BP EXPLORATION (XEU) WELL TESTING PROCEDURES MANUAL
SECTION 2100
SUBJECT PRESSURE TESTING FLOWHEAD & SURFACE LINES
REVISION 0
DATE 01/10/92
3.8. On successful completion of the previous test, pressure up to equalise across the Master valve and open same. Bleed off all pressure.
END OF PRESSURE TESTING
3.9 Confirm that the Emergency Shut Down ( ESD ) controls at each ESD station are functioning correctly by :
a) check all lines are open to the flare
b) pump through at a slow rate - say 1 bbl/min
c) when flow comes out at the flare boom - initiate ESD d) stop pumping at cement unit when pressure reaches 500 psi e) repeat b) - d) above for each ESD control point
3.10 Make tannoy announcement that "HIGH PRESSURE TESTING IS NOW COMPLETE".
The aim of the in situ pressure testing of the flowhead and choke manifold is to test all the newly made connections and to retest immediately before use, those valves whose function is critical to the well test.
It is not necessary to in situ test every valve from every side if the valve has recently been pressure tested on the deck.
For example, this procedure does not pressure test the master valve from above. This is because the lubricator valve would be used for any pressure testing related to wireline work. Should the lubricator valve develop a leak from above then the master valve would be pressure tested from above at this time.
4.2 Where sand filters are installed upstream of the choke it may be necessary to install an additional valve to isolate the sand filters during pressuring up for perforating. When this safety valve is fitted the most efficient time to in situ pressure test it, is between step 3.5 and step 3.6.
3.5.1 On successful completion of the previous test and while maintaining pressure:
Close the safety valve.
Bleed off pressure at the choke manifold to 500 psi.
Pressure test to _____ psi for 10 minutes.
4.3 On some rigs it may be possible to rig up and pressure test the choke manifold before installing the flowhead. In such cases the pressure test between the choke manifold and the heater inlet may be deleted (Step 3.4)
4.4 Valve spindles tend to be the most likely place for small leaks and it is worthwhile checking the spindles for leaks even though the chart may indicate a good pressure test.
4.5 Depending on the sequence of operations it may be more efficient to install and pressure test additional equipment, eg Coiled Tubing/Wireline BOP's, at the time of pressure testing the flowhead.
BP EXPLORATION (XEU) WELL TESTING PROCEDURES MANUAL
SECTION 2100
SUBJECT PRESSURE TESTING FLOWHEAD & SURFACE LINES
REVISION 0
DATE 01/10/92
4.6 Step 3.4 has two purposes :
- to pressure test the connections between the choke manifold and the heater that were not already tested as part of the surface equipment pressure testing sequence.
- to pressure test the choke back valves from the direction they will see pressure during a choke change.
By monitoring the pressure upstream of the choke manifold and between the choke manifold and heater, it is possible to tell the location of any leak. No leakage to the atmosphere is acceptable. No leakage past the back chokes is acceptable. A leak of up to 100 psi in ten minutes past either of the heater valves is considered acceptable since these valves are primarily for flow diversion.
Note
Step 3.4 may have already been carried out as part of the Surface Equipment Pressure testing procedure. In this case step 3.4 may be deleted provided that none of the connections down stream of the choke were broken and remade during rig up of the flowhead.
4.7 Step 3.5 is to confirm the integrity of the lines two and from the flow head and to confirm that the front choke valves are sealing. No leakage to the atmosphere is acceptable. No leakage past the front chokes is acceptable.
4.8 Step 3.6 is to confirm the integrity of the Flow valve and Kill valve/NRV combination from the well stream side. No leakage is acceptable.
4.9 Step 3.7 is to confirm the integrity of the Master valve against the well stream.
1.1 Check that the work permit held by the Well Test Supervisor fully covers the scope of the operation.
1.2 Ensure that the equipment to be tested is rated to the proposed test pressure.
1.3 Use water as the pressure testing medium and as far as possible ensure there is no air trapped in the equipment under test.
1.4 Always increase pressure slowly in steps to the final pressure.
1.5 Ensure that all areas exposed to high pressure are roped off. A P/A announcement detailing the areas where High Pressure Testing will be taking place must be made before the start of the operation.
Note
BPPD HSEQ Policy allows for a competent person to approach and visually inspect an item under test so long as the equipment has been subject to the particular pressure for 5 minutes, a state of equilibrium has been achieved and the test medium is water.
1.6 Ensure that the standby boat or rescue craft is in position/on alert whenever personnel are working over the side of the rig. This includes any work on the flare booms.
1.7 Prior to pressure testing the PE must walk the lines to check that all the equipment and lines are made up according to the P&ID diagram and that all lines to be pressure tested are chained down.
1.8 Before flushing through the burners, check that the standby boat/ rescue craft have moved clear.
1.9 During flushing and pressure testing, if there are any unexpected pressure build ups, bleed pressure off via the cement unit & check the line up of all valves.