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ABC Guide to
Temporary Pipework
Practices to implement EP 2006-5393
Shell Global Standard for Temporary Pipework
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
"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
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
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
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.
Temporary
Pipework
To temporary
pipework system
Permanent
Pipework
Pipework part of
original design
(e.g. production
facilities)
Ver. 2.0
Equipment Involved
Pipework
Ver. 2.0
Hammer-type connections.
Hub-type connections.
Flange connections.
Pipe body to pipe body (welded).
Hammer-type Union
Flange Connection
Welded Connection
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:
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.
Ver. 2.0
Stored Energy
Yield strength
Dynamic Loading
11
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
Ver. 2.0
12
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
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
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)
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
Test manikins
destroyed
Piece of loop
flies outward
Ver. 2.0
17
Historic Incidents
Equipment
Operation
Event
Cause
Chicksan
Pressure
Testing
Hammer
Union
Pressure
Testing
Mismatch
between standard
2 1502 WECO
Union and rigs
2 1002 WECO
union
Hammer
Union /
Chiksan
connection
Making
up pipe
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
Ver. 2.0
18
Equipment
Operation
Event
Cause
Hammer
Union Seal
Well Cleanup
Operation
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.
Flexible
Hose
In Service
Hammer
Union
Equipment
Testing
Incident
occurred
during water
flow test
through a
Mud Line
Cellar Bit.
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.
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
20
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:
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
1 1/2
400, 1002
22
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
MIS-MATCH!
2 1502
Wing Nut
2 602
Standard
Male Sub
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
24
MIS-MATCH!
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!
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.
Ver. 2.0
25
SPM 3 HD-LR
male ball race end
No step between
second and third race
FMC 3 TripleStep
female ball race end
FMC 3 TripleStep
male ball race end
SPM 3 HD-LR
female ball race end
Mismatch Avoided
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:
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
27
2
3
SF4
PN
15m
Chain block
Cable
Deck beam
4
3
Ver. 2.0
28
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.
Drilling and Well Services
Ver. 2.0
29
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
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.
Restricted
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
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
Drilling and Well Services
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
Ver. 2.0
32
End A
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
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.
11
12
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.
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.
Ver. 2.0
35
Ver. 2.0
36
End
D
End
B
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
End
B
Figure 21 - Recommended fibre rope spine installation method.
Drilling and Well Services
Ver. 2.0
37
Anchor Points
Anchor points of sufficient structural integrity or mass must be
used.
Certify as lifting appliance
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:
Acceptable
Unacceptable
Ver. 2.0
39
Courtesy of
WeirSPM
Gauges
When reading gauges on
pressured pipework, keep
body out of line of fire of
connections.
Gauge
Connection
Ver. 2.0
40
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
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key feat
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Construct ion
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A Toolbo
of Conne
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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
Ver. 2.0
41
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
4" 602
Example of marking
up P and ID
42
ABC Guide to Temporary Pipework
Ver. 2.0
43
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
Ver. 2.0
44
Insufficient/inappropriate support
Also confirm that the design is not flawed e.g. check-valve reversal!
Drilling and Well Services
Ver. 2.0
45
46
Ver. 2.0
SHELL