WELLHEAD MAINTENANCE PROCEDURE TRNC-WM-001 Rev 0

WELLHEAD MAINTENANCE ODIDI FIELD

OML 42 (NPDC)
TRNC-WM-001

0 03-03-15 DRAFT FOR REVIEW OA OL

Prepared Reviewed Approved

Reason for Issue
Rev. Issue Date by by by

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TABLE OF CONTENT

1.0 INTRODUCTION ....................................................................................................... 3

1.1 STANDARD ABBREVIATIONS ................................................................................. 4
1.2 SAFETY .................................................................................................................... 5
1.3 WELLHEAD COMPONENTS .................................................................................... 5
2.0 SCOPE OF WORK.................................................................................................... 6
3.0 RESPONSIBILITIES ................................................................................................. 6
4.0 FIRST LINE MAINTENANCE SERVICES PROCEDURE .......................................... 6
4.1 REVIEW RISK, COSHH AND MANUAL HANDLING ASSESSMENTS ..................... 6
4.2 VISUAL INSPECTION OF WELLHEAD COMPONENTS .......................................... 7
4.2.1EXTERNAL DAMAGE INSPECTION ........................................................................ 7
4.2.1.1 TREE VALVES .................................................................................................... 7
4.2.1.2 INTEGRITY CHECKS AND FUNCTION TESTING CHRISTMAS TREE
COMPONENTS AND VALVES ………………………………………………………………….... 8
4.3 PRESSURE INTEGRITY TEST................................................................................. 8
4.3.1 KILL WING VALVE................................................................................................... 8
4.3.2 LOWER MASTER VALVE ........................................................................................ 8
4.3.3 UPPER MASTER VALVE ......................................................................................... 8
4.3.4 PRODUCTION WING VALVE .................................................................................. 9
4.3.5 SWAB VALVE .......................................................................................................... 9
4.3.6 ABOVE PRODUCTION WING VALVE ..................................................................... 9
4.3.7 ABOVE SWAB VALVE ............................................................................................. 9
4.3.8 BELOW KILL WING VALVE ..................................................................................... 9
5.0 LEAK-OFF TEST ...................................................................................................... 10
5.1 LOWER MASTER VALVE ....................................................................................... 10
5.2 UPPER MASTER VALVE........................................................................................ 10
6.0 SV/SCSSV FUNCTION / INTEGRITY TEST ........................................................... 10
APPENDIX ...................................................................................................................... 11

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1.0 INTRODUCTION

At the Royal Niger we pride ourselves on providing Hydraulics, Controls, Drilling and
Production Equipment and services to the Local and International energy and Marine
industries.

In conjunction with our technology partners, we are committed to engineering and

manufacturing innovative solutions for asset life extension and enhanced oil recovery
tailored to each customer’s unique needs and specifications for their brownfield
developments while complying with current standard and directives.

At the helm of the Royal Niger is a team of experienced industry professionals who, because
of their understanding of your operational imperatives, strive to deliver quality products and
services ranging from product design and manufacture to complete asset management
support.

When our proven solutions won’t meet the specific requirements of a customer, our
specialist teams will work with that customer to create one that does – technically and
commercially.

Head Office Address: Royal Niger Emerging Technologies Limited.

No 8, Saka Jojo Street,
Victoria Island, Lagos, Nigeria

Service Location: Royal Niger Emerging Technologies Limited

Plot 139 Trans-Amadi Industrial Layout,
Port Harcourt, Nigeria
Phone: 08097000111

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This Maintenance Manual covers general information on first line maintenance on Odidi field
wellhead systems.

1.1 STANDARD ABBREVIATIONS

API American Petroleum Institute

ASME American Society of Mechanical Engineers
AP Annulus Pressure
BHF Button Head Fitting
BOP Blow Out Preventer
BSI British Standards Institution
BSP British Standard Pipe
CA Certifying Authority
COSHH Control Of Substances Hazardous to Health.
C/T Coiled Tubing
DHSV Down Hole Safety Valve
EDP Emergency Disconnect Package
FAT Factory Acceptance Test
HPHT High Pressure High Temperature
IT Intervention Tool
ITC International Electrochemical Commission
LMRP Lower Marine Riser Package
LRP Lower Riser Package
MPR Middle Pipe Rams
MWP Maximum Working Pressure
MWT Maximum Working Temperature
NACE National Association of Corrosion Engineers
NPT National Pipe Thread
POOH Pull Out Of Hole
PSL Product Specification Level
PSI Pounds per square inch
PSIG Pounds per square inch gauge
PUP Pipe Utility Piece
QTC Qualification Test Coupon
RIH Run In Hole
SCSSV Surface Control Subsurface Safety Valve
SITHP Shut-In Tubing Head Pressure
SSV Surface Safety Valve
TH Tubing Hanger
THP Tubing Head Pressure
TP Test Pressure
TPI Threads Per Inch
WH Wellhead
WP Well Pressure
UNC Unified National Coarse
WHP Wellhead Pressure
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WOCS Work-over Control System

1.2 SAFETY
Safety is paramount. All applicable legal and company safety standards must be adhered to
at all times. Where any procedure gives cause for uncertainty or concern, clarification must
be sought from responsible company representatives before proceeding. The following
categories are examples of these areas of consideration:
 Lifting by mechanical or manual means.
 Pressure testing and pressure containing equipment where the pressure may
range from compressed air to that required by full working pressure tests.
 COSHH the Control of Substances Hazardous to Health. For example
Lubricants and coating materials.
Precautionary statements can be found throughout the manual to highlight special situations.
The statements included describe as many of these special situations as have been
identified, although others may exist. These statements are as follows:

NOTE: A comment of general nature to clarify or explain special situations.

CAUTION: An instruction that must be followed to avoid damage to, or problems with,
equipment.

WARNING: An instruction that must be followed to avoid injury to personnel.

None of the statements issued in this document are not intended to supersede safe site
practices or safety regulations. The recommended procedures included in this manual are of
a general nature and may not address all of the variables that may occur when carrying out
tasks on location. They are not intended to obviate the need for sound engineering.

1.3 WELLHEAD COMPONENTS

Wellheads serve as connection points for tubular and surface flow lines and well pressure
control.
The conductor pipe forms the lower section of the wellhead and is fitted with a slip type or
threaded casing head, also known as wellhead flange. The conductor pipe supports the BOP
during drilling or work-over operations.

Annulus port on the wellhead allows communication with the annulus when additional casing
string is run.
Casing-head housings are attached to the upper end of the surface casing.
The casing-head spools are attached to the top connector of housings or other spools. Both
casing-head housings and spools are designed to accommodate hanging and packing
mechanism that can be used to suspend and seal tubing strings.

Tubing-head spools are attached to the top connector of the casing-head housings or
spools. These are designed to accept packing mechanisms which seal casing strings and
hanger and packing mechanism which can be used to suspend and seal tubing strings.
Metal-to-metal seals are used to create leak prove barriers between the wellhead and
multiple tubing spools in severe (sour) service environment.

Most wellheads are designed to API 6A/ISO 10423 specifications.

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The upper section of the wellhead, known as Christmas tree is comprised of control (gate)
valves. The tree sits on top of tubing hanger spool and holds the valves for well operation
and control.

A typical tree will have at least four to five valves.

 Lower and upper master valves are found on the lower section of the tree which are
normally in fully open position during well flow and only closed during emergency
situations.
 The lower master valve is manually operated and used for well isolation during well
intervention (wireline, coiled tubing) operations.

The upper master valve is in most cases is hydraulically operated and can be remotely
operated to facilitate well shut-in during emergency. Some trees have manually operated
gate valves as well.

 Situated immediately above the upper master valve are the production (flow) wing
valve and kill wing valve.

The flow wing or production wing valve is hydraulically actuated and designed to fail
safe close. The valve closes at the loss of control line pressure.
Situated opposite the production wing valve is the kill wing valve, used for injection of well kill
fluids and chemicals into the well to prevent hydrate formation. The kill wing valve is also
used for the pressure testing of surface equipment and down-hole tools.

 The swab valve sits on top of the Christmas tree. The swab valve is normally
manually operated and allows the rig up and pressure testing of surface equipment for
well intervention operations.
Some trees have dual swab valves.

2.0 SCOPE OF WORK

The work scope for the provision of preventive maintenance services for about 20 wellheads
with the following well names; 3S, 3L,15L, 18T, 19S, 19L, 21S, 22S, 23S, 23L, 24L, 28S,
31L, 31S 32T, 34S, 34L, 35S, 35L, 37S, 37L, 38L, 43L, 44S, 44L, 46S, 46L, 48T and 51T in
OML 42, is on call out basis for NPDC wellhead. These among others are:

3.0 RESPONSIBILITIES

It is the duty of the field supervisor to ensure that activities are carried out in safe and control
manners and work procedures and processes are fully implemented and adhered to.

4.0 FIRST LINE MAINTENANCE SERVICES PROCEDURE

4.1 REVIEW RISK, COSHH AND MANUAL HANDLING ASSESSMENTS

 Carry out and review risk assessment prior to commencement of tasks.

 Review MSDS of chemicals before use.
 Hold JSA ensuring all personnel involved in the tasks fully understand tasks to be
carried out and responsibilities.
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 Use mechanical lifting device for heavy loads.

4.2 VISUAL INSPECTION OF WELLHEAD COMPONENTS

4.2.1 EXTERNAL DAMAGE INSPECTION

4.2.1.1 Tree valves – inspect flow paths and valves internals for signs of erosion or
corrosion damage
 Actuators
 Check valves
 Chokes
 Connectors and fittings
 Cross-over connectors (including thickness checks)
 Tubing-head adapters
 Top connectors
 Adapters and spacer spools
 Fluid sampling spools
 Casing and casing hangers
 Mandrel hangers
 Slip hangers
 Surface and under water safety valves – control panels and control lines
 Loose connectors – flanged, threaded and other end connectors:
i Weld neck connectors
ii Blind connectors
iii Threaded connectors
iv Adapter and spacer connectors
v Bull-plugs
vi Valve removal plug

4.2.1.2 INTEGRITY CHECKS AND FUNCTION TESTING CHRISTMAS TREE

COMPONENTS AND VALVES

NOTE: Refer to equipment manufacturers’ instruction manuals where applicable.

 Record tubing head pressure and temperature

 Where applicable, bleed off down-hole safety valve control line pressure to zero to
shut-in well.
 Bleed down pressure above down-hole safety valve via production wing valve to 200
psi and monitor well pressure above down-hole safety valve (DHSV) for 15 minutes.
 Bleed down pressure above down-hole safety valve to zero after a good leak-off test.

Caution:(monitor tubing head and annulus pressure at all times).

 Cycle lower master valve to close position and record valve turns.
 Cycle lower master valve to open position, taking note of the number of turns.
 If hydraulically operated, function the upper master valve to a close position and
record pump strokes.
 If hydraulically operated, function the upper master valve to open position. Record
pump strokes.
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 Using the valve handle, close tree kill wing valve. Record valve handle turns.
 Using the valve handle, open tree kill wing valve. Record valve handle turns.
 Using hydraulic pump, apply 2000 psi pressure to production wing valve actuator to
open the production wing valve. Monitor open line pressure for 15 minutes.
 Vent down control line pressure to zero to shut-in production wing valve. Record time
for full valve closure.
 Using the gate valve handle, close the swab valve fully and record valve turns.
 Using the gate valve handle, open the swab fully and record valve turns.
 Repeat the above and grease all valves bodies and bonnets.

4.3 PRESSURE INTEGRITY TEST

 Ensure that all tree valves are in open position.

 Ensure that DHSV is in close position.
 Rig up hydrostatic test equipment (high pressure test pump, chart recorder).

4.3.1 KILL WING VALVE

 Install test cap on kill wing valve outlet.

 Close kill wing valve and connect test line to the downstream side of the kill wing
valve.
 Using high pressure test pump, pressure test kill wing valve from below to 5000 psi.
 Monitor test pressure for 15 minutes.
 Acceptance criteria: +- 5% of test pressure (API 6A).
 Bleed down test pressure to zero and open kill wing valve.

NOTE: cycle and grease valve if leaks are observed.

4.3.2 LOWER MASTER VALVE

 Install test caps and needle valves on production wing valve and swab valve.
 Close needle valves on production wing valve and swab valve outlets.
 Close Lower master valve.
 Connect test line via kill wing valve and pressure test against lower master valve
from above to 5000 psi.
 Monitor test pressure for 15 minutes.
 Acceptance criteria: +- 5% of test pressure (API 6A).
 Bleed down test pressure to zero and open lower master valve.

NOTE: cycle and grease valve if leaks are observed.

4.3.3 UPPER MASTER VALVE

 Close upper master valve Connect test line via kill wing valve and pressure test
against upper master valve from above to 5000 psi.
 Monitor test pressure for 15 minutes.
 Acceptance criteria: +- 5% of test pressure (API 6A).
 Bleed down test pressure to zero and open upper master valve.

NOTE: cycle and grease valve if leaks are observed.

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4.3.4 PRODUCTION WING VALVE

 Close production wing valve and open needle valve on the valve outlet.
 Pressure test production wing valve from below to 5000 psi via kill wing valve.
 Monitor test pressure for 15 minutes.
 Acceptance criteria: +- 5% of test pressure (API 6A).
 Bleed down test pressure to zero and open production wing valve.

NOTE: cycle and grease valve if leaks are observed.

4.3.5 SWAB VALVE

 Close swab valve and open needle valve on the valve outlet.
 Pressure test swab valve from below to 5000 psi via kill wing valve.
 Monitor test pressure for 15 minutes.
 Acceptance criteria: +- 5% of test pressure (API 6A).
 Bleed down test pressure to zero and open swab valve.

NOTE: cycle and grease valve if leaks are observed.

4.3.6 ABOVE PRODUCTION WING VALVE

 Close production wing valve and connect hydraulic test line to valve outlet.
 Pressure test production wing valve from above to 5000 psi.
 Monitor test pressure for 15 minutes.
 Acceptance criteria: +- 5% of test pressure (API 6A).
 Bleed down test pressure to zero and open production wing valve.

NOTE: cycle and grease valve if leaks are observed.

4.3.7 ABOVE SWAB VALVE

 Close swab valve and connect hydraulic test line to valve outlet.
 Pressure test swab valve from above to 5000 psi.
 Monitor test pressure for 15 minutes.
 Acceptance criteria: +- 5% of test pressure (API 6A).
 Bleed down test pressure to zero and open swab valve.

NOTE: cycle and grease valve if leaks are observed.

4.3.8 BELOW KILL WING VALVE

 Close kill wing valve and open need valve on valve outlet.
 Pressure test kill wing valve from below via top of swab valve to 5000 psi.
 Monitor test pressure for 15 minutes.
 Acceptance criteria: +- 5% of test pressure (API 6A).
 Bleed down test pressure to zero and open kill wing valve.

NOTE: cycle and grease valve if leaks are observed.

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5.0 LEAK-OFF TEST

NOTE: This is applicable if well is flowing:

5.1 LOWER MASTER VALVE

 Ensure that all tree valves are in open position and close needle valves on
production wing, kill wing and swab valves outlet.
 Confirm the status of SSV/SCSSV. Function SSV/SCSSV open if in close position.
 Monitor THP and record stable THP.
 Close lower master valve and gradually bleed down pressure above lower master
valve to 100 psi via kill wing valve.
 Monitor pressure above lower master valve for 15 minutes.
 Acceptance criteria: Pressure increase should exceed 5% of bleed-off pressure (API
6A).
 Bleed down pressure above lower master valve to zero and open lower master valve.
 Record THP.

5.2 UPPER MASTER VALVE

 Ensure that all tree valves are in open position and close needle valves on production
wing, kill wing and swab valves outlet. Confirm the status of SSV/SCSSV. (Function
SSV/SCSSV open if in close position).
 Monitor THP and record stable THP.
 Close upper master valve and gradually bleed down pressure above upper master
valve to 100 psi via kill wing valve.
 Monitor pressure above upper master valve for 15 minutes.
 Acceptance criteria: Pressure increase should not exceed 5% of bleed-off pressure
(API 6A).
 Bleed down pressure above lower master valve to zero and open upper master valve.
 Record THP.

6.0 SV/SCSSV FUNCTION / INTEGRITY TEST

The purpose of this test is to confirm the integrity and functionality of the SSV/SCSSV,
control lines and actuators.
 Record tubing head pressure.
 Record control line pressure at the control panel.
 Vent down control line pressure to zero on the control panel.
 Slowly bleed down SITHP by 20% of recorded THP.
 Monitor shut-in pressure for 15 minutes and record final shut-in pressure.
 At the control panel pressure and open SSV/SCSSV.
 Confirm SSV/SCSSV is fully opened and record pressure.
 Monitor line pressure for leaks.

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APPENDIX

Fig 1 – WELLHEAD EQUIPMENT DATA SHEET (CHRISTMAS TREE AND CHOKE)

WELLHEAD EQUIPMENT DATA SHEET – CHRISTMAS TREE AND CHOKE

Christmas tree Single Dual Solid Block Stacked (tick as appropriate)

Size Material Ext coating Flanged bolting (bolt/nut)Ring gasket type

Lower master valve
Upper master valve
Swab valve
Production wing valve
Kill wing valve
Tee/cross
Choke
End flange
Companion flange
Instrument flange
Tree cap/top connection

Choke type Adjustable Fixed

Flowline connection Size:Type:

Upper master valve type actuator requirement: Pneumatic/piston Hydr/piston Electric

Supply pressure power: Pneumatic/diaphragm Hydr/diaphragm Electric

Air Gas

Supply pressure ………………..

Other …………………………….

Fig 2 – WELLHEAD EQUIPMENT DATA SHEET (TUBING HEAD ADAPTER)

WELLHEAD EQUIPMENT DATA SHEET – TUBING HEAD ADAPTER

Tubing head adapter PSL - Pressure rating
PR-
Bottom connection Size - RWP -
Top connection Type - RWP -
SCSSV
Electrical feed-through
connection
External coating
Internal coating
Flange bolting requirement Non-exposed Exposed Exposed(low strength)

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Fig 3 – WELLHEAD EQUIPMENT DATA SHEET (CROSS OVER FLANGE)

WELLHEAD EQUIPMENT DATA SHEET – CROSS-OVER FLANGE

Tubing head adapter PSL - Pressure rating
PR-
Bottom connection Size - RWP -
Top connection Type - RWP -
Pack-off type
Size
External coating Yes No
Internal coating Yes No
Flange bolting requirement Non-exposed Exposed Exposed(low strength)

Fig 4 – WELLHEAD EQUIPMENT DATA SHEET (CASING HEAD HOUSING)

WELLHEAD EQUIPMENT DATA SHEET – CASING-HEAD HOUSING

Casing-head housing: PSL: PR:
Bottom connection: size: type: rated working pressure:
Top connection: size: type: rated working pressure:
Outlets: size: type: rated working pressure:
Equipment for outlets:
Valve removal plug:
Valves (inboard) qty: PSL: PR:
Valves (other) qty: PSL: PR:
Companion flange: qty: PSL:
Bull—plug: qty:
Nipples: qty:
Gauges: qty:

Lock screws Yes No

External coating Yes No
Flange bolting requirement Non-exposed Exposed Exposed(low strength)
Test and auxiliary requirement:
Wear bushing:
Running and retrieving tools:
Test plug:
Flange bolting requirements:
Main run(studs) (nuts)
Outlet inboard (studs) (nuts)
Outlet other (studs) (nuts)
Casing hanger:
Size:
Type:
PSL:
PR:

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Fig 5 – WELLHEAD EQUIPMENT DATA SHEET (CASING HEAD SPOOL)

WELLHEAD EQUIPMENT DATA SHEET – CASING-HEAD SPOOL

Casing-head housing: PSL: PR:
Bottom connection: Size: Type: Rated working pressure:
Top connection: Size: Type: Rated working pressure:
Outlets: Size: Type: Rated working pressure:
Equipment for outlets:
Valve removal plug:
Valves (inboard) qty: PSL: PR:
Valves (other) qty: PSL: PR:
Companion flange: qty: PSL:
Bull—plug: qty:
Nipples: qty:
Gauges: qty:

Lock screws Yes No

External coating Yes No
Flange bolting requirement Non-exposed Exposed Exposed(low strength)
Test and auxiliary requirement:
Wear bushing:
Running and retrieving tools:
Test plug:
Casing hanger:
Size:
Type:
PSL:
PR:

Flange bolting requirements:

Main run(studs) (nuts)
Outlet inboard (studs) (nuts)
Outlet other (studs) (nuts)
Casing hanger:
Size:
Type:
PSL:
PR:

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Fig 6 – WELLHEADEQUIPMENT DATA SHEET (TUBING HEAD SPOOL)

WELLHEAD EQUIPMENT DATA SHEET – TUBING-HEAD SPOOL

Tubing-head spool PLS: PR:
Bottom connection: size: type: rated working pressure:
Top connection: size: type: rated working pressure:
Outlets: size: type: rated working pressure:
Equipment for outlets:
Valve removal plug:
Valves (inboard) qty: PSL: PR:
Valves (other) qty: PSL: PR:
Companion flange: qty: PSL:
Bull—plug: qty:
Nipples: qty:
Gauges: qty:
Lock screws Yes No
External coating Yes No
Flange bolting requirement Non-exposed Exposed Exposed(low strength)
Test and auxiliary requirement:
Wear bushing:
Running and retrieving tools:
Test plug:
Flange bolting requirements:
Main run(studs) (nuts)
Outlet inboard (studs) (nuts)
Outlet other (studs) (nuts)
Tubing hanger:
Size:
Type:
PSL:
PR:
Back-pressure valve type:
SCSSV control lines:

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Fig 7 - INSPECTION AND TEST FORM

Customer: INSPECTION AND TEST PLAN for:

Contract Number:
Ref Number:
Ref Operation or stage of Stage/ Recor Requirem Accepta Inspecti Inspection *what/who
work frequen ds ent/ nce on/ test
Descripti Characteris cy standard/ criteria procedu Emplo Service Custome
on tics specificati re yee provide r
on r

Fig 8 - CHECK LIST

INSPECTION AND TEST PLAN CHECKLIST for:

(To be completed by the person(s) directly responsible for the work)
Contract Number: Work area: Checklist Number:
Contract/Project Name:
Contractor:
Subcontractor
Work Items/activities to be verified Reference Initialled/ Comments
OK

I have carried out allnecessary inspections and verify that Name:

the above items/activities conform to the contract Signature:
specification/documents Date:

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I have carried out allnecessary inspections and verify that Name:

the above items/activities conform to the contract Signature:
specification/documents Date:

I have carried out allnecessary inspections and verify that Name:

the above items/activities conform to the contract Signature:
specification/documents Date:
I have carried out allnecessary inspections and verify that Name:
the above work for this work area has been completed and Signature:
conforms to the contract specification/documents Date:

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