connections on vessels and flowline equipment.
Restraints
The system of restraints demonstrated in this Section is provided
by WeirSPM.
The WeirSPM system of restraint has sufficient strength to restrain
pipework for the loading tabulated in the Temporary Pipework
Standard, Appendix 3 (reproduced below), and has been tested at
the instigation of Shell for restraining pipework rigged up for high
temperature (250oF) operations.
EP 2006-5393
- 22 -
APPENDIX 3.
DYNAMIC LOADING ON RESTRAINTS PIPEWORK

CONNECTION BURST CASE
Dynamic Forces created by Seawater for

system pressures
(Kilo Pounds-Force / Metric Tonnes)
Nominal
Pipe OD
(ins)
2
3
4
Restricted
Dynamic Forces created by Gas (N2) for

system pressures
(Kilo Pounds-Force / Metric Tonnes)
5,000 psi
10,000 psi
15,000 psi
5,000 psi
10,000 psi
15,000 psi
21 / 9.55
41 / 18.6
68 / 30.9
42 / 19.1
82 / 37.3
135 / 61.4
64 / 29.1
124 / 56.4
204 / 92.7
17 / 7.7
33 / 15.0
55 / 22.0
31 / 14.1
56 / 26.8
99 / 45.0
42 / 19.1
82 / 37.3
138 / 62.7
Note: Information extracted from Reference [5]
Figure 15 - Extracted table showing Dynamic Loading on Restraints

Note that liquids produce higher dynamic loading than gas at the
same pressure. The reason for this is that loading is proportional to
the density of the fluid being discharged. With gas the discharge to
low pressure takes longer, but the intitial shock is less than that
from liquid at the same pressure.
Fibre Rope Restraints (FRRs) are intended to help contain highpressure piping and components in case of rupture or excessive
impulse during the pumping process. When flow lines fail, whether
it is due to excess pressure, faulty connections, worn components,
damage to the piping connection, or otherwise, the results can be
devastating and catastrophic to both equipment and people. The
metal components that were previously being subjected to up to
15,000 p.s.i. of internal pressure are suddenly and instantly forced
to release that stored energy. In a failure there could be hundreds
Ver. 2.0
31
or even thousands of pounds of iron pipe flailing about in an unrestrained condition. In that scenario, there is a high likelihood of
severe personal injury or death. FRRs reduce, but do not eliminate,
that risk.
Installation of individual FRR components as well as the system
itself should be done by trained personnel.
Installation Steps
Install FRR system after entire flow line is setup.

Hammering wing nuts can be clumsy with FRR equipment
installed.
When possible, fill the flow line system with water (no pressure) and look for leaks before installing FRR system components.
After the safety restraint system is installed, check every
connection, every link, and every FRR component to ensure
that there is a continuous connection from anchor point to
anchor point.
After FRR system is installed, make sure:
a) All FRR ribs are installed as tight as possible around flow
line components.
b) All main line and anchor line spine FRRs are as tight as
possible from anchor point to anchor point.
Always keep ALL personnel not essential to the operation away

from flow line system while under pressure. This applies even when
a safety restraint system is installed.
The following pictures illustrate the jacketed fibre rope flowline
restraint system supplied by WeirSPM.
Ver. 2.0
32
Step by Step Installation

1
End A
End B
Position the rib beneath the flowline and straddling

the union assembly. It may be necessary to raise the
flowline slightly with a pipe jack to achieve this.
Keeping end B stationery, bring end A up over

the union assembly towards end B
B
Next, bring end A down through the end B
opening.
Continue to pull end A through the end B opening and under the union assembly back towards the
end A starting point.
A
B
B
Again, loop end A over the union assembly
towards end B
Draw end A even with B end, ensuring that the

rib fits snugly around the union assembly.
Ver. 2.0
33
A
A
Both loop ends are now gathered ready for installing To take up any slack and ensure a more secure conthe spine.
nection, both loops are rotated together from flat.
10
A
Ideally, this rotation should be continue through 270
degrees.
If there is not enough slack to allow a rotation of 270

degrees, then the rotation cand be stopped at 90
degrees from flat.
11
Once this twist loop has been formed, the end of

the spine can be fed through it.
12
The spine can then continue to be pulled through

other installed ribs. Note, it is recommended that all
ribs are installed before installing the spines.
Figure 16 - Recommended fibre rope installation method
Ver. 2.0
34
Rib Locations
Union connections
FRR Ribs should be installed on EVERY union connection on the
flow line (one rib per union). The rib envelope must always straddle
both sides of the union in order to help contain each end of the
adjoining pipes/components.
Figure 17 - Fibre rope rib installation at a Union Connection
Swivel Assemblies
Swivel assemblies should have FRR ribs installed at the two wing
union connections at each end, and also around unsecured swivel
joint connections.
Figure 18 - Fibre rope rib installation at a Swivel Assembly

Ver. 2.0
35
Flow Line Components

Virtually all flow line components utilise two wing union connections usually male x female. Therefore, most flow line components
(check valves, plug valves, etc.) require FRR ribs installed at each
end as shown.
Figure 19 - Fibre rope rib installation at a Flow Line Component
Long Piping Assemblies

Most piping assemblies can be treated like other flow line components - with one FRR Rib installed on each union connection at
each end. However, on piping assemblies 10 feet or longer, it is
required that a third FRR rib also be installed midway between
the two union connections.
This centre rib will not have the union connection to help prevent it
from moving, however, field testing has shown that this rib will
help provide extra support should a failure occur.
Figure 20 - Fibre rope rib installation on a Long Piping Assembly
Ver. 2.0
36
Installing Fibre Rope Spines

Installing Fibre Rope Spines on a Flowline System, as shown
above, requires that spines be linked together in a safe manner to
provide the length required between anchor points.
Linking Spines
1
End
C
End
A
End
D
End
B
Lay out Fibre Rope Spines. end to end as shown.

(here they have been labelled ends A to D for
clarity.
Keeping end B stationery, draw C through the

loop of B as shown.
D
C
C
B
B
Continue to pull C back over loop B and then
Pull the remainder of C end through until D
inserted under loop D as this is pulled in the direc- draws close to B end as shown.
tion of B
5
End
D
t
ig h
T
ll
Pu
While holding B end stationary (using a second

person or placing a weight on the A-B fibre
rope) keep pulling C end until the B-D connection can no longer be tightened. Notice how the
B and D ends of the spines have now swapped
places.
End
B
Figure 21 - Recommended fibre rope spine installation method.
Ver. 2.0
37
When linking such Spines, there are a few points to remember:

Never tie knots in Spines, use only the approved linking

method (described below).
Every spine to spine link must be tight.
Never link Spines and Ribs together. Spines generally have
twice the strength rating of Ribs and therefore such mixed
linking must be avoided. (Ribs may be linked to each other
using this method if a single Rib is too short to install properly.)
Ribs must never be substituted for Spines.
Anchor Points
Anchor points of sufficient structural integrity or mass must be
used.
Certify as lifting appliance
2 tonne concrete block

used as anchor point
Wellhead structure used as tie-down point

Figure 22 - Example Anchor Points
Ver. 2.0
38
Avoiding Injury
Hammering Unions
In order to minimise the risk of injury while hammering unions,
the following points must be followed:

The heads of hammers should be made of Copper/Beryllium

(CuBe) or similar material that cannot cause sparking.
The hammer heads and lugs on the Hammer Union Wing
Nut should be in good condition.
Acceptable
Unacceptable
Figure 23 - Condition of Lugs on Hammer Union Wing Nuts

The hammer shaft, if wood, should be in good condition.

Preferably the hammer shafts should be made of composite
material
Consideration should be given to using Safety Iron where
possible.
Courtesy of
WeirSPM
Figure 24 - WeirSPM Safety Iron
Ver. 2.0
39
Where hammer unions cannot be avoided then the WeirSPM

Safety Hammer should be considered.
Note: the picture shows a

union with threaded makeup to the pipe body.
This is banned in Shell
Courtesy of
WeirSPM
Figure 25 - WeirSPM Safety Hammer
Gauges
When reading gauges on
pressured pipework, keep
body out of line of fire of
connections.
Gauge
Connection
Figure 26 - Gauge positioned

directly above a pressurised
pipe connection
Ver. 2.0
40
Completing the Connection Interface Diagram

In order to mitigate against the safety and operational risks associated with incorrect connections in temporary pipework, a toolbox
has been intoduced to standardise the construction of Completion
Interface Diagrams (CIDs).
The objectives of this toolbox are:

To create a consistent standard for representation of temporary pipework connections.

To simplify layouts to remove unnecessary or confusing information.
To make identification of critical connections easier.
To mitigate against incorrect connections at pipe interfaces
The procedure begins with a layout drawing or P&ID and, with the
use of a MS Word templates or Visio templates (Visio is much easier to use), aides the construction of a clear layout design.
A guide to using this toolbox along with a video tutorial have been
prepared and should be reviewed before attempting the construction of the CID for your operation.
Constru
3. CID
Ke
Software
Shell Exp
loration and
y Featur
ction and
Implem
entation
es
of Connec
tion Inte
rface Dia
grams
Platform
All existing
CIDs hav
versions
of this soft e been created
in Microso
ware pac
is advisab
ft
kage that
le,
are availabl Word. They sho
should mak but not necessa
uld be read
e. All new
ry, to use
e the crea
able and
CIDs sho
the
tion and
editable
uld be crea
Microso
editing pro most recent vers
in most
ft Wo
ted in Mic
ion of this
cess mor
rosoft Wo
of this guid rd has been cho
e simple.
software
sen
rd. It
e, users
that is avai
will be fam over other pac
that it and
lable as
kages due
they can
iliar with
this
to its alm
produce
the draw
ost univ
the desired
Figure 1
ing method
ersa
shows a
l use on
results in
s used in
complet
PCs. By
are desc
terms of
the packag
ed CID
the end
ribed as
nea
e
t,
for
and
clea
follows;
Well Tes
r and con
will be con
ting Tem
sistent CID
fident
porary Pipe
s.
work. The
Production
key feat
ures of this
diagram
ion and
Construct ion
x for the
ct
A Toolbo
of Conne
n
tio
ta
Implemen
Diagrams
Interface
Comprising
part of the
Guidance
to the Tem
porary Pipe
Figure
1 - Well
Testing
June 2006
Shell
work Stan
dard
CID
Rev. 1
Explora
tion and
Production
Nexus
Consult
ing, 200
6
Page 4
Figure 27 - CID toolbox guide

Ver. 2.0
41
Figure 28 - CID toolbox video tutorial.
The completed CID for an operation will be used as a check when

walking the lines to confirm that it is safe to test.
Alternatively, Piping and Instrument Drawing (P and ID) can be
used to show the connections and their interfaces and as reference
when walking the lines.
Ver. 2.0
2"
1502
3"
1502
3" x 2" 1502
X-over
3" 1502
4" 602
4" 602
Female - Male
X-Over
4" 602 x 4" 206
All blanked-off outlets on vessels

must be identified.
To be used when "Walking-the-Lines"

prior to pressure testing.
EXAMPLE: P and ID Marked-up showing

Connection Interface
4" 602
Example of marking
up P and ID
42
Figure 29 - P & ID showing connections marked-up for Walking - the - lines
Ver. 2.0
43
Walking the Lines

Prior to pressure testing, the test set up and spread shall be
'walked' and checked against the connection schematic (CID) to
confirm that it is safe to test, there being no connection mismatches, that the pipework restraint arrangements have been installed
as planned, and that suitable pressure test safety precautions such as valves being in the correct position, air bleed points, and
barriers - are all in place. Items of equipment that cannot be individually restrained, such as hammer union blanking plugs on
process equipment outlets shall be specifically identified and
checked for compatibility with the mating union and process equipment rating.
Example walkthrough
Some things to look out for, in addition to those previously mentioned, include:
All connections and long runs of pipework
should be suitably restrained
Insufficient restraints
Earthing Point corroded
Ver. 2.0
44

Pipework and connections must be adequately
supported
Insufficient/inappropriate support
NPT thread showing some corrosion

Flange bolts should extend completely through
the nut with at least one thread exposed
Flange bolts do not fully penetrate nuts
Figure 30 - Example things to consider during walking the lines
Also confirm that the design is not flawed e.g. check-valve reversal!
Ver. 2.0
45
Awareness of Safety Initiatives

FMC Technologies Ltd
The following safety initiatives have just been commercialised by
FMC.
[No pictures of this equipment have been provided by FMC at the
time of issue of this Guide.]
The initiatives comprise:

1)
2)
3)
4)
A lifting device for plug valves.

A Chiksan Swivel work bench.
The manufacture of a Truncated 2" FIG 602 female sub.
A Guided Hammer.
1) The lifting device allows heavy plug valves to be moved around

and lined up without risk of personal injury/strain.
2) The Chiksan swivel work bench streamlines the redressing and
improves the quality of the maintenance of swivels, the swivels
being better supported and more accessible, compared with their
placement in a vice, for instance. This is a tool for the workshop.
3) The truncation of the 2" FIG 602 female sub is identical to the
step taken by Anson in 2001, cutting 30/1000" off the thread OD
and putting a shoulder on the female sub to prevent make-up of
the 2" FIG 602 female sub to the 2" FIG 1502 male union. Since
there is no compromise on the banning of 2" FIG 602 unions, the
truncated 2" FIG 602 subs should not appear on Shell installations, even though their construction prevents mismatch makeup.
4) The Guided Hammer avoids the wing nut make-up on "hammer
unions" using a sledge hammer. The wing nut is replaced with
one that will accept an FMC jarring device. The wing nut is
replaced with one comprising the nut (lugs removed) with a continuous plate (the nut and plate is a single forging) on the outside of the nut with 3 holes appearing in the plate where the
lugs used to be. The jar consists of a yoke (which is pinned for
making up the connection in one of the holes on the nut) connected to a mandrel on which rides a cylindrical weight. The
Ver. 2.0
46
weight, being "Guided" by the mandrel, is slammed/Hammered

against the yoke to make the union nut up tight to the female.
Since Shell requires that the unions on all pipework be forged or
welded, the wing nuts with lugs cannot be removed and replaced
with this new type of nut. So the introduction of this system
requires the replacement of all existing pipework with that having the new nut type.
Ver. 2.0
SHELL
This document is the property of Shell,

and the copyright therein is vested in
Shell. All rights reserved. Neither the
whole nor any part of this document may
be disclosed to others or reproduced,
stored in a retrieval system, or transmitted
in any form by any means (electronic,
mechanical, reprographic recording or
otherwise) without prior written consent
of the copyright owner.
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Drilling and Well Services

ABC Guide to Temporary Pipework

Basics for Common Understanding

The identification of the Female and Male parts of a

Drilling and Well Services

ABC Guide to Temporary Pipework

The meaning of "Temporary"

Drilling and Well Services

ABC Guide to Temporary Pipework

What is Temporary Pipework

Hazard Identification and Mitigation

Drilling and Well Services

ABC Guide to Temporary Pipework

Completing the Connection Interface Diagram

Drilling and Well Services

ABC Guide to Temporary Pipework

What is Temporary Pipework

From a pump to a wellhead.

Usually one source

Drilling and Well Services

ABC Guide to Temporary Pipework

Temporary pipework is piping and flowline equipment that is

General Pumping Operations (transfer of fluids, mud/brine

Figure 2 - Typical Temporary Pipework Set-ups

ABC Guide to Temporary Pipework

Pipework runs (straights), pup joints, elbows.

Chiksan (Swivel) Joint

Typical Coflexip Line

Figure 3 - Some typical equipment involved

Drilling and Well Services

ABC Guide to Temporary Pipework

The pipework connections referred to in the guide are known as:

Graylok Hub-type Connection

Figure 4 - Temporary Pipework Connections

In summary, Temporary Pipework (chicksan, flowline equipment)

Drilling and Well Services

ABC Guide to Temporary Pipework

Mechanically sound and has been properly inspected prior to

Drilling and Well Services

ABC Guide to Temporary Pipework

Figure 5 - Relative Pressure Comparison

Thinking about the forces involved, it should be clear why it is vital

Drilling and Well Services

ABC Guide to Temporary Pipework

Stored energy is the capacity

Yield Strength is the stress a

Long pipe runs .

Drilling and Well Services

ABC Guide to Temporary Pipework

Figure 6 - Vibration in Temporary Pipework

Common causes of Vibration

Excessive Pulsation (from pumps for example).

Figure 7 - Bend is being straightened due to bending forces

Drilling and Well Services

ABC Guide to Temporary Pipework

Drilling and Well Services

ABC Guide to Temporary Pipework

Figure 8 - Erosion point in a short radius bend

Erosion can lead to leakage a rapid failure and it is therefore

ABC Guide to Temporary Pipework

Predicted erosion rates

Figure 9 - Erosion of common equipment

Drilling and Well Services