Global Maintenance Guidelines PDF

SERVICE GUIDELINES
TITLE
GLOBAL MAINTENANCE GUIDELINES
BUSINESS UNIT
PowerWell Services
OWNER
Global Service Quality Coordinator
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor
POWERWELL SERVICES MANAGEMENT SYSTEM

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
PAGE
1 0f 17
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
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Subject
New Equipment
Equipment Trace Numbering System
Equipment Data Packages & Maintenance Files
Personnel Competency
Maintenance Checklists
Maintenance
rd
Inspection of 3 Party Equipment
Local Manufacture And Purchase
Thread Inspection
After Assembly Test And Inspection
Instrument Calibration
Hydrostatic Pressure Test
Periodic Inspection
Tagging System
Document Control
Reviewing Maintenance Procedures
Equipment Transfer
Page
2
2
3
3
4
5
7
8
8
9
9
10
10
10
10
10
11
Once printed this document becomes uncontrolled, refer to PowerWell Services Management System for controlled copy.
SERVICE GUIDELINES
TITLE
BUSINESS UNIT
PowerWell Services
OWNER
1.
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
PAGE
2 0f 17
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.
SERVICE GUIDELINES
TITLE
BUSINESS UNIT
PowerWell Services
OWNER
2.
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
PAGE
3 0f 17
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 intercompany 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
EQUIP DESIGNATION
SEQUENCE NUMBER
ASSIGNED TRACE NUMBER
STE
CHM
001
SURFACE TEST EQUIPMENT

CHOKE MANIFOLD
NUMBER ONE
STE-CHM-001
SERVICE GUIDELINES
TITLE
BUSINESS UNIT
PowerWell Services
OWNER
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
PAGE
4 0f 17
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
LOCATION
SEQUENCE NUMBER
ASSIGNED TRACE NUMBER
01
XAF
001
SEPARATOR
ABERDEEN
SEPARATOR NUMBER ONE
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.
SERVICE GUIDELINES
TITLE
BUSINESS UNIT
PowerWell Services
OWNER
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
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
PAGE
5 0f 17
SERVICE GUIDELINES
TITLE
BUSINESS UNIT
PowerWell Services
OWNER
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
NUMERIC EQUIPMENT CODE DESIGNATION (contd)
EQUIPMENT I.D
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
PAGE
6 0f 17
SERVICE GUIDELINES
TITLE
BUSINESS UNIT
PowerWell Services
OWNER
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
NUMERIC EQUIPMENT CODE DESIGNATION (contd)
EQUIPMENT I.D
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)
PAGE
7 0f 17
SERVICE GUIDELINES
TITLE
BUSINESS UNIT
PowerWell Services
OWNER
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
PAGE
8 0f 17
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)
SERVICE GUIDELINES
TITLE
BUSINESS UNIT
PowerWell Services
OWNER
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
PAGE
9 0f 17
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.
SERVICE GUIDELINES
TITLE
BUSINESS UNIT
PowerWell Services
OWNER
4.
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
PAGE
10 0f 17
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.
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
LEVEL A
PRE/POST JOB
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
Description
Work to be carried out every job or if stored for a period greater than
three months
SERVICE GUIDELINES
TITLE
BUSINESS UNIT
PowerWell Services
OWNER
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
PAGE
11 0f 17
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:
6.
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.
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

rd
If 3 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.
SERVICE GUIDELINES
TITLE
BUSINESS UNIT
PowerWell Services
OWNER
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
PAGE
12 0f 17
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.
SERVICE GUIDELINES
TITLE
BUSINESS UNIT
PowerWell Services
OWNER
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
PAGE
13 0f 17
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.
rd
Inspection of 3 Party Rental Equipment

rd
Rental of 3 party supplied equipment is a day to day part of our business.

rd
Each and every location must manage and audit their 3 party rental suppliers.
rd
3 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.
SERVICE GUIDELINES
TITLE
BUSINESS UNIT
PowerWell Services
OWNER
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
PAGE
14 0f 17
rd
The checklists that have been provided for Power Well Testing use may be used to check and verify 3 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.
SERVICE GUIDELINES
TITLE
BUSINESS UNIT
PowerWell Services
OWNER
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
PAGE
15 0f 17
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.
SERVICE GUIDELINES
TITLE
BUSINESS UNIT
PowerWell Services
OWNER
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
PAGE
16 0f 17
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.
SERVICE GUIDELINES
TITLE
BUSINESS UNIT
PowerWell Services
OWNER
Note:
REGION
Global
APPROVED
Global SQC
FUNCTION
Power Well Testing
JOB REVISION
Global Advisor

DOCUMENT NUMBER
GD-GL-WT-006
REVISION DATE
04-Nov -04
REVISION
A
REVIEW DATE
PAGE
17 0f 17
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
rd
Inspection Guidelines, then the sending location will be recharged ALL costs (transport, inspections, 3 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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SERVICE GUIDELINES

POWERWELL SERVICES MANAGEMENT SYSTEM

POWERWELL SERVICES MANAGEMENT SYSTEM

POWERWELL SERVICES MANAGEMENT SYSTEM

Equipment Trace Numbering System

ASSIGNED TRACE NUMBER

SURFACE TEST EQUIPMENT

POWERWELL SERVICES MANAGEMENT SYSTEM

ASSIGNED TRACE NUMBER

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

Stainless Steel band on the equipment itself.

UNIQUE TRACE NUMBER

POWERWELL SERVICES MANAGEMENT SYSTEM

NUMERIC EQUIPMENT CODE DESIGNATION

INDIRECT FIRED HEATER

STEAM HEAT EXCHANGER

DESANDERS / FILTERS / SAND SEPARATORS

BURNER BOOMS (BOOM SECTIONS, KP, STRUTS etc)

CHEMICAL INJECTION PUMPS

SURFACE TEST TREE

SURFACE TEST TREE SWIVEL

SURFACE TEST TREE LMV

SURFACE TEST TREE LIFITNG SUB / STIFF JOINTS

SURFACE TEST TREE CHEMICAL INJECTION SUB

REMOTE MANUAL OR SURFACE SAFETY VALVE

SURFACE SAFETY VALVE CONTROL MANIFOLD

SURFACE TEST TREE CHECK VALVE

FLOWLINE CHECK VALVE

FLEXIBLE ARMOURED PIPE

POWERWELL SERVICES MANAGEMENT SYSTEM

NUMERIC EQUIPMENT CODE DESIGNATION (contd)

FLOWINE STRAIGHT JOINTS

WELLHEAD CONNECTIONS (OBSOLETE USE 28)

WELLHEAD CONNECTIONS & CROSSOVERS

FLEXIBLE FLOW HOSE DOWNSTREAM NON ARMORED

FLOWLINE DATA HEADER

COMBINATION UNIT SEPARATOR/HEATER

LAB A-60 TYPE INTRINSICALLY SAFE

QUICK CONNECTS/DISCONNECTS (QC/DC)

BASKETS AND PIPE RACKS

GENERATORS (STEAM AND/OR ELECTRIC)

MISCELLANEOUS (CATCH ALL)

WORK SHOPS LABS NON INTRINSIC

HYDROCYCLONE DE-OIL DE-WATER SYSTEMS

MULTI PHASE FLOW METER

PRESSURE RELIEF VALVE

SURFACE / DIFFERENTIAL CHART RECORDER

POWERWELL SERVICES MANAGEMENT SYSTEM

NUMERIC EQUIPMENT CODE DESIGNATION (contd)

TRAILER FOR TRAILER MOUNTED UNITS

ALPHA LOCATION CODE DESIGNATION

CANADA ST. JOHNS

POWERWELL SERVICES MANAGEMENT SYSTEM

ALPHA LOCATION CODE DESIGNATION (contd)

EQUITORIAL GUINEA - MALABO

RUSSIA (SAKHALIN ISLAND)

GENERAL (SPECIAL PROJECT)

POWERWELL SERVICES MANAGEMENT SYSTEM

Equipment Data Packages & Maintenance Files

maintenance file the following information shall be placed in separate sections:

POWERWELL SERVICES MANAGEMENT SYSTEM

Work to be carried out yearly, except when equipment is due a