global maintenance guidelines.pdf

SERVICE GUIDELINES TITLE GLOBAL MAINTENANCE GUIDELINES

BUSINESS UNIT PowerWell Services

REGION Global

FUNCTION Power Well Testing

POWERWELL SERVICES MANAGEMENT SYSTEM DOCUMENT NUMBER

GD-GL-WT-006

OWNER Global Service Quality Coordinator

APPROVED Global SQC

JOB REVISION Global Advisor

REVISION DATE 04-Nov -04

REVISION A

REVIEW DATE

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Once printed this document becomes uncontrolled, refer to PowerWell Services Management System for controlled copy.

The following is the Power Well Testing global minimum requirement for workshop maintenance. Some locations may exceed these requirements. Local Governmental regulations and industry directories may impose requirements for fabrication and inspections that differ from the Power Well Testing guidelines or standards. This is acceptable provided that the specifications set forth in this document are also met, and that all traceability documents and scheduled tests and inspections will be maintained.

Index Section Subject Page 1 New Equipment 2 2 Equipment Trace Numbering System 2 3 Equipment Data Packages & Maintenance Files 3 4 Personnel Competency 3 5 Maintenance Checklists 4 6 Maintenance 5 7 Inspection of 3rd Party Equipment 7 8 Local Manufacture And Purchase 8 9 Thread Inspection 8 10 After Assembly Test And Inspection 9 11 Instrument Calibration 9 12 Hydrostatic Pressure Test 10 13 Periodic Inspection 10 14 Tagging System 10 15 Document Control 10 16 Reviewing Maintenance Procedures 10 17 Equipment Transfer 11



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1. New Equipment

New equipment must be built and conform to Power Well Testing Procurement and Fabrication Specifications. These specifications are based on best practices and industry standards, and help ensure that all equipment provided for Power Well Testing operations meets or exceed applicable industry standards with reduced risk and liability. Applicable Industry Standards. Equipment must be designed and fabricated to meet or exceed the above referenced specifications as applicable to their area of operation and intended purpose. Additional specifications may be required to meet low temperature applications or local governmental requirements. These additional requirements can be met, however they will need to be reviewed case by case with Technology for design and approval. When a new piece of equipment is bought from a supplier, the following will occur: SAP will assign a number called the SAP Equipment Master Number to an assembly when it is entered into the system. Locations should contact Global Asset Coordinator to have this equipment loaded and number assigned. This will ensure the right Activity Codes, Descriptions etc are being used. This unique identifier will be maintained for the life of the equipment, even if transferred to another location. For Capital purchase items, verify equipment has been assigned an SAP Asset Number and the Asset

Number is set up in your location. Note: SAP Asset Accounting will assign a number called the SAP Asset Number to an assembly

when it is bought using Capital Funds.

This SAP Asset number will remain the same as long as the equipment remains in the same field location. When it is transferred a new number will be created in the receiving location. Once the SAP Asset Number and SAP Equipment Master Number are obtained, the SAP Asset Number must be physically entered into the appropriate field in the SAP Equipment Master to link them together.

Initiate a maintenance file for each piece of equipment. Refer to Minimum Global Inspection Guidelines.

The files can be kept on electronic media or hard copy. However all maintenance files must be able to be retrieved at any time and be sent with equipment.

Visually inspect each piece of equipment. Confirm all parts (including ship loose items) have been received

and no damage has occurred during transportation. Report to manufacturing, using CPI, any problems encountered. Copy Global Technical Advisor. Record the trace number and description in the maintenance file and in your locations Equipment Trace

Number database (i.e. STE-STT-001). Follow the maintenance procedures for the particular equipment type and carry out a function and pressure

test.

In the event that this is a new piece of equipment with no procedure, contact Global Technical Advisor and have the Maintenance Supervisor or other authorised personnel direct the maintenance procedures.



REGION Global



GD-GL-WT-006


APPROVED Global SQC



REVISION A

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2. Equipment Trace Numbering System

In addition to the details contained above in New Equipment, all Power Well Testing assemblies that are, hydrocarbon pressure containing or hydrocarbon wetted must be identified with a unique identification number. This means each pressure vessel, heater, test tree, manifold, remote valve, pipe joint, data header, crossover, pump, burner, each and every system assembly that is contained in the Power Well Testing inventory must be uniquely identified with trace number.

In recognition that specific inspection and testing of non-hydrocarbon pressure containing equipment such as electric motors, lifting skids, pipe baskets, generators etc shall be required, the Trace Number system has been expanded to include abbreviations for these items. These trace numbers, along with asset registry numbers, provide the only means of maintaining the traceable history of the equipment to a data book and maintenance file. Without this cradle to grave documentation the asset brings high risk and liability upon the company. Therefore without the complete package of documentation, traceable back to the equipment, the item will not be used in operations for delivery of services. All trace numbers for capital assets will be assigned by the Global Technical Advisor or Global Asset Coordinator, the Service Coordinator. All trace numbers for non capital assets will be assigned by the Service Coordinator or Quality Representative that has been assigned to manage the database and the quality assurance program at the country operations level.

Note: We cannot use the SAP Asset Number as trace number, since this asset number will change if

equipment is transferred. The only constant to the asset for trace purposes is the assigned Trace Number and the SAP Equipment Master number.

Note: New build equipment must have trace number assigned prior to delivery. During the

procurement process, the trace number shall be supplied on the WBS or SAP requisition so that P&M can provide to the vendor for placement on the equipment, and data package.

Note: This unique trace number is to be entered in the Tech ID field in the SAP Equipment Master

record.

Assignment of the Trace Number is a one-time event. The Trace Number assigned to the equipment shall remain unchanged for the life of the equipment and shall not be changed for any reason, including inter-company transfer.

Previously issued Trace Numbers from equipment that has been permanently removed from service are NOT to be re-issued to new equipment. The trace number for Capital equipment shall be made up of a unique set of numeric/alpha characters that consist of: EXAMPLE:

PSL - STE - SURFACE TEST EQUIPMENT EQUIP DESIGNATION - CHM - CHOKE MANIFOLD SEQUENCE NUMBER - 001 - NUMBER ONE

ASSIGNED TRACE NUMBER - STE-CHM-001



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The trace number for Non Capital equipment shall be made up of a unique set of numeric/alpha characters that consist of: EXAMPLE:

EQUIP DESIGNATION - 01 - SEPARATOR LOCATION - XAF - ABERDEEN SEQUENCE NUMBER - 001 - SEPARATOR NUMBER ONE

ASSIGNED TRACE NUMBER - 01-XAF-001

The trace number in both cases will be placed on the following:

Stainless Steel band on the equipment itself. Stamped into the equipment (WITH LOW STRESS DOT STAMPS) Written onto all data package covers for the equipment. Written on the top right corner of each document page in the data package. Written on the Maintenance work file cover. Written on each document placed into the Maintenance work file. Welded onto the skid of the equipment along with asset number. Database of asset registry, will include trace number.

Note: Under no circumstances shall the assigned QA Trace Number be welded directly to the pressure containing body of the asset!

Note: The stainless steel identification band will be placed on each piece of equipment that has been

identified under the quality assurance documents. This SS band is the main identifier that the scheduled inspections and testing as per Minimum Global Inspection Guidelines have taken place, and that the equipment is compliant.

This SS banding will be made out of 1 wide x 1/8 thick (nominal size) stainless banding, wrapped around the equipment and welded to itself so that it cannot be removed without some difficulty. The band should be fitted loosely to allow it to rotate or slide on the equipment, however not so loose that it might slip off the equipment or otherwise become a hazard.

Scribed information will be placed on the band, either by an etcher or by stamp lettering method. Bands should be placed on all loose pipework, elbows and crossovers and on inlet manifolds of pressure vessels. On choke manifolds the band should be placed on pup between valve and choke or other suitable place on piping connection. All other equipment bands should be placed in easily identifiable place. The following information is to be stamped or etched onto the stainless steel band:

UNIQUE TRACE NUMBER MAWP (MAXIMUM ALLOWABLE WORKING PRESSURE) in PSI and BARG SERVICE (H2S OR STD) TRACE NUMBER ASSIGNMENT DATE ANNUAL INSPECTION DUE DATE

Date format shall be 2 digit Numeric Month/Year (e,g. Feb, 2000 designated as 02/00) Annual inspection dates shall be stamped so that successive years follow chronologically around the band.



REGION Global



GD-GL-WT-006


APPROVED Global SQC



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NUMERIC EQUIPMENT CODE DESIGNATION

EQUIPMENT I.D UNIQUE # DESIGNATION SEPARATOR 01 INDIRECT FIRED HEATER 02 STEAM HEAT EXCHANGER 03 CHOKE MANIFOLDS 04 DIVERTER MANIFOLDS 05 VERTICAL SCRUBBERS 06 DESANDERS / FILTERS / SAND SEPARATORS 07 BURNER BOOMS (BOOM SECTIONS, KP, STRUTS etc) 08 BURNERS 09 AIR COMPRESSORS 10 TRANSFER PUMPS 11 CHEMICAL INJECTION PUMPS 12 TEST TANKS/ATMOSPHERIC 13 TEST TANKS/PRESSURIZED 14 SURFACE TEST TREE 15 SURFACE TEST TREE SWIVEL 16 SURFACE TEST TREE LMV 17 SURFACE TEST TREE LIFITNG SUB / STIFF JOINTS 18 SURFACE TEST TREE CHEMICAL INJECTION SUB 19 REMOTE MANUAL OR SURFACE SAFETY VALVE 20 SURFACE SAFETY VALVE CONTROL MANIFOLD 21 SURFACE TEST TREE CHECK VALVE 22 FLOWLINE CHECK VALVE 23 FLEXIBLE ARMOURED PIPE 24



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NUMERIC EQUIPMENT CODE DESIGNATION (contd)

EQUIPMENT I.D UNIQUE # DESIGNATION FLOWINE STRAIGHT JOINTS 25 FLOWLINE ELBOWS 26 WELLHEAD CONNECTIONS (OBSOLETE USE 28) 27 WELLHEAD CONNECTIONS & CROSSOVERS 28 FLOWLINE SWIVELS 29 STEEL BAILS 30 FLEXIBLE FLOW HOSE DOWNSTREAM NON ARMORED 31 FLOWLINE DATA HEADER 32 COMBINATION UNIT SEPARATOR/HEATER 33 LAB A-60 TYPE INTRINSICALLY SAFE 34 GAS BOOTS 35 FLARE STACKS 36 QUICK CONNECTS/DISCONNECTS (QC/DC) 37 BASKETS AND PIPE RACKS 38 GENERATORS (STEAM AND/OR ELECTRIC) 39 MISCELLANEOUS (CATCH ALL) 40 WORK SHOPS LABS NON INTRINSIC 41 HYDROCYCLONE DE-OIL DE-WATER SYSTEMS 42 SEA CHEST 43 BURNER MANIFOLD 44 MULTI PHASE FLOW METER 45 DEADWEIGHT TESTER 46 RANAREX 47 PRESSURE RELIEF VALVE 48 SURFACE / DIFFERENTIAL CHART RECORDER 49



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NUMERIC EQUIPMENT CODE DESIGNATION (contd)

EQUIPMENT I.D UNIQUE # DESIGNATION PIPING TEEs 50 TRAILER FOR TRAILER MOUNTED UNITS 51 GEOLOGIC SAMPLER 52

ALPHA LOCATION CODE DESIGNATION CODE OPERATION LOCATION XAF ABERDEEN UK XAK ALASKA ATT ALGERIA XAC ANGOLA XAL ANGOLA LUANDA XRH ARGENTINA XDR AUSTRALIA DARWIN XPE AUSTRALIA - PERTH XBL BOLIVIA XRZ BRAZIL XSJ CANADA ST. JOHNS XDT CANADA DARTMOUTH XOL COLOMBIA XCN CONGO XDN DENMARK XDB DUBAI XEG EGYPT XEC EUROPE (MAINLAND)



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ALPHA LOCATION CODE DESIGNATION (contd)

CODE OPERATION LOCATION XGM GULF OF MEXICO XHL HOLLAND XIN INDIA XJK INDONESIA XKA KAZAKHSTAN XML EQUITORIAL GUINEA - MALABO XMX MEXICO XMH MICHIGAN XNZ NEW ZEALAND XNP NIGERIA XNR NORWAY XNE RUSSIA (GENERAL) XNS RUSSIA (SAKHALIN ISLAND) XOM OMAN XQP PERU XQT QATAR XSB SAUDI ARABIA XSI SINGAPORE XTR TRINIDAD XTU TURKMENISTAN XTN TUNISIA XTV VENEZUELA (EAST) XMV VENEZUELA (WEST) XXX GENERAL (SPECIAL PROJECT)



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EXEMPTION:

A grandfather clause exists for equipment serialised as per previous revisions of this document provided all other aspects, including electronic data base of Trace Numbering exists. This exemption grandfather clause allows the location to maintain their existing Trace Numbering system, as long as it is easily identifiable to the current Alpha Numeric desginations. It is required that for Trace Numbering systems outside of this documents requirements, the country maintain a data base that keeps a current Trace Number as per this document next to the desginated Trace Number. Over time the serial numbers of existing equipment and all new build equipment will be re-allocated to the new Power Well Testing numbering system. This will be done on the database to maintain the existing and old Trace Number assignments. Equipment already serialized under the old numbering system needs to have an additional identification added to identify it as Power Well Testing equipment and not Halliburton. After the Trace Number place the following: (PWT)

3. Equipment Data Packages & Maintenance Files

All Power Well Testing equipment must have a data package and maintenance file as defined in Design And Construction Guidelines Fabrication Documentation.

MAINTENANCE FILES Each asset must have a maintenance file set up that is traceable to the data package and the equipment. The maintenance file can be kept in electronic format or hard copy as long as it is filed and maintains the cradle to grave requirements of the quality assurance program. Day to day replacement of parts, trim as well as scheduled quality inspections and tests require file keeping outside of the original data package. Each maintenance file has to be accessible to audit, as do original data packages. In each maintenance file the following information shall be placed in separate sections: Copy of the Data Package Compliance Form All scheduled periodic Ultra Sonic Wall Thickness Test reports All scheduled periodic hydrostatic working pressure test reports Copies of all Safety Relief Valve set pressure and function test reports Copies of all Lift Lug Inspections and Load Tests All scheduled and non scheduled repair documentation,

E.g. Material certificates for valve trim replacement controller calibration, Meter Run Repair, Effluent Meter repair. Written reports with COCs of parts replaced, MTRs etc..

Letters of compliance to specifications from component suppliers as required maintenance requires replacement.

All correspondence relating to equipment transfer to other country. The maintenance files should have a cradle to grave history of equipments movement.

Any correspondence relevant to the equipments daily life.



REGION Global



GD-GL-WT-006


APPROVED Global SQC



REVISION A

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A copy of the equipment certifications, for example if a pressure vessel, copies of the U1A Manufacturers Certification to Construction, or PD5500 (formerly BS5500) equivalent. Copy of third party certifications such as DNV or ABS.

R1 for any major vessel repair from code shop Any documents that relate to the equipments maintenance, repair, replacement of parts, and or

modification from original manufacturer. 4. Personnel Competency

Within the Maintenance Procedures there are references to approvals by authorised personnel at Hold Points. Each location will be required to designate the authorised personnel qualified to sign-off at these critical points. At the time of preparing this document the competency program for personnel involved in equipment maintenance has not been completed. Until the competency program is completed, as an interim measure the following competency definition guidelines are recommended:

1. Level I Maintenance Technician / Service Operator Adheres to all HSE guidelines including job risk assessment, read equipment drawings, disassemble equipment, wash parts, reassembly equipment, inspect and install new seals as needed, install O-rings, drift equipment and completes appropriate paperwork. 2. Level II Maintenance Technician / Service Specialist - Adheres to all HSE guidelines including job risk assessment, read equipment drawings, disassemble equipment, wash parts, reassembly equipment, inspect and install new seals as needed, install O-rings, replace metal parts after inspection and approval by Level III, drift equipment, gauge threads, caliper and dimension check part components, completes appropriate paperwork, conduct pressure tests. Has the ability and authorisation to accept or reject pressure tests on individual items and assemblies. 3. Level III Maintenance Technician / Service Leader - Adheres to all HSE guidelines including job risk assessment, Read equipment drawings, disassemble equipment, wash parts, reassembly equipment, inspect and install new seals as needed, install O-rings, drift equipment, inspect and replace metal parts, drift equipment, caliper and dimension check part components, completes appropriate paperwork, conduct pressure tests, perform visual inspection and gauging of threads, perform visual inspection of components, conducts tool functionality tests. Has the ability and authorisation to accept or reject pressure tests on individual items and assemblies. Has the ability and authority to accept and reject component parts based on the visual inspection. Has the ability and authority to accept or reject equipment functionality tests.

5. Maintenance Checklists The documenting of maintenance allows Power Well Testing to formally compile information enabling tracking of the performance of our equipment and allows improvement of the maintenance process. It also allows us to meet the requirements of the PowerWell Services Management System. There are currently four different levels of maintenance as detailed below:-

Maintenance

Level Frequency Description

LEVEL A PRE/POST JOB Work to be carried out every job or if stored for a period greater than three months

LEVEL B ANNUAL Work to be carried out yearly, except when equipment is due a LEVEL C or D service

LEVEL C 2 YEAR Work to be carried out every 2 years, except when equipment is due a LEVEL D service

LEVEL D 5 YEAR Work to be carried out every five years



REGION Global



GD-GL-WT-006


APPROVED Global SQC



REVISION A

REVIEW DATE

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A matrix of current inspections by Maintenance Level can be found at the following link: Inspection And Maintenance Requirements Matrix The functions of the Maintenance Check Sheets are as follows:

Defines the planned maintenance of each item of equipment before the work starts, documents

supervisory controls, and has each major step in the process signed by the person(s) completing the work.

Ensures that all of the key steps of a maintenance procedure are defined and recorded. Records all of the relevant information on the maintenance of any piece of equipment. Records the replacement of all metal components not considered consumables. Records the date, times and reason for any maintenance delays. References relevant documents detailing problems that occurred while using the equipment at field

location so the information can be used to better define the required maintenance. This might include any function or inspection steps to be carried out (and possibly customer-witnessed) prior to the strip down of the equipment. Copies of the referenced documents should accompany the Maintenance Check Sheet.

Provides a basis for internal and third party "fit for purpose" acceptance.

6. Maintenance

Follow maintenance procedures for specific equipment. In addition to assembly specific instructions, comply with the following: Inspection And Maintenance Requirements Matrix Minimum Global Inspection Guidelines

6.1 Maintenance Planning

The Service Coordinator / Maintenance Supervisor or his designate will be responsible for prioritising equipment for maintenance to produce a green tagged inventory to support anticipated operational needs.

A complete equipment inventory status will be visible by means of a whiteboard, excel spreadsheet or

similar method that records the following information: Equipment Description Equipment Trace Number Pressure Rating Size i.e. 42 x 15 Separator Connections i.e. Inlet, Outlet, Top, Bottom Equipment Status i.e. On a Job, In Workshop (Green Status), In Workshop (Red Status) Customer Name / Rig / Country if on a Job, or designated to a job Mobilisation Date Date last maintenance was performed Date last Annual Maintenance was performed Comments

Example Equipment Status Report If 3rd party certification is required by local, government regulations the date of previous / next inspections can be added to the whiteboard. For transfer pumps etc additional information such as power requirements, motor size, engine size etc should be included on the whiteboard.



REGION Global



GD-GL-WT-006


APPROVED Global SQC



REVISION A

REVIEW DATE

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All Equipment will be entered into SAP.

Spares stock levels will be maintained to support the equipment inventory based on historical and

anticipated usage. Equipment must be maintained within 30 days of receipt to service centre. In the event that spare parts are

not currently available at the service centre to meet this criteria the equipment should be removed from service and red tagged.

Vessels must be flushed as soon as possible to remove oil, mud etc that can cause increased corrosion.

Equipment that has had chemicals, sand etc flowed into or through it must be flushed and cleaned etc as

soon as possible to find any erosion and prevent corrosion.

6.2 Visual Inspection

All components will be inspected for corrosion, erosion and physical damage. Refer to Minimum Global Inspection Guidelines Visual Inspection Refer to Inspection And Maintenance Requirements Matrix

6.3 Elastomers

All elastomers, seals and back-up rings will be removed during shop maintenance. These components will be replaced with the exceptions noted below.

When a component or assembly containing elastomers is stripped down all elastomers will be replaced. When a component or assembly containing elastomers is stripped down all Teflon back-up seals will be

replaced. High temperature, plastic back-up rings (Peek) may be used repeatedly until they are broken, chipped,

cracked or deformed.

6.4 Seal Selection During normal operations Viton O-rings should be used with a minimum of 90 duro. Viton is a fluorocarbon, and therefore cannot be used with Amine inhibitors. In this instance locations should use Saturated Nitrile such as HNBR (90 duro) or metal to metal seals where Amines are used or CO2 content is higher than 8% in presence of H2S. In presence of CO2 alone, seals made from Nitrile materials should be OK, however seal failure can occur and may be caused by explosive decompression. This is where CO2 is entrained into non-metal seals under pressure. When the system is depressurised suddenly the CO2 expands 60 fold and ruptures the seal. Shutdown and depressurisation of the welltest system must be controlled. If seal failure occurs during operations this will result in uncontrolled release of hydrocarbons.

6.5 Elastomer Storage

Ambient temperature shall not exceed 120 o F (48.9 o C). Elastomeric items are not to be stored in open air (oxygen). Contaminants must not come into contact with elastomeric items (oils, solvents, etc.). Elastomers shall not be stored in direct sunlight.



REGION Global



GD-GL-WT-006


APPROVED Global SQC



REVISION A

REVIEW DATE

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Elastomeric items shall not be stored in an area where ozone is produced by electrical devices. Elastomeric items shall not be stored in the vicinity of radiation producing equipment. Elastomeric items shall be stored in an unstressed condition. Avoid squeezing by stack weight or any other confinement to smaller storage space. Warehouse stock shall be rotated by an ongoing procedure of always using the oldest cure dates which still are acceptable on the basis of shelf life guidelines.

Warehouse stock shall be reviewed on a periodic basis to determine those items with an expired shelf life. Elastomers should remain in original packaging until used. Packaging should display the following as a minimum:

Manufacturer Compound Number Batch Number Quantity Part Number Purchase Contract Number Cure Date

6.5 Elastomer Shelf Life(1)

TRADE NAME MAX. AGE

COMPANY WAREHOUSE (QTRS/YRS)

RECOMMENDED MAX. SHELF LIFE

FIELD WAREHOUSE (QTRS/YRS)

MAXIMUM AGE IN AN ASSEMBLY (QTRS/YRS)

NITRILE

28/7 40/10 19/4.75

VITON 72/18.5 80/20

26/6.5

(1) These shelf life are based on the above recommendations on storage being strictly observed. Any deviation will reduce the rated shelf life.

7. Inspection of 3rd Party Rental Equipment

Rental of 3rd party supplied equipment is a day to day part of our business. Each and every location must manage and audit their 3rd party rental suppliers. 3rd party rental suppliers must be on the approved vendors list. 3rd party rental suppliers do not have to meet our maintenance guidelines, but they must have in place their own maintenance and QA/QC system. This should as a minimum include the following: -

Unit trace numbering system Maintenance checklists Historical maintenance Unit data package

Upon request, they must be able to provide documented evidence of carrying out maintenance on equipment supplied to Power Well Testing locations.



REGION Global



GD-GL-WT-006


APPROVED Global SQC



REVISION A

REVIEW DATE

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The checklists that have been provided for Power Well Testing use may be used to check and verify 3rd party rental equipment.

8. Local Manufacture and Purchase

Wherever possible local manufacture of capital equipment is to be avoided and should be ordered through the Global Asset Coordinator

8.1 Local Manufacture of Equipment

Use of locally manufactured equipment will only be permitted as long as they conform to Power Well Testing Procurement and Fabrication Specifications and time does not permit to have the equipment purchased through the Global Asset Coordinator. Input and approval must be given by Technology through the Global Technical Advisor and Global Asset Coordinator.

8.2 Local Manufacture of Crossovers

Local manufacture of crossovers will only be permitted as long as they conform to Power Well Testing Procurement and Fabrication Specifications.

9. Thread Inspection

All ACME/Stub ACME load bearing threads on Surface Test Trees and their components (Swivels, Handling Subs, Chemical Injection Subs, Lower Master Valves, X-Overs etc) must be visually inspected during redress procedures. All adjustable and fixed choke body and choke cap threads must be visually inspected during redress procedures. Magnetic Particle Inspection must be performed on top and bottom surface tree load bearing ACME joint threads, every 10 runs using the following procedure. Note: Definition of a run is, from the time the tree is connected to the string to the time it is

disconnected from the string. Magnetic Particle Inspection must be performed on all load bearing ACME joint threads (Handling Sub, Stiff Joint, Swivel, Block, Crossovers, Saver Sub, Lower Master Valve, Chemical Injection Sub), every 12 months using the following procedure. In some locations customers may require thread inspection after every trip to the field. Magnetic Particle Inspection can only be carried out by personnel qualified to ASNT-TC-1A Level II or higher.

Note: ASNT-TC-1A Level I personnel are not permitted to carry out any NDT work on Power Well

Testing equipment.



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APPROVED Global SQC



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To perform a magnetic particle inspection on threads:-

1. Thoroughly clean the connection. It must be free from all lubricants, paint, and grease.

2. Ensure the connection has proper magnetic field for detection of defects.

3. Visually inspect threads and sealing area for handling damage, galling, etc.

4. Determine any pin stretch using a thread profile gauge.

5. Check the box connection for belling.

6. Spray the connection with magnaglow, fully covering the connection.

7. Inspect the connection using a UV lamp to detect cracks. The following colour code is used for dispositions of parts.

Blue Band - Chase and Face

Yellow Band - Recut

White Band - Good Connection

8. Document the thread inspection as a process on the Maintenance Checklist and have the shop supervisor or an authorized person sign off on the Maintenance Checklist.

The inspection company should submit a typed, signed report. This report may be for a single connection or a group of connections. From the report, individual certificates for each tool should be filed in the relevant Maintenance File.

9. Grease the connection.

10. Install the thread protector.

All NPT threads must be visually inspected during redress procedures. All non corrosion resistant material NPT threads (i.e. carbon steel, 4130, 4140 etc) must be tested using thread gauges at least once every 12 months.

10. After Assembly Test And Inspection

Drift all Surface Test Trees with a 42 inch long bar that is 0.05 - 0.06 inches smaller than the nominal ID. All equipment must be pressure tested after assembly. If no pressure test instructions are given in the maintenance section, test to the working pressure of the equipment.

A pressure test fluid that is non-corrosive or that inhibits corrosion must be used. Refer to Power Well Testing, Global Pressure Test Procedure, and Minimum Global Inspection Guidelines Hydrostatic Testing. Equipment that has been inspected and tested and then placed in storage for greater than three months and are to be mobilised for a job must be pressure tested, function tested as applicable and drifted prior to mobilisation.



REGION Global



GD-GL-WT-006


APPROVED Global SQC



REVISION A

REVIEW DATE

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11. Instrument Calibration

All devices used to perform measurements related to service quality: pressure gauges, pressure recorders, oxygen detectors, temperature recorders and equipment drifts must be calibrated at a minimum of twelve month intervals.

Refer to Power Well Testing, Global Pressure Test Procedure (page 5) for details.

12. Hydrostatic Pressure Test

For details of pressure testing standards, refer to HSE Standard Category 4 Standard 5, Pressure Test Facilities, Power Well Testing, Global Pressure Test Procedure, and Minimum Global Inspection Guidelines Hydrostatic Testing

As a minimum the following information must be recorded on a pressure test chart:

Equipment Trace Number (e.g. STE-CHM-001) Date Pressure Test Conducted Scale of Chart Name of Person Conducting Pressure Test Name of Person Approving Pressure Test Chart Recorder ID Number Chart Reference Number (if maintenance data is stored in an electronic format)

13. Periodic Inspection

All equipment must be pressure tested at least once a year to rated working pressure. A record of this test is kept in the individual equipment file. Refer to Minimum Global Inspection Guidelines Refer to Inspection And Maintenance Requirements Matrix

14. Tagging System

All equipment is to be tagged to show equipment status and for Lock Out / Tag Out of safety critical items as per the instructions set out in Work Method WM-GL-HES-PA-011.

15. Document Control

The current revisions of the various documents used in this system e.g. Maintenance Check Sheets, Maintenance Procedures, Equipment Drawings, will be maintained on the PowerWell Services Management System database. It will be the responsibility of the location through proper document control to ensure that only the current revisions of these documents are used.

16. Reviewing Maintenance Procedures

The testing supervisor for Surface Test Equipment and the shop supervisor will review the maintenance procedures for Well Test Equipment every twelve months. The testing supervisor should contact the Global Technical Advisor with any suggested changes or additions to global supplied material by e-mail or fax within 30 days of the review.

In addition to the twelve month formal review there should be continual evaluation of maintenance procedures and processes with improvement suggestions forwarded to the Global Technical Advisor using CPI or e-mail.



REGION Global



GD-GL-WT-006


APPROVED Global SQC



REVISION A

REVIEW DATE

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Note: The testing supervisor, with the help of his personnel, is encouraged to submit content for

additions to the manual to be evaluated by Technology for inclusion in this manual. Submissions by the testing supervisor will create a formal review of the documentation. Any revisions will be available prior to the next review period.

17. Equipment Transfer

As per Minimum Global Inspection Guidelines - Responsibility, the Country Manager, Service Coordinator and Field Service Quality Coordinator are responsible for ensuring that all Power Well Testing equipment at their delivery point is in compliance with the global guidelines. If any equipment is transferred to another location and found to be out of compliance with Minimum Global Inspection Guidelines, then the sending location will be recharged ALL costs (transport, inspections, 3rd party, repairs etc) associated with bringing the equipment into compliance. If assets being transferred to another location are in compliance with Minimum Global Inspection Guidelines then the location receiving the equipment will be responsible for paying the shipping costs.

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