Maintenance and Inspection Guidelines for Flowline Equipment

Flowline Equipment

(M95)

Maintenance and Inspection Guidelines

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TABLE OF CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 18.1

Important – Mismatching of Hammer Unions Scope General Visual Inspection before and after each use Annual Inspection Oilfield Media Compatibility Chart Minimum Eroded Thickness – Swivel and Loops Minimum Eroded Thickness – Full Bore Pup Joints Minimum Eroded Thickness – LW, Cross, Tee, Y, Lateral and SR Elbow Minimum Eroded Thickness - LR Elbow Minimum Eroded Thickness - Crossover, Male Major, Female Minor Minimum Eroded Thickness - Crossover, Male Minor, Female Major Minimum Eroded Thickness - Crossover, Equal Size Minimum Eroded Thickness - Inline Check Valves Minimum Eroded Thickness - Premier & Compact Plug Valves Minimum Eroded Thickness - DB Plug Valves Minimum Eroded Thickness - Choke Valves Minimum Eroded Thickness – Record Sheet Minimum Eroded Thickness – Record Sheet (Guidance Notes)

Page 3 Page 4 Page 4 Page 5 to 6 Page 7 to 8 Page 9 Page 10 Page 11 Page 12 Page 13 Page 14 Page 15 Page 16 page 17 Page 18 Page 19 Page 20 Page 21 Page 22

NOTE : This generic document compiled by Anson Ltd does not cater for any customer specific requirement. Calculations for sections 7.0 to 18.0 to :< 7.5K > 7.5K

ASME B31.3 Section 304.1.2 (2006) ASME B31.3 Chapter IX Section K304.1.2 (2006)

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1.0 IMPORTANT !! – Mismatching of Hammer Unions

It is possible for some unions with different Fig. Numbers (working pressure rating) to be screwed together. These will not make a pressure tight seal and such combinations are highly DANGEROUS !!! In particular: •

1” fig 602 and 1002 have the same ACME thread 1½” figs 602 and 1002 have the same ACME thread 2” fig 602 and 1002 have the same ACME thread

for example Fig 1002 nuts could be used with Fig. 602 subs. •

2” Fig. 1502 nut can be screwed onto 2” Fig. 602 or Fig 1002 female subs. Although the ACME thread diameter is different, the number of threads per inch is the same. This combination of nut and sub has a very small thread mating overlap and WILL FAIL TO HOLD AT HIGH PRESSURE.

•

Similarly, a 2” Fig. 1502 nut fits over a 2” Fig. 602 or 1002 male sub, but the nut shoulder has a minimal overlap with the shoulder of the male sub. USE OF THIS COMBINATION IS HIGHLY DANGEROUS.

•

A 3” Fig. 1502 nut can be installed on a 3” Fig. 602 or 1002 male sub. This will reduce the overlap between the shoulders of the nut and sub in each case. The 3” Fig. 1502 nut cannot be connected to the 3” Fig. 602 or Fig. 1002 female subs. THE USE OF 3” FIG. 602 OR FIG. 1002 MALE SUBS WITH 3” FIG. 1502 NUTS IS DANGEROUS.

PARTS OF DIFFERENT FIG. NUMBERS SHOULD NOT BE CONNECTED TOGETHER H2S (Sour Gas) * and Standard Service Unions of the same Fig number will connect together BUT SHOULD NEVER BE MIXED ANSON SOUR GAS UNIONS ARE MARKED SG

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2.0 Scope

This maintenance publication describes methods put into practice by some end users of Anson flowline equipment. Because of the wide range of applications this type of equipment is used for, it has not been possible to cover every eventuality. It is therefore the end users responsibility to ensure correct maintenance routines are developed specific to there own operating conditions and that this publication (M95) is only used as reference in producing these maintenance routines. All such procedures should include safety instructions on how to carry out inspections and in particular Pressure Testing. The inspection guidelines within this publication are only relevant to the valves listed and “Integral” (some times referred to as one piece) equipment in the following “fig” numbers, 602; 1002; 1502; 2002; 2202. Welded Equipment is not covered by this publication.

3.0 General Operation and maintenance instructions for specific Anson Flowline products detail the required methods for dismantling and rebuilding each piece of equipment. Refer to these publications when overhauling / dismantling equipment for inspection. A documented history of maintenance carried out to equipment detailing parts replaced and the results of measurement obtained can prove to be a useful guide to the life expectancy of equipment. Anson strongly advise that such a data base be maintained for all equipment subjected to these inspection guidelines. All Anson Integral Flowline equipment will be issued with a serial number hard stamped on the equipment at the time of manufacture. It is common practice for end users to also give their own asset number to the equipment. Maintenance records should cross reference the end users asset number with the Anson Serial number which can prove to be a useful aid when ordering spares or making enquiries to Anson about the use of equipment.

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4.0 Visual Inspection Before and After Each Use 1. 2.

Positively identify the equipment to ensure it is of the correct “fig” number / pressure rating for the intended use. Most Integral equipment uses a detachable nut on the male (non threaded) end retained by three segments and a circlip. All three segments must be present and held in place by the circlip. (see fig 1).

Fig 1 3.

4. 5.

Remove any end protectors and visually inspect the thread for damage. Threads should be lightly greased before and after each use as an aid to assembly and to prevent corrosion. NOTE the grease used must be compatible with the anticipated working conditions especially in very low temperature situations. IMPORTANT – Avoid the use of copper based grease Union lip seals must be in good condition any torn or damaged seals must be replaced. NOTE ensure seals are replaced with the correct type for the intended service. Wing nuts must be in good condition and should be replaced if they have become worn to such an extent that lugs on the nut have become deformed. In Fig 2 below a slightly damaged but acceptable nut can be seen in the top two frames. The deformed raised section should be ground flat before use. In the lower two frames a badly damaged nut can be seen that should be replaced, as insufficient material will be left after grinding away the raised section.

Fig 2 Page 5 of 23

4.0 Visual Inspection Before and After Each Use 6.

Plug valves - should be lubricated before use and operated from the open to closed to open position to ensure they operate correctly. Stop plates should be in good condition, valves with actuators or gear operators should be correctly adjusted to achieve full 90 degree operation of the plug. In all cases ensure the valve bore aligns correctly when the valve is operated to the fully open position. 7. Adjustable Choke Valves – ( Needle and Seat design) – The stem and seat must be in good condition to ensure correct control of fluid pressure passing though the valve. This can sometimes be determined by visual inspection through the inlet side of the choke and rotation of the stem. In other cases it may be necessary to remove the bonnet for a full inspection of these components. 8. Swivels and Loops - rotate each articulate section of the swivel or loop to check for free rotation. Ensure all locking rings and circlips are in place at each swivel housing. IMPORTANT – the locking ring must be held snug up against the nut by the circlip to prevent the nut from rotating. 9. Pressure Testing – Publication M90 is available as a guide line to pressure testing Anson flowline equipment. 10. All equipment - after use flush the flowbore to remove production fluids, cements, acids etc. Spray the bore with a rust preventative and lightly grease the union end (See note at 3 above). Replace protective end connectors. 11. Loops – Return to their shipping configuration where the male and female ends are connected together. 12. Plug Valves – operate to the fully open position for storage.

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5.0 Annual Inspection The following Annual inspection guidelines provide the minimum requirements for maintaining flowline equipment. The level of activity / use of the equipment may warrant a more frequent inspection level. The owner of the equipment should determine the inspection periods based on the history of its use.

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5.0 Annual Inspection

1.

Dismantling for inspection.

Dismantle in accordance with the relevant maintenance procedure, contact Anson for details. Replace all soft seals and any damaged components. Remove hammer union nuts, segments (dogs) and circlips to allow for crack detection and load shoulder inspection. 2.

Visual inspection.

Thoroughly clean all components prior to visual inspection. Check through bores for washout, sealing surfaces for corrosion / pitting and threads for damage. 3.

Wall thickness test.

Using an ultrasonic tester check the wall thickness at the points indicated, (Tables as shown in this publication ). Any component with a wall thickness at or below the dimensions shown should be taken out of service and destroyed. The ultrasonic tester must be calibrated in accordance with the manufacturers instructions. Proof of calibration must be maintained and certificates referenced on inspection reports. 4.

Union inspection.

Check threads for damage and wear using pitch gauges after removing any debris from the threads. Minor damage may be removed from the thread using a light file. Check the load shoulder of the male head for excessive wear using the appropriate form gauge. Segments (Dogs) should be sand blasted to remove corrosion and then crack detected using MPI. Circlips used to retain the segment must be in good condition, compare the old circlip alongside a new one and if in comparison the old circlip appears worn replace with the new. 5.

Identification and Banding of assemblies.

All Anson assemblies will carry a unique serial number which will be hard stamped and start with the letters S/N. This number will be referenced on Anson material certification supplied with the equipment. Identification bands applied by the equipment owner should be stamped with this number alongside any asset number. Alternatively the database used to store information should have a cross-reference to this number. 6.

Pressure Testing

A formal pressure test procedure should be in place before any pressure testing is carried out. Ensure all personnel who carry out pressure testing are fully aware of the safety issues involved, and that adequate training has been provided. Pressure tested assemblies should be isolated from test personnel behind blast walls, and visual inspection carried out during test using cameras or through blast proof observation windows. 7.

Documenting inspection / test results

Document all results from the test and record all components replaced.

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6.0 Anson High Pressure Seals for Hammer Unions - Oilfield Media Compatibility Chart 4177

4151

HNBR

HNBR (Low Temp.)

HNBR (Arctic)

1 1 1 3 1 1 1 1 1 3 2 3 3 1 1 2 3 2 3 1 2 1 2 3 1 3 2 1 3 1 1 2 1 3 1 1 1 1 1 3 1 3 3 2 3 3

2 3 1 3 1 C 1 2 3 1 1 1 2 1 1 2 3 1 3 1 1 1 1 1 1 2 1 3 1 1 1 2 1 1 1 C 1 1 1 2 1 1 3 1 1 1

2 3 1 3 1 C 1 2 3 1 1 1 2 2 2 2 3 1 3 1 1 1 2 1 1 2 1 3 1 1 1 1 1 1 1 C 1 1 1 2 1 1 3 1 1 1

2 3 1 3 1 C 1 2 3 1 1 1 2 2 2 2 3 1 3 1 1 1 2 1 1 2 1 3 1 1 1 1 1 1 1 C 1 1 1 2 1 1 3 1 1 1

200 -30 392 -22

160 -25 320 -13

150 -35 302 -31

160 -46 320 -50

Anson Specification

4023 4028 4039 4083

4024 4029 4040 4090

4048 4077

4106 4152 4168

Material Type

Nitrile

Flurocarbon

Superseal

Weak Mineral Strong Mineral Acids Weak carboxylic Strong carboxylic Aliphatic hydrocarbons Aromatic hydrocarbons LD – Ca/NaCI HD – Na/CaBr Brines HD – ZN bromide Alakline – Na/KOH Carbon Dioxide Amine based Corrosion inhibitors Pot. carbonate Crude oil, sweet