TITLE : PROCEDURE FOR WELL MAINTENANCE

1. HS&E Precautions

Normal safety precautions are required in the wellhead areas with regard to
hazardous area classification – Zone 1 or 2

Open venting / draining of hydrocarbons must be minimised and work procedures

adopted which limits the risk of exposure.

When working on or dismantling the high pressure components of the system,

particular care must be exercised in case of trapped pressure in the pipe work or
components.

Where items of equipment on the wellheads are not readily accessible, proper
temporary access, by staging must be arranged when required.

All personnel who are employed in the execution of operational and maintenance
duties, must take full account of the potential environmental impacts associated
with their activities. This is especially important during all shutdown, isolation,
maintenance, de-isolation and start-up of plant and equipment. Care must be
taken to reduce environmental risk exposure to ALARP levels, and necessary
steps must be taken to eliminate risk of all fugitive emissions and discharges

All Maintenance and Well Intervention activities must take place under the ‘Permit
to Work’ (PTW) system and the Marine Transportation Procedure must be
followed for all excursions to offshore wellheads

2. Well Maintenance – Monthly

Inspections

Procedures for Wellhead Equipment

Choke and Actuator Maintenance Instructions

Whilst the flowline is depressurised during Xmas Tree leak-off tests, using soap
solution, visually inspect all flowline joints and valves between the choke and the
final joint for leakage to atmosphere. Also carefully inspect the hydraulic cabinet
and associated hydraulic pipework for leaks. Rectify any leaks found during the
well maintenance period to avoid further shutdown of well.
 Visually inspect the Xmas Tree for any leaks/defects paying particular attention to
the following:

 Wellhead/Xmas tree Flange connection.

 Bonnet grease fittings.
 Manual valve stem packing.
 Actuated valve stem packing
 All actuators.
 Bonnet joints.
 Flange connections.
 Test and bleeder fittings, instrument connections and instrumentation /
gauges.

Refer to drawings in Wellhead Equipment manual for test/vent port descriptions

and schematics showing positions of all test/vent/bleeder/ports.
All ports on the wellhead are stamped to identify their purpose.

Visually inspect the Wellhead for any leaks/defects paying particular attention to
the following:

 Instrument air facilities

 Test and bleeder fittings.
 Control Panel Integrity
 Chemical Injection Facilities
 Instrument connections / needle valves.
 Fusible fire loops
 Instrumentation /gauges.
 CO2 Fire extinguishers
 Flange connections.
 Wellhead Davit and 2500kg Pulley
 Drains sump
 Annulus valve (Bonnet grease fittings, stem packing. bonnet gaskets).
 Cellars below ground level should be pumped out of any rain/flood water.

Well Maintenance – Yearly

Repeat all monthly maintenance.

Leak Tests

If the well is flowing then it shall be closed in at the wellhead choke and wing valve
before commencing the tests. Leak test the following valves in order presented
below:

1. Complete confidence test of Choke and Test Flow Wing Valves (See
Appendix B for test procedure and I for Leak Criteria)
2. SCSSSV (See Appendix C for test procedure and I for Leak Criteria)
 3. Lower Master Valve
4. Upper Master Valve (SSV) (See Appendix D2 for test procedure and I for Leak
Criteria)
5. Actuated Wing Valve (ESD) (See Appendix E for test procedure and I for Leak
Criteria) – Note: Manual FWV leak test will already have been completed
as part of Appendix “B”
6. Swab Valve (See Appendix F for test procedure and I for Leak Criteria)
7. Upon completion of the valve tests, refer to Appendix G for Well Re-
instatement

Service Routines
 Inject recommended grease into all manual valve bonnet caps.
 Lubricate all Christmas tree valve cavities.
 Fully stroke the annulus valves and confirm smooth operation and full travel
and also that the valves were found in the correct position. (For annulus
pressure monitoring requirements, the correct position is Open).
 Lubricate the annulus valve bonnet caps and valve body cavities.
(These valves are rarely operated and not exposed to hot gas flow therefore
minor top up of body cavities is all that is required)

Note: Complete wellhead checks as per Monthly Maintenance Checks

APPENDIX A

Limitations

The following maintenance routines address the application of routine valve testing, valve
servicing and system testing. The testing procedures involve the removal of some protection
devices, (e.g. PSHL Override) and these shall be controlled under Procedure for Control of
Overrides and Inhibits and reinstated as soon as practicable. The tests may reveal
unacceptable equipment performance which the operator must take into account at the time.
(e.g. – If the choke or any of the tree valves pass excessively, then the operator shall
consult with the SSI Site Manager or his delegate before proceeding further)

This procedure is sequential. Where only parts of the system are to be tested the operator
should be aware that if they are simply extracted from the sequence then certain preparatory
conditions may be missed. The procedure is a guide for the use of competent personnel and in
no way negates the need for job planning.
APPENDIX B

Choke confidence check and Flow Wing Valve Test

Lo-Lo PSHL pressure pilot must be overridden in accordance with Safe Isolations
procedure OP/123/12 to stop the Actuated Wing Valves from closing, prior to
commencement of Maintenance routines.

Check that the well head pressure gauge on the well head between the master valve (SSV)
and the flow wing valve (XV) is in close agreement with the PI reading. If it is not, change
out the gauge or have the instrument calibrated

1. Obtain control of the well from the CCR

2. Bubble test all flanges around well site for leaks and organise maintenance to rectify as
necessary

3. Check hydraulic cabinet for leaks and rectify as necessary

4. Close well in on the Choke and determine the Choke shut-off performance (The hot
closed in tubing head pressure (hot CITHP) should rise close to that expected)

5. Close Flow Wing Valve (XV) for leak off test (See number of turns in Appendix J)

6. Open the Choke and observe the hot closed in tubing head pressure, which should not
drop (Warning: Close the Choke and Re-open the manifold block valve if the flow line
pressure rises rapidly towards the CITHP)

7. Close the flowline Downstream valve (D/S of NRV before tie in to gathering system)

8. Depressurise flowline to around 1000kPa and then allow to stabilise

9. Close Master Valve (SSV) (See number of turns in Appendix J)

10. Ensure Swab valve is open

11. Depressurise Xmas Tree to zero above MV through bleed valve on tree cap

12. Close swab valve and tree cap bleed

13. Monitor Xmas Tree for buildup (If any pressure buildup is apparent – Assess whether
this is from well or flowline before continuing)

14. Seal and Grease FWV as per Service Routines

15. Open MV

16. Test FWV by monitoring for any pressure buildup in flowline due to FWV passing

17. When test is complete open flowline D/S block valve

 18. Close the Choke

19. Continue with remainder of leak off tests and service routines

APPENDIX C

Subsurface Safety Valve (SSSV) Test:

Assuming successful initial test of the Choke and Flow Wing Valve:

Starting Point status:-

1. Confirm that all wellhead annulus pressures at Surface are within the Maximum
allowable Annulus Surface Pressure (MAASP) limits

2. Blow down if necessary (See Casing Leak Off test)

3. With annulus surface pressures within limits, close the Subsurface Safety Valve from the
local panel observing that the control line pressure gauge drops to zero

4. Ensure that LMV/UMV are open

5. Open the Flow Wing Valve and crack open the Choke to depressurise the tubing above
the closed SCSSSV to export line pressure. (Note: If the SCSSSV shut-off is in doubt
then, during the depressurisation, close the Choke to see if the THP rises rapidly or not).

NB: To achieve this, the flow line Lo-Lo pressure pilot must be overridden to stop the
Actuated ESD Wing Valve or MV (SSV) from closing during the depressurisation

(The downstream temperature on any process lines should not be less than minus 20°C)

6. Observe for any rise on the THP gauge above the LMV/UMV’s

7. Close in D/S block valve when THP has reached flowline export pressure

8. Depressurise flow line and Xmas tree above SSSV to 2000 kPa

9. Close FWV, open swab valve, and depressurise Xmas Tree above SSSV to zero
through tee cap bleed valve

10. Close swab valve and tree cap bleed valve

11. Inform CRO to trend/record 30 mins THP leak off test in CCR
 12. Observe the THP pressure rise for 30 minutes to obtain a reliable pressure gradient (See
leak acceptance criteria in the table at the end of this text).

13. Whilst the SCSSSV is shut and Xmas Tree is depressurised the remaining wellhead
valves can be sealed and lubricated. See OEM instructions and Service Routines

NB: Ensure that FWV and Choke remain closed throughout the Service Routines and
have the MV closed whilst exercising the Flow Wing Valve

14. Open SSSV as per opening procedure and observe for expected CITHP on THP gauge

15. Close LMV

16. Continue with LMV test as per Appendix D1

APPENDIX D (1)

Upper Master Valve test: Following on from the SSSV valve test; Valve Status at Start;

Valve Tag Valve Description Valve Position

Sub-Surface Safety Valve Open
Lower Master Valve Open
Upper Master Valve – Actuated (ESD) Open
Manual Flow Wing Valve –(XV) Closed
Actuated Wing Valve (ESD) Open
Swab Valve Closed
Flow Control Choke – Remote Actuated Closed
Block Valve D/S of Choke Closed
Kill Valve (KV) Closed

1. Ensure D/S block valve is closed and flow line is at approximately 1000 kPa

2. Ensure Choke, FWV and Swab valve are closed

3. Ensure SSSV is open

4. Ensure that LMV is closed

5. Ensure that UMV is open

6. Ensure that swab valve is open

 7. Bleed off pressure in Xmas Tree to zero through swab valve and tree cap bleed

8. Close swab valve and tree cap bleed

9. Observe for any pressure rise on the tubing head gauge to determine if the LMV is
passing

10. Proceed with Actuated Upper Master Valve (ESD) leak off test

APPENDIX D (2)

Upper Master Valve test: Following on from LMV valve test; Valve Status at Start;

Valve Tag Valve Description Valve Position

Sub-Surface Safety Valve Open
Lower Master Valve Open
Upper Master Valve – Actuated (ESD) Closed
Manual Flow Wing Valve –(XV) Closed
Actuated Wing Valve (ESD) Open
Swab Valve Closed
Flow Control Choke – Remote Actuated Closed
Block Valve D/S of Choke Closed
Kill Valve (KV) Closed

11. Ensure D/S block valve is closed and flow line is at approximately 1000 kPa

12. Ensure Choke, FWV and Swab valve are closed

13. Ensure SSSV is open

14. Ensure that LMV is open

15. Ensure UMV is closed

16. Ensure that swab valve is open

17. Bleed off pressure in Xmas Tree to zero through swab valve and tree cap bleed

18. Close swab valve and tree cap bleed

19. Observe for any pressure rise on the tubing head gauge to determine if the UMV is
passing

20. Proceed with Actuated Flow Wing Valve (ESD) leak off test
APPENDIX E

ESD Actuated Wing valve:

Following on from the MV test - Valve Status at Start;

Valve Tag Valve Description Valve Position

Sub-Surface Safety Valve Open
Lower Master Valve Open
Upper Master Valve – Actuated (ESD) Open
Manual Flow Wing Valve –(XV) Closed
Actuated Wing Valve (ESD) Open
Swab Valve Closed
Flow Control Choke – Remote Actuated Closed
Block Valve D/S of Choke Closed
Kill Valve (KV) Closed

1. Ensure that D/S flowline block valve is closed and flowline pressure is ~ 1000 kPa

2. Close actuated wing valve

3. Open FWV (XV)

4. Open UMV

5. Open the Choke +/- 10%

6. Observe for any pressure rise in the flow line to determine the leakage through the
Actuated Wing Valve (ESD)

7. Close FWV

8. Open Actuated Wing Valve

9. Close choke and continue with Swab Valve test as per Appendix F
APPENDIX F

Swab Valve test: Following on from the ESD Wing Valve test. Valve Status at Start;

Valve Tag Valve Description Valve Position

Sub-Surface Safety Valve Open
Lower Master Valve Open
Upper Master Valve – Actuated (ESD) Open
Manual Flow Wing Valve –(XV) Closed
Actuated Wing Valve (ESD) Open
Swab Valve Closed
Flow Control Choke – Remote Actuated Closed
Block Valve D/S of Choke Closed
Kill Valve (KV) Closed

1. With Swab valve closed open the tree cap bleed to release any trapped gas (Take relevant
precautions when releasing gas to atmosphere)

2. Fit a calibrated 0 – 2000psi pressure gauge (with tee-piece) to tree cap

3. Open tree cap valve to measure pressure above swab valve and monitor for any swab valve
leakage

4. Close gauge isolation valve and remove pressure gauge, ensuring tree cap valve closed

5. Observe tree cap for possible tree cap valve leakage

6. Prepare well for production reinstatement as per Appendix G

APPENDIX G
Re-instatement of Well after Swab Valve test

The following sequence of events covers the re-pressurisation of the wellhead and flow line in
preparation for well restart

Valve status:

Valve Tag Valve Description Valve Position

Sub-Surface Safety Valve Open
Lower Master Valve Open
Upper Master Valve – Actuated (ESD) Open
Manual Flow Wing Valve –(XV) Closed
Actuated Wing Valve (ESD) Open
Swab Valve Closed
Flow Control Choke – Remote Actuated Closed
Block Valve D/S of Choke Closed
Kill Valve (KV) Closed

1. Check that the flow line pressure gauge is on line.

2. Open the manual Flow Wing Valve

3. Carefully crack open the Flow Control Choke to equalise pressure across the
Downstream Isolation valve.

4. Close Flow Control Choke , close Flow Wing Valve

5. Re-instate the flow line PSHL pressure trip

6. Return control of the Well to the control of SSI operations and the CCR.

Refer to:
Procedure for Well Start-up and Operation OP/123/13
APPENDIX H Tubing Hanger Seal Assembly

Monitor “A” annulus pressure continuously/ as required to check for tubing hanger seal leaks.

APPENDIX I Allowances and Closure Timing Details

Test criteria and Technical details

Location Test Max leak rate Comment on Duration Frequency

boundary leak criteria of test of test
Sub surface Swab & flow 100 kPa THP rise in 30 Based on API 30 6 months
Valve wing valve mins 14C for minutes
subsurface
safety valve
Master Swab & flow Nil 10 6 months
Valves (2) wing valve minutes
minimum
Flow Wing Manifold Nil 10 6 months
valve valves and minutes
flow line

Actuated Manifold Nil 10 6 months

Wing Valve valves and minutes
(XV) flow line minimum

Swab Valve Tree cap Nil 10 mins 6 months

minimum

Closure times For Xmas Tree Actuators

Actuated valve Actuator maximum
time to close in
seconds
Actuated Wing Valve and MV (ESD/SSV) 18 seconds
SSSV and ESD differential between closure 9 seconds

Xmas Tree and Well Head Manual Valve Closure Details

Valve Size / Pressure Rating No. of Turns between fully open and
fully closed
2-1/16” 5K 13 turns
4-1/16” 5K 24 ½ turns
 Appendix J: SCSSSV Leak-Off Test Data

SSSV DATA SHEET

WELL NAME/NO

DATE BAKER TRSSSV SERIAL

WELL SHUT IN AT

WAIT ONE HOUR

RECORD SHUT IN PRESSURES SIUCP (PI) KPA

SIUCP Keller KPA

BLEED DOWN TO 2/3 OF SIUCP FOR LEAK OFF SIUCP (PI) kPA

SIUCP Keller kPA

CLOSE SURFACE MASTER VALVE TIME: HOURS

RECORD SIUCP READINGS EVERY TWENTY MINUTES FOR ONE HOUR FOR LEAK OFF
Indicate if the reading is via the PI & or Keller
TIME SIUCP kPA

HAS SIUCP PRESSURE INCREASED MORE THAN 3500 KPA OVER A ONE HOUR PERIOD
IF YES, ADVISE PRODUCTION SUPERVISOR AND LEAVE WELL SHUT IN WHILE MONITORING PRESSURE EVERY TWENTY MINUTES
FOR AN ADDITIONAL HOUR.

IF NO, PROCEED AS FOLLOWS

EQUALISE ACROSS SSSV USING SSSV HYDRULIC PUMP

EQUALISED PRESSURE SIUCP kPA

CYCLE SSSV SIX TIMES AND OPEN SSSV TIME: HOURS

TIME WELL OPENED AND FLOWING @ HOURS

SIGNED: DATE NEXT TEST DUE:

Appendix K SSSV Cycle

SSSV CYCLE
Slowly shut the well/s in by closing the production choke. Record the shut in time on the subsurface safety valve Leak Off
and Cycling test Data Sheet
Fit a calibrated pressure gauge to the connection on the top of the tree, the gauge shall be at least 0-5000 psig or 0-35000kpa.
The Vatrex fitting can be fitted to the kill wing v/v point if required, take care while removing the plug to fit the gauge or the
Vatrex fitting, ensure the swab v/v and kill wing v/v are both closed prior to fitting the gauge or plug.
With the production choke closed, Close the WV and open the SV and KWV (if vatrex fitting is fitted) and allow 30 to 50
minutes for the Well to stabilise. Thermal contraction of the gas may be experienced.
Record SIUCP from the PI fitted to the tree top and off the Vatrex gauge and record this on subsurface safety valve Leak Off
and Cycling test Data Sheet
Close the UMV & SSSV valve by pushing the appropriate HS on the well hydraulic panel.
If only a SSSV cycle test is to be performed, cycle the SSSV by buy pulling and closing the HS on the hydraulic panel. Cycle
the SSSV 6 times. When pushing the HS insure the hydraulic pressure returns to zero to insure the SSSV has closed. Allow 30
secs between the v/v operations
Leave the SSSV in the open position on the completion of the cycles and complete the cycle section of subsurface safety valve
Leak Off and Cycling test Data Sheet
Close the SV and Kill wing valve and remove the PI and Vatrex gauge (if fitted) from the wellhead and recap the fittings.
Reopen the UMV & WV and restart the well as normal, be sure not to allow the formation of hydrates
SSSV LEAK OFF TEST
For a SSSV leak off test, Slowly shut the well in by closing the production choke. Record the shut in time on subsurface
safety valve Leak Off and Cycling test Data Sheet.
Fit a calibrated pressure gauge to the connection on the top of the tree, the gauge shall be at least 0-5000 psig or 0-35000kpa.
The Vatrex fitting can be fitted to the kill wing v/v point if required, take care while removing the plug to fit the gauge or the
Vatrex fitting, ensure the swab v/v and kill wing v/v are both closed prior to fitting the gauge or plug.
With the production choke closed, Close the WV and open the SV and KWV (if vatrex fitting is fitted) and allow 30 to 50
minutes for the Well to stabilise. Thermal contraction of the gas may be experienced.
Record SIUCP from the PI fitted to the tree top and off the Vatrex gauge and record
To Close the SSSV Valve Do not operate the hand switch. From the control panel at the well site, close the instrument gas
supply valve directly upstream of the regulator to the Hydraulic pump.
Remove the hydraulic pressure in the SSSV by bleeding the SSSV supply line back to the tank by using the accumulator return
valve provided. This valve is located under the hydraulic oil tank at bottom of the control panel. The SSSV supply pressure
gauge will drop of, leave the v/v open to ensure the line does not re-pressure.
Reopen the WV and slowly de-pressure the flow line above the SSSV through the production choke until the recorded SIUCP
is reduced from that recorded in step 5.13 by one third.
NOTE; Consider putting on the Low-pressure override for the relevant well if bleed down pressures warrant this to prevent the
closing of the WV and UMV.
Record the time and the SIUCP on sheet. For a SSSV leak off test record the SIUCP via the fitted PI and Vatrex (if fitted)
every twenty minutes on the test data sheet for one hour (three readings plus original shut in).
Leakage through the SSSV would be indicated by an increase in SIUCP. The leakage rate should not exceed 900 SCF of gas
per hour or 6.3 gallons of liquid per hour (400cc/min) during the test, if so the test will be required to run for another hour.
If the SIUCP increases by more than 3500 kPa in one hour (this is a easily identifiable guide figure) The Zamzama IM shall be
notified. And the test may need to be continued for another hour and the pressures recorded. A leak rate can be calculated
using the API RP 14B procedure if required.
If the test result is unacceptable or SSSV closure problems are encountered, notify the I.M. immediately.
EQUALISING AND VALVE REOPENING
Equalising is only required after the down stream pressure has been reduced across the SSSV. Hence it is not required if only
performing a cycle.
Close the accumulator return valve that was opened in step 5.15
Wind back the instrument gas regulator to ensure the hydraulic pump does not operate. Reopen the instrument gas supply
valve to the regulator that was closed in step 5.14.
To start to equalize across the SSSV slowly wind in the instrument gas regulator to the hydraulic pump supply to 2.65 bar,
this equals a pump supply pressure of 4500 psi (310 Bar). The pump ratio is 117 to 1.
Wait and Monitor the SIUCP watching the PI or Vatrex, It should start to rise and equalise, be patient.
When SIUCP recorded in step 5.13 is reached increase the hydraulic pump supply regulator to 3.83 Bar, this equals a pump
supply pressure of 6500 psi (448 Bar). The pump will pump 1 litre of oil to fully open the SSSV.
Cycle the SSSV as per the cycle procedure.
Close the SV and Kill wing valve and remove the PI and Vatrex gauge (if fitted) from the wellhead and recap the fittings.
Reopen the WV and commence to flow the well. CCR to Monitor FUCP to insure SSSV is open. Be sure to prevent the
formation of hydrates on start up.
Remove any overrides applied during this activity